Lincoln Electric ZIPLINE IM596-2A User manual

LN-10 / ZIPLINE BOOM PACKAGE
®
OPERATOR’S MANUAL
IM596-2A
March, 2001
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
For use with “K” Sales Spec Numbers: K1564-2
K1564-3
K1564-5
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.

i
SAFETY
i
WARNING
READ AND FOLLOW ALL WARNING INFORMATION IN THIS AND ALL OTHER MANUALS
SPRING UNDER PRESSURE
Release of spring pressure can cause serious personal injury and equipment
damage.
• Do not remove spring rod shipping support until boom is completely assembled
and all components are installed.
• Do not service or adjust spring pressure on boom without the spring rod shipping
support securely installed.
WARNING
FALLING BOOM CAN CAUSE SERIOUS PERSONAL INJURY AND EQUIPMENT
DAMAGE.
• Securely attach pallet base or pedestal to floor before operating boom arm.
WARNING
MOVING BOOM PARTS CAN CAUSE SERIOUS PERSONAL INJURY.
• Keep hands away from spring rod clevis and swivel plates.
WARNING
CAUTION
UNBALANCED BOOM CAN CAUSE SERIOUS PERSONAL INJURY AND
EQUIPMENT DAMAGE.
• Do not remove wire drive unit without the spring rod shipping support securely
installed.
WARNING
ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS
EQUIPMENT.
READ AND FOLLOW THE MANUFACTURER’S INSTRUCTIONS AND YOUR
EMPLOYER’S SAFETY PRACTICES.

Thank You for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
iiii
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your sales information.
Model Name and Sales SpecNumber (K-xxx) _____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

iii
iii TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Product Description ..............................................................................................................A-1
Zipline Boom Models............................................................................................................A-1
Recommended Wire Feeder - Power Source Combinations ...............................................A-2
Product Specifications..........................................................................................................A-2
Unpacking and Checking Kit Contents.................................................................................A-3
Installation Procedure...........................................................................................................A-7
Tools Required..............................................................................................................A-7
Install the Wire Drive Assembly ....................................................................................A-7
Install the Control Box Assembly .................................................................................A-7
Install the Power Input Cable Assembly........................................................................A-7
Install the Electrode Weld Cable ...................................................................................A-7
Install the Control Cable Assembly ...............................................................................A-7
Install the Gas Hose......................................................................................................A-7
Install the Conduit Bushings and Electrode Conduit .....................................................A-8
Install the 2” Spindle Assembly .....................................................................................A-8
Install the Gun Control Plug Cable Assembly and the Gun and Cable Assembly ........A-8
Install the Welding Power Source .................................................................................A-8
Install the Wire Reel, Drive Rolls and Guides ...............................................................A-8
Dimension Prints ............................................................................................................Section B
12 Ft. Spring Balanced Zipline Boom Assembly ..................................................................B-1
12 Ft. Hydraulic Zipline Boom Assembly..............................................................................B-2
16 Ft. Spring Balanced Zipline Boom Assembly ..................................................................B-3
16 Ft. Hydraulic Zipline Boom Assembly..............................................................................B-4
Control Box Assembly ..........................................................................................................B-5
Wire Drive Assembly ............................................................................................................B-6

