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Warrior™Feed304,
Warrior™Feed304w
Instruction manual
0463 343 131 US 20181009
Valid for: serial no. 324-xxx-xxxx, 526-xxx-xxxx
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TABLE OF CONTENTS
1
SAFETY ....................................................................................................... 3
1.1 Meaning of symbols ............................................................................... 3
1.2 Safety precautions ................................................................................. 3
1.3 User responsibility ................................................................................. 7
2
INTRODUCTION.......................................................................................... 11
2.1 Overview ................................................................................................. 11
2.2 Equipment............................................................................................... 11
3
TECHNICAL DATA ...................................................................................... 12
4
INSTALLATION............................................................................................ 14
4.1 Overview ................................................................................................. 14
4.2 Lifting Instructions ................................................................................. 14
5
OPERATION ................................................................................................ 16
5.1 Overview ................................................................................................. 16
5.2 Connections and control devices ......................................................... 18
5.3 Water connection ................................................................................... 18
5.4 Starting procedure ................................................................................. 18
5.5 Explanation of functions........................................................................ 18
5.6 Wire feed pressure ................................................................................. 19
5.7 Changing and loading wire.................................................................... 20
5.8 Changing feed rollers............................................................................. 20
6
MAINTENANCE........................................................................................... 21
6.1 Overview ................................................................................................. 21
6.2 Inspection and cleaning......................................................................... 21
7
ORDERING SPARE PARTS........................................................................ 22
DIAGRAM ............................................................................................................ 23
WEAR PARTS...................................................................................................... 25
ORDER NUMBERS ............................................................................................. 29
ACCESSORIES ................................................................................................... 30
Rights reserved to alter specifications without notice.
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1 SAFETY
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer's safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety Precautions can result in
injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
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1 SAFETY
4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4. Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the
input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
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1 SAFETY
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power, before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may
interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when
possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on
the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being
welded.
e) Keep welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.
4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
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CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
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1 SAFETY
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
3. Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1. Keep all doors, panels, guards, and covers closed and securely in place.
2. Stop the engine or drive systems before installing or connecting a unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or
any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.
• Keep cables and cords away from moving vehicles when working from an
aerial location.
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1 SAFETY
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation,
troubleshooting and maintenance work. Do not perform any electrical
work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power
supply in safe working order. Do not operate any equipment in faulty
condition.
4. Do not abuse any equipment or accessories. Keep equipment away
from heat sources such as furnaces, wet conditions such as water
puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good
repair.
6. Use equipment only for its intended purpose. Do not modify it in any
manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging.” Form 52-529.
The following publications are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"
3. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"
4. AWS SP - "Safe Practices" - Reprint, Welding Handbook
5. ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and
Cutting of Containers That Have Held Hazardous Substances"
6. OSHA 29 CFR 1910 - "Safety and Health Standards"
7. CSA W117.2 - "Code for Safety in Welding and Cutting"
8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
9. CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
10.ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
1.3 User responsibility
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed, in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations, which
could result in injury to the operator and damage to the equipment.
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1 SAFETY
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorized person is within the working area of the equipment when it is
started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Wire feeders are intended to be used in GMAW (MIG/MAG) mode only.
If used in any other welding mode, such as SMAW (MMA), the welding cable
between wire feeder and power source must be disconnected, or else the wire
feeder becomes live or energized.
WARNING!
Arc welding and cutting may cause injury to yourself and others. Take
precautions when welding and cutting.
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1 SAFETY
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves,
or wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Pose health risks
• Welders with pacemakers fitted should consult their doctor before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep the welding power source and cables
as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to your health
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause a fire. Therefore, make sure that there are no
inflammable materials nearby
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
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1 SAFETY
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information, contact your local ESAB dealer or visit us on
our website.
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2 INTRODUCTION
2 INTRODUCTION
2.1 Overview
The Warrior Feed 304, Warrior Feed 304w wire feed unit is intended for GMAW (MIG/MAG)
welding together with the welding power sources:
• Warrior 400i CC/CV
• Warrior 500i CC/CV
They are available in different versions, see chapter "ORDERING NUMBER".
The wire feed units are sealed and contain four-wheel drive wire feed mechanisms as well as
control electronics.
