Operator’s Manual ZIPLINE BOOM PACKAGE · 2014. 3. 25. · ZIPLINE ®BOOM PACKAGE ... 21....

Operator’s Manual

ZIPLINE ®BOOM PACKAGE

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IM10184 | Issue D ated Dec- 13

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

K4047-XX, K4048-XX

Save for future reference

Date Purchased

Code or K#: (ex: Kxxxx-xx)

Serial: (ex: U1060512345)

2

SAFETYZIPLINE® BOOM PACKAGE

READ AND FOLLOW ALL WARNINGINFORMATION IN THIS AND ALL

OTHER MANUALS.

SPRING UNDER PRESSURERelease of spring pressure can cause serious personal injuryand equipment damage.

• Do not remove spring rod shipping support until boom iscompletely assembled and all components are installed.

• Do not service or adjust spring pressure on boom without thespring rod shipping support securely installed.

MOVING BOOM PARTS CAN CAUSE SERIOUSPERSONNEL INJURY.

• Keep hands away from spring rod clevis and swivel plates.

FALLING BOOM CAN CAUSE SERIOUS PERSONALINJURY AND EQUIPMENT DAMAGE

• Securely attach pallet base or pedestal to floor beforeoperating boom arm.

UNBALANCED BOOM CAN CAUSE SERIOUSPERSONAL INJURY AND EQUIPMENT DAMAGE.

• Do not remove wire drive unit without the spring rod shippingsupport securely installed.

ONLY QUALIFIED PERSONNEL SHOULD INSTALL USEOR SERVICE THIS EQUIPMENT.

READ AND FOLLOW THE MANUFACTURERSINSTRUCTIONS AND YOUR EMPLOYER’S SAFETY

PRACTICES.

WARNING

CAUTION

WARNING

WARNING

WARNING

WARNING

TABLE OF CONTENTSZIPLINE® BOOM PACKAGE

PageSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation......................................................................................................................................................Section A

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Product Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Spring Balanced Single Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 thru A-5Hydraulic Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Dimension Prints ...........................................................................................................................................Section B8 Ft. Spring Balanced Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-18 Ft. Hydraulic Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-212 Ft. Spring Balanced Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-312 Ft. Hydraulic Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-416 Ft. Spring Balanced Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-516 Ft. Hydraulic Zipline Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

A-1

PRODUCT DESCRIPTIONZIPLINE® BOOM PACKAGE

PRODUCT DESCRIPTIONThis wire feeder boom package comprised of Lincoln equipment willallow you to setup a boom welding system when used in conjunctionwith Zipline® boom products. This boom package includes everythingyou need from Lincoln to easily setup a standard 8 ‘, 12 ‘ or 16 Footfeet welding station using the Zipline boom product line.

The Lincoln boom packages will include the following items:

1. Wire Drive Assembly

2. Control Box Assembly

3. Pallet Base (Optional)

4. Boom Arm Assembly

5. Pedestal

6. Mast Assembly

7. 8’ Linc-Net Cable

8. Polymer Weld Wire Conduit (1 per Head)

9. Spindle Assembly (1 per Head)

10. Hardware Kit

11. Conduit Bracket (1 per Head)

12. Gun Control Plug Cable Assembly (1 per Head)

13. Wire Feeder Instruction Manual

14. Boom Package Instruction Manual

PRODUCT SPECIFICATIONSProduct Number

K4047-8S

K4047-8H

K4047-12S

K4047-12H

K4047-16S

K4047-16H

K4048-8D

K4048-8H

K4048-12D

K4048-12H

K4048-16D

K4048-16H

Product Description

PF-84 Single Boom Package, 8FT

PF-84 Single Hydraulic Boom Package, 8FT





PF-84 Dual Boom Package, 8FT

PF-84 Dual Hydraulic Boom Package, 8FT





12

45

7 8

9 10 11 1213

14

6

3

A-2

INSTALLATIONZIPLINE® BOOM PACKAGE

BOOM INSTALLATION

INSTALL THE PEDESTAL

1. Pallet Base (Optional)

2. 3/4-10 x 1.5” Bolts

3. Pedestal

Mount the pedestal assembly on the pallet base using the (4) 3/4-10 x1.5” bolts, nuts and washers provided. If a pallet base is not used,mount the pedestal directly to a solid concrete floor. Use (4) 3/4”concrete anchors (not provided) with washers.