A-1
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-1
PRODUCT DESCRIPTION
This wire feeder boom package comprised of Lincoln
equipment will allow you to setup a boom welding sys-
tem when used in conjunction with Zipline® boom
products. This boom package includes everything you
need from Lincoln to easily setup a standard 12 or 16
foot welding station using the Zipline boom product
line.
You will need to purchase the boom and related prod-
ucts from Bird Machine and Repair, Inc., 100 Station
St., Johnstown, PA. 15905, [phone], the manu-
facturer of the Zipline® boom product line.
The Lincoln boom package will include the following
items:
Wire Drive Assembly
Control Box Assembly
Electrode Weld Cables
Control or Linc-Net Cables
Gas Hoses
Electrode Conduits
2" Spindle Assemblies
Hardware Kit
Conduit Bushing Kit
Gun Control Plug Cable Assembly (1 per Head)
Wire Feeder Instruction Manual
Boom Package Instruction Manual
ZIPLINE BOOM MODELS
Both 12 and 16 foot boom length models are available
from Zipline. Two different boom balancing designs
are also available; a spring balanced boom model and
a hydraulic boom model. The standard Zipline boom
configurations are as follows:
12' Spring Balanced Zipline Boom
16' Spring Balanced Zipline Boom
12' Hydraulic Zipline Boom
16' Hydraulic Zipline Boom
The following items will be provided by Bird Machine and Repair
Inc., the manufacturer of the Zipline boom product line:
Pallet Base Assembly (optional)
Pedestal Base Assembly
Boom Mast
Spring Retainer Housing or Hydraulic Device
Boom Arm
Cable and Hose Trough
Conduit Bushing Bracket
Provisions to Mount 2" Spindle Assembly
Control Box Support Assembly (optional)
Feeder Mount Bracket and Cage Assembly (optional)
See Figure A.1 for illustration of the Zipline products.
See the following pages for illustrations of the Lincoln
Products.
24078
7
ZIPLINE BOOM PACKAGES
5
BOOM MAST & SPRING RETAINER HOUSING ASSY
1
2
3
10 8
9
12
11
4
S
A
24078
DESCRIPTIONITEM
1
2
PALLET BASE ASSEMBLY (OPTIONAL)
3
PEDESTAL ASSEMBLY
4
QTY.
5
SPRING ROD CLEVIS
MAIN SWIVEL PIN
6
7
8
1
9
10
FRICTION CONTROL KNOB
1
11
12
1
BOOM ARM ASSEMBLY
CONDUIT BUSHING BRACKET
SPRING ROD SHIPPING SUPPORT
1
CABLE & HOSE TROUGH
1
CONTROL BOX SUPPORT ASSEMBLY (OPTIONAL)
1
1
2
1
1
2
FEEDER MOUNT BRACKET & CAGE ASSEMBLY (OPTIONAL) 1
6
FIGURE A.1

A-2
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-2
RECOMMENDED WIRE FEEDER -
POWER SOURCE COMBINATIONS
The Zipline booms have been designed to integrate
with newer wire feeders and power sources. The fol-
lowing is a list of wire feeders and power sources that
are compatible with the Zipline boom’s pallet base,
control box support and feeder mount bracket/cage
assembly.
Wire Feeders Power Sources
LN-10 CV-250
DH-10 CV-300-I
CV-300
CV-400-I
CV-400
CV-500-I
CV-655
** DC-250
DC-400
** PP-500
** DC-600
DC-655
** DC-1000
PF-10 PW-455
STT-10 STT-II
** A K1520-1 115V/42V Transformer Kit is required
with these power sources.
PRODUCT SPECIFICATIONS
Product Number Product Description Net Weight (lbs.)
K1564-2 LN-10 Boom Package - 90
12' Zipline Boom
K1564-3 LN-10 Boom Package - 103
16' Zipline Boom
K1564-5 LN-10 Boom Package - 90
12' Zipline Boom
See the appropriate Dimension Print in Section B of
this manual for details on the physical size of the
equipment.

A-3
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-3
7
(1) GUN CONTROL ASSEMBLY
6
(1) ELECTRODE WELD CABLE
45
(1) POWER INPUT CABLE ASSEMBLY (1) GAS HOSE
1
K1564-2 LN-10 B00M PACKAGE - 12' ZIPLINE BOOM
K1564-3 LN-10 B00M PACKAGE - 16' ZIPLINE BOOM
INSTRUCTION MANUAL
REQUIRED TOOLS
11/16" WRENCH7/16" WRENCH 3/4" WRENCH
1/2" WRENCH FLAT HEAD SCREWDRIVERPHILLIPS HEAD SCREWDRIVER
UNPACK THE BOOM PACKAGE
K1564-3K1564-2
DESCRIPTION REQ'D
ITEM
CHECK YOUR BOOM PACKAGE
FOR THE FOLLOWING:
PART NO.PART NO.
1
WIRE DRIVE ASSEMBLY
M18899-1
1
M17869-5 1
CONTROL BOX ASSEMBLY
2
1
CONTROL CABLE ASSEMBLY
3
M18298-2-10 1
POWER INPUT CABLE ASSEMBLY
4
L9776-C-18 L9776-C-22
CL012325 1
CL012326 ELECTRODE WELD CABLE
5
1
S18453-3 GAS HOSE
6
1
S20023-A-21S20023-A-17
ELECTRODE CONDUIT
7
1
M14935-1 2" SPINDLE ASSEMBLY
1
(1) WIRE DRIVE ASSEMBLY (1) CONTROL BOX ASSEMBLY (1) CONTROL CABLE ASSEMBLY
S23858-2 HARDWARE KIT
9
1
S23859 CONDUIT BUSHING KIT
10
1
M15608 GUN CONTROL ASSEMBLY
11
L3326-169
BOOM PACKAGE INSTRUCTION MANUAL
12 1
L2213-528 WIRE FEEDER INSTRUCTION MANUAL
13 1
3
2
8
11
8
(1) 2" SPINDLE ASSEMBLY
(1) ELECTRODE CONDUIT