They can be used together with wire on ESAB's MarathonPac, or on wire bobbin (standard Ø
12 inch, accessory Ø 17 inch).
The wire feed unit can be placed on a trolley, suspended above the workplace with a lifting
eye, on a counter balance or on the floor with or without a wheel set.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The Warrior Feed 304 and Warrior Feed 304w wire feed units are delivered with:
• Instruction manual
• Sticker with recommended wear parts.
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3 TECHNICAL DATA
3 TECHNICAL DATA
Warrior Feed 304, Warrior Feed 304w
Power Supply voltage 42 V AC, 50–60 Hz
Power requirement 252 VA
Rated supply current I
1
6 A
Settings data
Wire feed speed
Creep start
2/4 stroke
Wire selection
4.9-82 ft/min (1.5-25.0 m/min)
OFF or ON
2 stroke or 4 stroke
Solid or Cored
Torch connection EURO
Max. diameter wire bobbin 300 mm (*440 mm)
12 inch (*17 inch)
Wire dimension
Fe
SS
Al
Cored wire
.023 - 1/16 inch (0.6-1.6 mm)
.030 - 1/16 inch (0.8-1.6 mm)
.40 & 1/16 inch (1.0 & 1.6 mm)
.035 - 1/16 inch (0.9-1.6 mm)
Weight
WF 304 with bobbin cover
31.7 lbs (14.4 kg)
WF 304w with bobbin cover
32.4 lbs (14.7 kg)
Weight wire spool (ESAB standard)
Ø 200 mm
Ø 300 mm
Ø 440 mm
Dimensions (l × w × h)
basic
11.0 lbs (5 kg)
39.7 lbs (18 kg)
66.1 lbs (30 kg)
26.6×10.4×16.5 inch
(675×265×418mm)
Operating temperature +14° to +104°F (-10° to +40°C)
Transport and storage temperature -4° to +131°F (-20° to +55°C)
Shielding gas
max. pressure
Coolant(Warrior Feed 304w)
All types intended for GMAW welding
0.5 Mpa (5 bar)
ESAB's ready-mixed coolant 0.5 Mpa (5 bar)
max. pressure
Permissible load at
60% duty cycle
100% duty cycle
500 A
400 A
Enclosure class
with the Ø 17 inch (Ø 440 mm) bobbin and/or
the counterbalance device
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IP23
IP2X
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3 TECHNICAL DATA
* See the "ACCESSORIES" chapter in the instruction manual.
Duty cycle
The duty cycle refers to the time, expressed as a percentage of a ten-minute period, during
which you can weld or cut at a certain load without overloading. The duty cycle is valid for
104°F (40°C).
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Equipment marked IP2X is intended for indoor use.
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4 INSTALLATION
4 INSTALLATION
4.1 Overview
The installation must be carried out by a professional.
WARNING!
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol .
4.2 Lifting Instructions
CAUTION!
Risk of crushing when lifting the wire feeder. Mounting a large wire bobbin (17,32
inch, Ø 440 mm), may change the centre of gravity of the wire feeder and
increase the risk of tipping and crushing. Protect yourself and warn bystanders of
the risk.
CAUTION!
To avoid personal injury and / or equipment damage, lift using the method and
attachment points shown here.
The order number for the lifting eye can be found in the "ACCESSORIES" chapter.
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4 INSTALLATION
NOTE!
If another mounting device is used, this should be insulated from the wire feed
unit.
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
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5 OPERATION
5 OPERATION
5.1 Overview
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
WARNING!
To avoid shock, do not touch the electrode wire or parts in contact with it, or
uninsulated cable or connections.
NOTE!
When moving the equipment, use the handle intended for transportation. Never
pull the equipment by the welding torch.
WARNING!
Make sure the side panels are closed during operation.
WARNING!
To prevent the reel from sliding off the
hub: Lock the reel in place by turning
the red knob as shown on the warning
label attached next to the hub.
CAUTION!
Before threading welding wire, make sure the chisel point and burrs have been
removed from the end of the wire to prevent the wire from jamming in the torch
liner.
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5 OPERATION
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when
inserting the welding wire between the feed rollers.
WARNING!
There is a risk of tipping, if the wire feed unit is fitted with a counterbalance arm.
Be sure to install the stabilizer kit and secure the equipment, especially if used on
an uneven or sloping surface.
