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

A-7
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-7
INSTALLATION PROCEDURE
Assemble the Zipline boom according to the installa-
tion instructions provided with the boom. Next, install
and assemble the wire feeder boom package as fol-
lows:
TOOLS REQUIRED
• 7/16" wrench
• 1/2" wrench
• 11/16" wrench
• 3/4" wrench
• Phillips head screwdriver
• Flat head screwdriver
INSTALL THE WIRE DRIVE ASSEMBLY
With a 1/2" wrench, install the wire drive assembly
using the (4) 5/16-18 X .75 bolts and washers provid-
ed. Screw the bolts and washers partially into the bot-
tom of the wire drive assembly before placing the wire
drive assembly onto the feeder mount bracket & cage
assembly. After the wire drive assembly is in place,
completely tighten the bolts.
INSTALL THE CONTROL BOX ASSEMBLY
With a 7/16" wrench, install the control box assembly
using the (3) 1/4-20 X.75 bolts and washers provided.
Screw the bolts and washers partially into the control
box support before placing the control box assembly
onto the control box support. After the control box
assembly is in place, completely tighten the bolts.
INSTALL THE POWER INPUT CABLE
ASSEMBLY
With a 3/4" wrench, install the 10' power input cable
assembly between the control box and the power
source. This assembly includes a control cable fas-
tened to a 3/0 weld cable. The pin end of the control
cable assembly connects to the power source. The
socket end of the control cable assembly connects to
the control box assembly. Install the user provided
electrode work cable between the power source and
work piece. Tighten all connections completely to
ensure a good electrical connection.
NOTE: The electrode weld cable provided with the
power input cable assembly is rated for 600 amps @
60 % duty cycle. If operating above this rating, an
additional cable should be used in parallel with the
cable provided.
INSTALL THE ELECTRODE WELD CABLE
With a 3/4” wrench, install the single 3/0 electrode
weld cable between the wire drive assembly and the
control box assembly. The cable MUST be routed
through the center of the boom arm steel tube.
Tighten all connections completely to ensure a good
electrical connection.
NOTE: The electrode weld cables provided with the
wire feeder boom package is rated for 600 amps @
60 % duty cycle. If operating above this rating, an
additional cable should be used in parallel with the
cable provided.
INSTALL THE CONTROL CABLE ASSEM-
BLY
Remove the trough cover on the top of the boom arm
assembly. Install the cable assembly between the wire
drive assembly and the control box assembly. The
pin end of the cable assembly connects to the control
box assembly. The socket end of the cable assembly
connects to the wire drive assembly. Neatly place the
cable in the trough and attach the cable to the control
box support using the supplied cable hangers.
Tighten all connections completely to ensure a good
electrical connection.
INSTALL THE GAS HOSE
With an 11/16” wrench, install the 25’ gas hose
between the wire drive assembly and a gas supply
connection. Neatly place the hose in the trough.
Tighten connections completely to ensure a good gas
connection.

A-8
INSTALLATION
LN-10 / ZIPLINE BOOM PACKAGE
A-8
INSTALL THE CONDUIT BUSHINGS and
ELECTRODE CONDUIT
With the provided 1/8” allen wrench, remove the
incoming guide on the wire drive assembly. Two dif-
ferent size conduit bushings are provided in the con-
duit bushing kit, .025 to .063 and .063 to .125. Based
on the wire used for your application, find two appro-
priate wire size conduit bushings. Install one of the
conduit bushings where the incoming guide was.
Install the second conduit bushing in the clamp on the
conduit bushing bracket, located on the boom mast
above the spindle mounting bracket. Install the elec-
trode conduit between the two conduit bushings.
Push the electrode conduit into the bushing until it
stops. Screw the knurled knob assembly into each
conduit bushing to securely hold the electrode conduit
in place. Neatly place the conduit in the trough. Re-
install the trough cover.
INSTALL THE 2” SPINDLE ASSEMBLY
With a 3/4” wrench, install the 2” spindle assembly
using the 1/2-13 x 3.00 bolt and washers provided.
Place the larger washer into the spindle assembly
before installation to the boom mast spindle bracket.
Line up the small hole on the spindle assembly with
the roll pin on the mast. After the 2” spindle assembly
is in place, completely tighten the bolt.
INSTALL THE GUN CONTROL PLUG
CABLE ASSEMBLY and
THE GUN AND CABLE ASSEMBLY
Install the provided gun control plug cable assembly to
the front of the wire drive assembly. Install the gun
and cable assembly per the instruction manual provid-
ed with the gun. Gun adapters may be required if
using a Non-Lincoln gun.
INSTALL THE WELDING POWER SOURCE
Install the welding power source per the instruction
manual provided with the power source.
INSTALL THE WIRE REEL, DRIVE ROLLS
AND GUIDES
Load the wire reel with a coil of wire so as to dereel off
the side of the coil closest to the conduit bushing.
Install the appropriate drive rolls and guides for your
specific wire size application per the instruction manu-
al provided with the wire feeder. Thread the wire
through the entire length of conduit to the drive rolls to
feed through the gun cable. Repeat this step for the
opposite side of your wire feeder.