INSTALL THE MAST ASSEMBLY

4. Mast Assembly

• Coat the bottom pipe with grease. Put mast assembly into pedestal.

INSTALL THE BOOM ARM ASSEMBLY

5. Boom Arm Assembly

6. 3/4-10 X 3.5 Bolt

7. Plain Washer

8. Lock Nut

Remove the friction knob from top of the mast. Place the swivel sail-in plate on the rear boom arm between the two mounting plates onthe top of the mast assembly. Install the main swivel pin first. Place 2plain washers under the head of the bolt and 2 under the lock nut.Tighten the lock nut completely and then back the lock nut off 1 fullturn for the main swivel pin, back the lock nut 2 full turn off for theclevis swivel pin. Re-install the friction control knob.

1

2

3

4

GREASE BOTTOM PIPE HERE

{

A-3


INSTALL THE CONDUIT BRACKET

9. Conduit Bracket

10. 1/4”-20 x .75” Bolt

11. 1/4” Plain Washer

12. 1/4” Lock Washer

13. 1/4”-20 HHN-1427

14. Bracket AD1329-279

15. Bulkhead Adapter Block AD1329-278

16. Quick Disconnect AD1329-53

Install the conduit bracket assembly to the mast using 1/4”-20 x .75”bolts, washers and nuts provided. Place 1 plain washer under thehead of the bolt and 1 under the lock washer. Line up the small holeson the bracket with the mounting holes on the mast. After the bracketis in place, completely tighten the bolt. Install bracket, bulkheadadapter and quick disconnect to conduit bracket. Repeat this step forthe opposite side if necessary.

INSTALL THE SPINDLE ASSEMBLY (OPTIONAL)

17. Spindle Assembly

18. Friction Washer

19. Plain Washer

20. Lock Washer

21. 1/2”-13 x 3.5” Bolt

Remove origin .625” bolt from the Spindle Assembly. Place 2additional friction washers under the spindle. Install the spindleassembly using the 1/2”-13 x 3.50” bolt and washers provided. Lineup the small hole on the spindle assembly with the roll pin on themast. After the spindle assembly is in place, completely tighten thebolt. Repeat this step for the opposite side if necessary.

A-4


INSTALL THE WIRE CONDUIT

22. Polymer Weld Wire Conduit

Mount conduit through cable trough. Connect the conduit to quickdisconnect.

INSTALL THE INLET GUIDE

16. Quick Disconnect AD1329-53

23. Wire Feeder

24. Inlet Guide AD1329-578

Remove original inlet guide from wire feeder. Install Inlet GuideAD1329-578 and quick disconnect. Repeat this step for the oppositeside if necessary.

INSTALL THE WIRE DRIVE ASSEMBLY

24. 5/16”-18 X .75” HHCS

25. 5/16” Lock Washer

26. 5/16” Plain Washer

Install the wire drive assembly using the (4) 5/16”-18 x .75” bolts andwashers provided. Screw the bolts and washers partially into thebottom of the wire drive assembly before placing the wire driveassembly onto the feeder mount bracket and cage assembly. Afterthe wire drive assembly is in place, completely tighten the bolts.Connect the wire drive to control cable, weld cable, gas hose and wireconduit.

INSTALL THE CONTROL BOX

27. Control Box Assembly

Unscrew the (4) 1/4”-20 x .75” bolts partially. Place the control boxassembly onto the control box support. Connect the control box tocontrol cable.

A-5


REMOVE THE SPRING ROD SHIPPING SUPPORT

Once all the welding equipment is installed, pull down on the feederend and test the amount of force acting on the boom. If the boom armimmediately springs back against the spring rod shipping support or ifthe feeder has already drooped downward without additional force,then the spring assembly must be rebalanced. See Boom BalancingInstructions steps 1 thru 6. If the boom arm can be pulled down and itstays in place or slightly creeps upward the spring rod shippingsupport can now be removed. Place it on the provided holder on themast top or in a handy location.

28. Red Spring Rod

Loosen the friction control knob until the desired boom balance isobtained. Again if the boom does not balance as desired, follow theprovided boom balancing instructions. But only after reinstalling thespring rod shipping support.

BOOM BALANCED INSTRUCTION

1. Re-install the red spring rod shipping support between the top ofthe spring retainer housing and the nut at the bottom of the clevison the spring rod.