Recommended maximum current values for connection set cables
I
max
450 A (60% duty cycle)
350 A (100% duty cycle)
550 A (60% duty cycle)
430 A (100% duty cycle)
450 A (60% duty cycle)
350 A (100% duty cycle)
550 A (60% duty cycle)
430 A (100% duty cycle)
Cable area Cable length Note
70 mm
95 mm
70 mm
95 mm
2
2
2
2
6.6 ft–114.8 ft
(2–35 m)
6.6 ft–114.8 ft
(2–35 m)
6.6 ft–114.8 ft
(2–35 m)
6.6 ft–114.8 ft
(2–35 m)
19 pole
19 pole
19 pole, water
19 pole, water
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 104°F (40°C).
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5 OPERATION
5.2 Connections and control devices
1. Display voltage (V) 9. Switch for 4 stroke / 2 stroke (inside)
2. Display current (A) 10. Switch for Cored wire / Solid wire (inside)
3. Knob for setting the wire feed speed 11. Switch for Creep start (inside)
4. Knob for setting the voltage 12. Connection for welding current from power
source (OKC)
5. Switch for wire inching or gas purge 13. Connection for control cable from power
source
6. RED connection for cooling water from
welding torch *)
7. BLUE connection for cooling water to the
welding torch *)
8. Connection for the welding torch 16. RED connection for cooling water to power
14. Connection for shielding gas
15. BLUE connection for cooling water from
power source (cooling unit) *)
source (cooling unit) *)
NOTE!
*) Cooling water connections are only available on certain models.
5.3 Water connection
When connecting a water-cooled welding torch, the power source's main power supply
switch must be in the OFF position and the cooling unit switch must be in position 0.
A water connection kit can be ordered as an accessory, see chapter "Accessories".
5.4 Starting procedure
When the wire feed starts, the power source generates the welding voltage.
If there is no welding current flow within three seconds, the power source switches the
welding voltage off. The wire feed continues until the welding torch's switch is switched to off.
5.5 Explanation of functions
Open the lid for access to the 4 stroke/2 stroke, the Cored/Solid wire and the Creep start
functions.
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5 OPERATION
2-stroke
With 2-stroke gas, pre-flow (if used) starts when the welding torch trigger switch
is pressed. The welding process then starts. Releasing the trigger switch stops
welding entirely and starts gas post-flow (if selected).
4-stroke
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is
depressed and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, the wire feed then stops and when
the switch is released the gas post-flow starts (if selected).
Wire selection – Cored wire
A constant burnback time is selected when the trigger is released, to adjust to
welding with cored wire.
Wire selection – Solid wire
Short Circuit Termination (SCT) behavior is selected when the trigger is
released, to adjust to welding with solid wire.
SCT is a new way to stop the welding that uses some small short circuits to
reduce the end crater and oxidation. It also gives the advantage of a good start
performance with solid wire.
Creep start
Creep start feeds out the wire at 4.9ft/min (1.5 m/min) until it makes electrical
contact with the workpiece.
Wire inching
Wire inching is used when feeding wire without applying a welding voltage. The
wire is fed as long as the button is depressed.
Gas purging
Gas purging is used when measuring the gas flow, or to flush any air or moisture
from the gas hoses before welding starts. Gas purging takes place for as long as
the button is held depressed and takes place without voltage or wire feed
starting.
Wire feed speed
This sets the required feed speed of the filler wire in inches per minute (in/min)
or meters per minute (m/min).
5.6 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then set the
pressure of the wire feeder's pressure rollers. It is important that the pressure is not too high.
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5 OPERATION
Figure A Figure B
To check that the feed pressure is set correctly, you can feed out the wire against an
insulated object, e.g. a piece of wood.
When you hold the welding torch approx. 5 mm from the piece of wood (figure A) the feed
rollers should slip.
If you hold the welding torch approx. 50 mm from the piece of wood, the wire should be fed
out and bend (figure B).
5.7 Changing and loading wire
• Open the side panel.
• Disconnect the pressure sensor by folding it backward; the pressure rollers slide up.
• Straighten out the new wire 4-8 in (10-20 cm). File away burrs and sharp edges from
the end of the wire before inserting it into the wire feed unit.