A-4
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-4
5
(1) SOCKET KEY-3/16 ALLEN WRENCH
12
(1) SOCKET KEY-1/8 ALLEN WRENCH
ITEM 9 S23858-2
11
(1) 1/2-13X3.0 HHCS-GR8
9
2
(4) PLAIN WASHER
LOW SPEED PINION
PLAIN WASHER
3/16 ALLEN WRENCH
DESCRIPTION
HARDWARE KIT
(3) PLAIN WASHER
(1) PLAIN WASHER
INSTRUCTION MANUAL
K1564-3 LN-10 B00M PACKAGE - 16' ZIPLINE BOOM
10
13
8 T8833-64
9
10 E106A-15
11 T11563-2
12 T11563-3
M18223-113
1
(3) 1/4-20X.75 HHCS-GR2
4
(4) 5/16-18X.75 HHCS-GR2
7
(1) PLAIN WASHER
8
6
3
(4) LOCK WASHER
(3) LOCK WASHER
(1) LOCK WASHER
(1) LOW SPEED PINION
B-RW
S23858-2
1
1
1
1
1
1
1
4
3
4
3
4
3
QTY.
PLAIN WASHER
1/8 ALLEN WRENCH
LOCKWASHER
5/16-18X.75HHCS-GR2
1/2-13X3.00HHCS-GR8
PLAIN WASHER
1/4-20X.75 HHCS-GR2
LOCKWASHER
PLAIN WASHER
LOCKWASHER
S9262-98
E106A-14
S9262-14
PART No.
E106A-2
CF000040
S9262-1
CF000014
S9262-30
1
3
7
4
2
5
6
ITEM
K1564-2 LN-10 B00M PACKAGE - 12' ZIPLINE BOOM

A-5
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-5
DESCRIPTION
CONDUIT BUSHING (.025-.063)
CONDUIT BUSHING (.063-.125)
KNURLED KNOB ASSEMBLY
INSTRUCTION MANUAL
CONDUIT BUSHING KIT
KNURLED KNOB ASSEMBLY
CONDUIT BUSHING (.025-.063)
CONDUIT BUSHING (.063-.125)
K1564-3 LN-10 B00M PACKAGE - 16' ZIPLINE BOOM
K1564-2 LN-10 B00M PACKAGE - 12' ZIPLINE BOOM
S23750-2
S23750-1
S22933
PART No.
1
3
2
ITEM
ITEM 10 S23859
B-RW
S23859
2
2
2
QTY.
1
2
3

A-6
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-6
FRONT VIEW
LN-10 CONTROL BOX ASSEMBLY
MOUNTING SLOTS
REINSTALL
COVER AFTER
CONNECTIONS
ARE MADE
CONNECT
ELECTRODE
WELD CABLE
TO WIRE FEEDER
HERE
CONNECT
ELECTRODE
WELD CABLE
FROM POWER
SOURCE HERE
MOUNTING SLOT CONNECT
POWER INPUT
CONTROL CABLE
FROM POWER
SOURCE HERE
CONNECT
CONTROL CABLE
ASSEMBLY TO WIRE
FEEDER HERE