Your question(s) are a bit all over the place, I'll try to answer and provide some tips the best I can.
If I'm interpreting your concern, you're basically having trouble getting a strong signal to your headphones, is that accurate? To start, Channel Faders have NO affect on your headphone output volume unless the cue knob is set accordingly and the cue button is engaged for the master out.
First things first: gain staging.
Assuming you're using a CDJ/Turntable setup, start with all of your volume faders lowered completely with the Master knob at the 12:00 position. Play a song on your playback device and adjust the gain knob on the Pioneer DJM until the channel meter tickles the amber color.
After ensuring your headphone cue knob is turned completely counter clockwise, press the "Cue" button on the channel you just adjusted the gain on. Turn up your headphone output. You should now hear sound.
You can then increase the volume of the master out. You'll want to stop increasing a couple ticks before you hit amber to allow a bit of headroom.
Lastly, if you're going to be primarily mixing in your headphones, I would suggest keeping your crossfader in the center position and use the volume faders to mix your tracks. Remember, if you're monitoring the master cue in your headphones you'll need to watch the position of the crossfader.
If you're still not receiving much of a signal in your headphones, then there's something going on with your headphone cable or the 1/4" adapter that connects the headphone cable to the mixer. I know with my V-Moda headphones I sometimes have to check to make sure I've screwed the adapter on completely, as it tends to become a bit loose after being used many times.
Personally, I mix in my headphones using the channel cues primarily until I'm ready to make the mix "live," at which point I would disengage the channel fader cues and use only the master out cue.
If none of the above help, I would urge you to make a video of the problem and post it here. I find that videos are the best way for others to understand the issue and quickly resolve it.
Cheers.