• Make sure that the wire goes properly into the feed roller's track and into the outlet
nozzle or wire guide.
• Secure the pressure sensor.
• Close the side panel.
5.8 Changing feed rollers
• Open the side panel.
• Disconnect the pressure sensor (1) by
folding it backwards.
• Disconnect the pressure rollers (2) by
turning the axle (3) 1/4 turn clockwise
and pulling out the axle.
The pressure rollers disconnect
• Disconnect the feed rollers (4) by
unscrewing the nuts (5) and pulling out
the rollers.
During installation, repeat the above in reverse order.
Choice of track in the feed rollers
Turn the feed roller with the dimensioning mark for the required track toward you.
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6 MAINTENANCE
6 MAINTENANCE
6.1 Overview
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.2 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
• Cleaning and replacement of worn parts in the wire feed unit mechanism should be
done at regular intervals in order to achieve trouble-free wire feed. Note that if the
pre-tensioning is set too hard, this can result in abnormal wear on the pressure roller,
feed roller and wire guide.
The brake hub
The hub is adjusted when delivered, if readjustment is required, follow the instructions below.
Adjust the brake hub so the wire is slightly slack when the wire feed stops.
• Adjusting the braking torque:
○ Turn the red handle to the locked
position.
○ Insert a screwdriver into the
springs in the hub.
Turn the springs clockwise to reduce
the braking torque.
Turn the springs counter-clockwise to
increase the braking torque.
Note: Make sure you turn both springs
by the same amount.
Welding torch
• Cleaning and replacement of the wear parts in the welding torch should be done at
regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean
regularly and clean the contact tip.
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7 ORDERING SPARE PARTS
7 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The Warrior Feed 304 is designed and tested in accordance with international and
European standard IEC/EN60974-5 and IEC/EN60974-10 Class A, Canadian standard
CAN/CSA-E60974-5 and U.S.standardANSI/IEC60974-5. Upon completion of service or
repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.
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DIAGRAM
DIAGRAM
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DIAGRAM
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WEAR PARTS
WEAR PARTS
Item Ordering
Denomination Wire type Wire dimensions
number
HI 1 0455 072 002
0456 615 001
HI 2 0469 837 880
0469 837 881
Intermediate nozzle
Intermediate nozzle
Outlet nozzle
Outlet nozzle
Fe, Ss & coredAlØ 2.0 mm steel for 0.6-1.6 mm
Fe, Ss & coredAlØ 2.0 mm steel for 0.6-1.6 mm
HI 3 0191 496 114 Key
HI 4 0215 701 007 Locking washer
HI 5a 0459 440 001 Motor gear euro,
drive gear
Item Ordering
number
Denomination Wire
type
HI 5b 0459 052 001 Feed/pressure rollers Fe, Ss
& cored
0459 052 002 Feed/pressure rollers Fe, Ss
& cored
0459 052 003 Feed/pressure rollers Fe, Ss
& cored
Ø 2.0 mm plastic for 0.8-1.6 mm
Ø 2.0 mm plastic for 0.8-1.6 mm
Wire dimen-
sions (mm)
Groove
type
Roller
markings
Ø 0.6 & 0.8 V 0.6 S2 &
0.8 S2
Ø 0.8 & 1.0 V 0.8 S2 &
1.0 S2
Ø 0.9/1.0 & 1.2 V 1.0 S2 &
1.2 S2
0459 052 013 Feed/pressure rollers Fe, Ss
& cored
0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 V-
0458 825 010 Feed/pressure rollers Cored Ø 1.2 & 1.2 V-
0458 825 002 Feed/pressure rollers Cored Ø 1.2 & 1.4 V-
0458 825 003 Feed/pressure rollers Cored Ø 1.6 V-
Ø 1.4 & 1.6 V 1.4 S2 &
1.6 S2
1.0 R2 &
knurled
1.2 R2
1.2 R2 &
knurled
1.2 R2
1.2 R2 &
knurled
1.4 R2
1.6 R2 &
knurled
2.0 R2
0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 U 0.8 A2 &
1.0 A2
0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 U 1.0 A2 &
1.2 A2
0458 824 003 Feed/pressure rollers Al Ø 1.2 & 1.6 U 1.2 A2 &
1.6 A2
Only use pressure and feed rollers marked A2, R2 or S2.
