ESAB Aristo Origo Feed 3004 User manual

Aristo®, Origo™
Instruction manual
0444 408 331 US 20200406 Valid for: from serial no. 910-, 236-, 540-, 628-xxx-xxxx
Feed3004

TABLE OF CONTENTS
0444 408 331 © ESAB AB 2020
1SAFETY ....................................................................................................... 3
1.1 Meaning of symbols ............................................................................... 3
1.2 Safety precautions ................................................................................. 3
1.3 User responsibility ................................................................................. 7
2INTRODUCTION.......................................................................................... 10
2.1 Equipment ............................................................................................... 10
2.2 Control panel .......................................................................................... 10
3TECHNICAL DATA ...................................................................................... 12
4INSTALLATION............................................................................................ 13
4.1 Lifting instructions ................................................................................. 13
5OPERATION ................................................................................................ 14
5.1 Connections and control devices ......................................................... 15
5.2 Water connection ................................................................................... 16
5.3 Wire feed pressure ................................................................................. 16
5.4 Replacing and inserting wire................................................................. 17
5.5 Changing feed rollers............................................................................. 17
6MAINTENANCE........................................................................................... 18
6.1 Inspection and cleaning......................................................................... 18
7ORDERING SPARE PARTS ........................................................................ 20
DIAGRAM ............................................................................................................ 21
WEAR PARTS...................................................................................................... 23
ORDERING NUMBERS....................................................................................... 28
ACCESSORIES ................................................................................................... 29
Rights reserved to alter specifications without notice.

1 SAFETY
0444 408 331 -3- © ESAB AB 2020
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.
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.

1 SAFETY
0444 408 331 -4- © ESAB AB 2020
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.
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.

1 SAFETY
0444 408 331 -5- © ESAB AB 2020
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.)
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:
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.

1 SAFETY
0444 408 331 -6- © ESAB AB 2020
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.
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.

1 SAFETY
0444 408 331 -7- © ESAB AB 2020
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:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
Containers That Have Held Hazardous Substances”
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot
Work"
• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
Cylinders”
• 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.
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

1 SAFETY
0444 408 331 -8- © ESAB AB 2020
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.
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

1 SAFETY
0444 408 331 -9- © ESAB AB 2020
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.
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.

2 INTRODUCTION
0444 408 331 - 10 - © ESAB AB 2020
2 INTRODUCTION
The wire feed unit Feed 3004 with control panel U6,MA23,MA24 or MA25 Pulse is
intended for MIG/MAG welding together with 400A, 500A and 600A CAN welding power
sources.
The wire feed units 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 300 mm, accessory Ø 440 mm).
The wire feed unit can be installed either on the power source trolley, suspended above the
workplace, on a counter balance device or on the floor with or without wheel set.
ESAB's accessories for the product can be found in chapter "ACCESSORIES" of this
manual.
2.1 Equipment
The wire feed unit is supplied with:
• instruction manual for the wire feed unit
• instruction manual in English for the control panel
Instruction manuals in other languages can be downloaded from the Internet:
www.esab.com
• decal with recommended wear parts.
2.2 Control panel
The wire feed unit is supplied with one of the following control panels:
Empty panel for use with double wire feed units or
with use of control box U82.
U6
Knobs for setting the voltage and the wire feed speed
/ current. Other parameters are controlled by
pushbuttons, with text in the display panel.
MA23
Knobs for setting the voltage and the wire feed speed
/ current. Other settings with push buttons.
MA24
Knobs for setting the voltage / QSet™ and the wire
feed speed / current. Other settings with push
buttons.

2 INTRODUCTION
0444 408 331 - 11 - © ESAB AB 2020
MA25
Pulse
Knobs for setting the voltage / QSet™ and the wire
feed speed / current. Other settings with push
buttons.
See the separate instruction manual for a detailed description of the control panels.

3 TECHNICAL DATA
0444 408 331 - 12 - © ESAB AB 2020
3 TECHNICAL DATA
Feed 3004
Mains voltage 42V, 50-60Hz
Power requirement 336VA
Motor current Imax 8A
Wire feed speed 32–984in./min (0.8–25.0m/min)
Torch connection EURO
Max. diameter wire bobbin 12in. (*17in.) (300mm / *440mm)
Wire dimension
Fe 0.030–1/16in. (0.8–1.6mm)
Ss 0.030–1/16in. (0.8–1.6mm)
Al 0.040 & 1/16in. (1.0 & 1.6mm)
Cored wire 0.035–1/16in. (0.9–1.6mm)
Weight 33.1lbs (15kg)
Dimensions l×w×h 27.2×10.8×16.6in. (690×275×420mm)
Operating temperature 14 to 104°F (-10 to +40°C)
Shielding gas All types intended for MIG/MAG welding
max pressure 73 PSI
Coolant ESAB ready mixed coolant
max pressure 73 PSI
Maximum permissible load at
60% duty cycle 630A
100% duty cycle 500A
Enclosure class IP23
*Accessories can be found in the "ACCESSORIES" chapter.
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) or below.
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.

4 INSTALLATION
0444 408 331 - 13 - © ESAB AB 2020
4 INSTALLATION
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 .
4.1 Lifting instructions
CAUTION!
To avoid personal injury and/or equipment damage, lift using method and attachment
point shown here.
Order number for lifting eyelet can be found in chapter "ACCESSORIES".
NOTE!
If another mounting device is used, this must be electrically insulated from the wire
feed unit.
CAUTION!
If equipment is placed on a surface that slopes more than 10°, toppling over may
occur. Personal injury and/or significant damage to equipment is possible.