2. Remove the spring retainer cap at the bottom of the spring retainerhousing by removing the four bolts which hold the spring retainercap onto the spring retainer housing.

3. Loosen the locking nut on the end of the spring rod. Loosen thelocking nut enough to permit loosening or tightening of theadjusting nut which is the nut held in place by the locking nut.

4. If the boom has a tendency to drift downward after being pushedup, it will be necessary to increase the spring compression bytightening the adjusting nut mentioned in step 3. If the boom has atendency to drift upward, it will be necessary to decrease thespring compression by loosening the adjusting nut mentioned instep 3.

5. After making the above adjustments, do the following:

a. Re-tighten the locking nut loosened in step 3.

b. Loosen the friction control knob.

c. Remove the spring rod shipping support installed in step 1.

d. Pull the boom down to a position which is horizontal, using arope of suitable strength. Loosen the grip on the rope enoughto see whether or not the boom is balanced. The best conditionof balance is obtained when the boom rises an inch or so whenthe pull on the rope is loosened.

e. Tighten the friction control knob to control this slight upwardmovement.

6. Re-install the spring retainer cap removed in step 2.

INSTALL THE GUN AND CABLE ASSEMBLIES

Install the provided gun control plug cable assemblies to the front ofthe wire drive assembly. Install the gun and cable assemblies per theinstruction manual provided with the gun. Gun adapters may berequired if using a Non-Lincoln gun.

INSTALL THE WELDING POWER SOURCE

Install the welding power source per the instruction manual providedwith the power source. Install the user provided electrode work cablebetween the power source and work piece. Tighten all connectionscompletely to ensure a good electrical connection.

NOTE: The electrode weld cables provided with the wire feeder boompackage is rated for 600 amps @ 60 % duty cycle. Ifoperating above this rating, an additional cable should beused in parallel with the cable provided.

A-6


HYDRAULIC BOOM INSTALLATION

1. Install the pedestal on the optional pallet base with the provided3/4”x 2” bolts and hardware. The pallet should be some securedto the floor using, at minimum, a lash style system to preventtipping. If the unit will be mounted directly to shop floor, mountthe pedestal using at least 3/4” diameter concrete anchors.Standard floor mounting company procedures should be followed.

2. Insert the machine end of the mast into the pedestal and insertgrease into the two zerks on the pedestal. Rotate the mast tocoat the inside of the pedestal pipe and insure the mast turnssmoothly.

3. Insert the boom between the two uprights of the mast top and lineup the axle holes. We recommend that at least to people involvethemselves in this operation. Insert the provided 3/4” x 7” axlepin through the mast and boom and secure with the hitch pin.The washers should be between the hitch pin and upright.

4. Install the jack using the 1/2” bolt to fasten to the mast mountand the 3/4” pins with hitch pins mounting the jack to the bottomof the boom.

5. Install the safety device using the provided pins, top and bottom,outside the jack toward the feeder end of the boom.

6. Insure that the jack raises the boom assemble using the suppliedhandle. The safety device will automatically expand to length asthe boom is raised. Using the handle, relieve the pressure on thejack, WHILE holding pressure on the safety device’s pipe clamptabs. This will allow the unit to drop until desired elevation isreached.

7. Mount feeder support and control box mount to boom and mastusing the provided 3/8” bolts. (See Spring Boom Mounting forgraphics in this Instruction Manual)

8. Mount the conduit bracket on the mast where the wire reel willmount. (See Spring Boom Mounting for graphics in this InstructionManual)

2

GREASE BOTTOM PIPE HERE

{

BOOM3/4”x 7 axle pin

Two uprights

1/2” bolts to mast

3/4” pins to mount jack to bottom end of boom

B-1

DIMENSIONZIPLINE® BOOM PACKAGE

8 FT. SPRING BALANCED ZIPLINE BOOM ASSEMBLY

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8 FT. HYDRAULIC ZIPLINE BOOM ASSEMBLY

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CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Operator’s Manual ZIPLINE BOOM PACKAGE · 2014. 3. 25. · ZIPLINE ®BOOM PACKAGE ... 21....

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Transcript of Operator’s Manual ZIPLINE BOOM PACKAGE · 2014. 3. 25. · ZIPLINE ®BOOM PACKAGE ... 21....