The rollers are marked with wire dimension in mm, some are also marked with inch.
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WEAR PARTS
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WEAR PARTS
Item Ordering number Denomination Notes
HI 6 Washer Ø 16/5×1
HI 7 Screw M4×12
HI 8 Screw M6×12
HI 9 Washer Ø 16/8.4×1.5
HI 10 0469 838 001 Cover
HI 11 0458 722 880 Axle and Nut
HI 12 0459 441 880 Gear adapter
HI 13 0455 049 001 Inlet nozzle Ø 3mm for 0.6-1.6mm Fe, Ss, Al and cored wire
0460 007 001 Inlet nozzle Long-life for Fe, Ss, and cored wire
HI 14 0458 999 001 Shaft
HI 15 Nut M10
HI 16 0458 748 002 Insulating
washer
HI 17 0458 748 001 Insulating
bushing
Item Ordering
Denomination Wire type Wire dimensions
number
HI 18 0156 602 001 Inlet nozzle Ø 16/5×1 Ø 2 mm plastic for 0.6 - 1.6 mm
Welding with aluminium wire
In order to weld with aluminium wire, U-shaped rollers, nozzles and liners for aluminium wire
must be used. It is recommended to use 3 m long welding torch for aluminium wire,
equipped with appropriate wear parts.
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WEAR PARTS
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ORDER NUMBERS
ORDER NUMBERS
Ordering Number Denomination Type
0465250880 Warrior ™ Feed 304
0465250881 Warrior ™ Feed 304w with water cooling
0459839085 Spare parts list
Technical documentation is available on the Internet at www.esab.com.
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ACCESSORIES
ACCESSORIES
0458 674 880 Bobbin cover kit, plastic Ø 300 mm
0458 707 880 Wheel kit
0458 707 881 Wheel kit
0459 233 880 Adapter for Ø 440 mm bobbin
Note! IP23 not valid for wire feeder with Ø
17,32 Inch (400 mm) bobbin.
0458 706 880 Lifting eye
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ACCESSORIES
0457 341 881 Strain relief for welding torch
F102 440 880 Quick connector MarathonPac™
0459 234 880 Strain relief bracket for connection set
0465 451 880 Remote kit
0459 491 895 Remote control unit M1
MIG/MAG: wire feed speed and voltage
0465 510 880 Trolley
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ACCESSORIES
0465 508 880 Trolley guide pin extension kit
Used together with the trolley when the wire
feed unit is equipped with wheel kit
0459 553 880 Remote cable 23 pole - 8 pole 5 m
0465 276 881 Water kit
0458 705 880 Counter balance device (includes mast and
counter balance)
Note! For use of the counter balance device,
a stabilizer kit (see below) is required!
Note! IP23 not valid for wire feeder with
counterbalance arm.
0465 509 880 Stabilizer kit Warrior™ (1)
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ACCESSORIES
0465 451 881 Remote Kit Railtrac / Miggytrac
Welding torch MXH 400w PP Note! MXH PP only recommended for Feed304/3004/L3004
0700 200 015
0700 200 016
0700 200 019
6 m
10 m
10 m, 45°
Welding torch MXH 300w PP Note! MXH PP only recommended for Feed304/3004/L3004
0700 200 017
0700 200 018
0700 200 020
6 m
10 m
10 m, 45°
Connection set, 70 mm², 19 poles
0459 836 880
0459 836 881
0459 836 882
0459 836 883
2 m
5 m
10 m
15 m
0459 836 884
0459 836 885
25 m
35 m
Connection set water, 70 mm², 19 poles
0459 836 890
0459 836 891
0459 836 892
0459 836 893
0459 836 894
0459 836 895
2 m
5 m
10 m
15 m
25 m
35 m
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ACCESSORIES
Connection set, 95 mm², 19 poles
0459 836 980
0459 836 981
0459 836 982
0459 836 983
0459 836 984
0459 836 985
2 m
5 m
10 m
15 m
25 m
35 m
Connection set water, 95 mm², 19 poles
0459 836 990
0459 836 991
0459 836 992
0459 836 993
0459 836 994
0459 836 995
2 m
5 m
10 m
15 m
25 m
35 m
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ACCESSORIES
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© ESAB AB 2018
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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
For contact information visit esab.com
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