5 OPERATION
0444 408 331 - 14 - © ESAB AB 2020
5 OPERATION
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 electrode wire or parts in contact with it, or uninsulated
cable or connection.
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.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
There is a risk of tipping, if the wire feed unit is fitted with a counterbalance arm.
Secure the equipment, especially if used on an uneven or sloping surface.
WARNING!
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the
welding wire between the feed rollers.
WARNING!
Before making any connections between the wire feeder and the welding power
source, turn off power to the welding power source and the wire feeder.

5 OPERATION
0444 408 331 - 15 - © ESAB AB 2020
WARNING!
Be sure to properly insulate this connection before applying power to the power
source. Uninsulated cable and parts can arc when contacting a grounded surface.
The arc may damage eyes or start a fire. Body contact with an uninsulated weld
cable connector, or uncovered conductor can shock, possibly fatally.
WARNING!
Unless starting to weld, do not allow the welding wire to touch a grounded metal
surface. The welding wire becomes electrically hot when the secondary contact is
closed. Keep fingers clear of the drive rolls; they will start turning when the torch
trigger is pressed.
WARNING!
When the power switch is on, and torch trigger is depressed, the electrode wire
becomes electrically hot and the wire feed rolls are activated. Do not touch the wire
as it may cause a possibly fatal shock. Unless welding, do not allow wire to touch a
grounded metal surface as it will cause an arc flash. Keep clear of feed rolls and
drive gears.
WARNING!
Prior to welding, it is imperative that proper protective clothing (welding coat and
gloves) and eye protection (glasses and/or welding helmet) be put on. Failure to
comply may result in serious injury.
WARNING!
Failure to shut off shield gas in a confined space may result in a build-up of fumes,
displacing oxygen.
CAUTION!
Do not terminate the arc by removing the torch from the weld area. Release the
torch trigger to stop welding before removing the torch.
NOTE!
When moving the equipment, use the handle intended for transportation. Never pull
the equipment by the welding torch.
5.1 Connections and control devices
1Control panel, (see separate instruction
manual)
6Connection for welding current from
power source, (OKC)
2a Connection for remote control unit 7Connection for control cable from power
source or cooling unit
2b Connection for U82
3Connection BLUE, with ELP* for coolant
to the welding torch
8Connection RED, for coolant to cooling
unit

5 OPERATION
0444 408 331 - 16 - © ESAB AB 2020
4Connection RED, for coolant from
welding torch
9Connection for shielding gas
5Connection for welding torch 10 Connection BLUE, for coolant from
cooling unit
NOTE!
Display (digital instrument) and coolant connections only available on certain models.
CAUTION!
Make sure the torch chosen is of the proper rating for the welding current to be used,
has the proper size and type of liner, the proper contact tip and the proper guide tube.
5.2 Water connection
The wire feed unit with water connection is equipped with a detection system ELP (ESAB
Logic Pump) which checks that the water hoses are connected. When connecting a
water-cooled welding torch, the water pump starts.
Detection only works with power sources that are equipped with ELP.
5.3 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
great.
Fig 1 Fig 2

5 OPERATION
0444 408 331 - 17 - © ESAB AB 2020
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 torch approx. 5 mm from the piece of wood (fig. 1) the feed rollers should
slip.
If you hold the torch approx. 50 mm from the piece of wood, the wire should be fed out and
bend (fig. 2).
5.4 Replacing and inserting wire
• Open the side panel.
• Disconnect the pressure sensor by folding it backward; the pressure rollers slide up.
• If necessary, roll back the wire and remove the wire bobbin.
• 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 outflow
nozzle or wire guide.
• Secure the pressure sensor.
• Close the side panel.
5.5 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.

6 MAINTENANCE
0444 408 331 - 18 - © ESAB AB 2020
6 MAINTENANCE
WARNING!
Be sure the branch circuit or main disconnect switch is off or electrical input circuit
fuses are removed from the power source main supply before attempting any
inspection or work on the inside of the wire feeder. Placing the power switch on the
welding machine in the off position does not remove all power from inside of the
equipment.
WARNING!
Inspection, troubleshooting, and repair of this equipment should be undertaken by a
competent individual having at least general experience in the maintenance and
repair of semi-conductor electronic equipment. Maintenance or repair should not be
undertaken by anyone without such qualifications.
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.
NOTE!
Regular maintenance is important for safe and reliable operation.
6.1 Inspection and cleaning
WARNING!
If uninsulated cable and parts are not replaced, an arc caused by a bared cable or
part touching a grounded surface may damage unprotected eyes or start a fire. Body
contact with bared cable, connector, or uncovered conductor can shock, possibly
fatally.
Wire feed unit
Regularly check that the wire feed unit is not clogged with dirt.
• Cleaning and replacement of worn parts in the mechanism of the wire feed should take
place at regular intervals in order to achieve trouble-free wire feeding.
NOTE!
If pre-tensioning is set too hard, this can result in abnormal wear on the pressure
roller, feed roller and wire guide.

6 MAINTENANCE
0444 408 331 - 19 - © ESAB AB 2020
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!
Turn both springs the same amount.
Welding torch
• The wear parts of the welding torch should be cleaned and replaced at regular intervals
in order to achieve trouble-free wire feeding. Regularly blow the wire guide clean and
clean the contact tip.

7 ORDERING SPARE PARTS
0444 408 331 - 20 - © ESAB AB 2020
7 ORDERING SPARE PARTS
CAUTION!
Do not make any repairs to the equipment unless you are fully qualified, as
described in the maintenance section.
Feed 3004 is designed and tested in accordance with the international and European
standards IEC/EN 60974-5 and IEC/EN 60974-10. It is the obligation of the service unit
that carried out the service or repair work to make sure that the product still
conforms to said standard.
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.