B-1
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-1
12 FT. SPRING BALANCED ZIPLINE BOOM ASSEMBLY
N.B.
.81
14.00
12.38 TYP.
R 144.0
18.28
88.25
46.00
60.00
60.00
5.00
15.00
(11'-3")
33.00
45.00
144.0
UPWARD 50 TO DOWNWARD 6.
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
46" X 48" OR 60" X 60".
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
7.75
135.0
38.25
52.25
17.38
(4 PLACES)
FOR 3/4" BOLTING
(R 12'-0")
HOLE
(12'-0")
.81
N.A.
165.6
(13'-10")
48.00
12.38
14.00
.81
TYP.
MAST PEDESTAL DETAIL

B-2
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-2
12 FT. HYDRAULIC ZIPLINE BOOM ASSEMBLY
5.00
16.45
15.00
60.00
48.00
17.38
7.75
38.25
52.25 46" X 48" OR 60" X 60".
UPWARD 50 TO DOWNWARD 18.
144.0
33.00
45.00
83.13
N.B.
.81
TYP.
MAST PEDESTAL DETAIL
.81 HOLE
(4 PLACES)
FOR 3/4" BOLTING
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
14.00
14.00
TYP.
N.A.
.81
12.38
46.00
60.00
XA
163.6
(12'-0")
(11'-1")
133.0
12.38
(12'-0")
R 144.0
(13'-8")

B-3
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-3
16 FT. SPRING BALANCED ZIPLINE BOOM ASSEMBLY
N.B.
.81
14.00
12.38 TYP.
88.25
46.00
XA
60.00
60.00
(R 16'-0")
R 192.0
213.6
(17'-10")
18.28
38.25
52.25
17.38
HOLE
FOR 3/4" BOLTING
(4 PLACES)
.81
192.0
183.0
(15'-3")
(16'-0")
N.A.
7.75
UPWARD 50 TO DOWNWARD 6.
46" X 48" OR 60" X 60".
45.00
5.00
15.00
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
33.00
48.00
TYP.
12.38
.81
MAST PEDESTAL DETAIL
14.00

B-4
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-4
16 FT. HYDRAULIC ZIPLINE BOOM ASSEMBLY
(4 PLACES)
HOLE
FOR 3/4" BOLTING
.81
14.00
TYP.
.81
12.38
12.38
60.00
48.00
17.38
7.75
38.25
52.25
.81
(16'-0")
N.A.
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
UPWARD 50 TO DOWNWARD 18.
46" X 48" OR 60" X 60".
5.00
46.00
60.00
33.00
45.00
N.B.
211.6
(17'-8")
192.0
XA
181.0
(15'-1")
16.45
83.13
TYP.
(16'-0")
R 192.0
MAST PEDESTAL DETAIL
14.00
15.00

B-5
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-5
WARNING
GRAPHICS SHOWN REPRESENT M17869-1.
3
YEAR
WARRANTY
4.58
4.27
5.25 2.80
R .141
(3 SLOTS)
10.92
18299
M
13.75
2.63
10.10
12.75
14.67
14.65
CONTROL BOX DIMENSION PRINT
5-2-97

B-6
DIMENSION PRINTS
LN-10 / ZIPLINE BOOM PACKAGE
B-6
M
3.00
6.00
2.42
12.74
7.81 6.55
2.25
10.40
4.08
WIRE DRIVE DIMENSION PRINT
14.71
4.44
5/16-18UNC-2B (4 PLACES)
5.25
4-24-98
18904
11.00

NOTES
LN-10 / ZIPLINE BOOM PACKAGE

NOTES
LN-10 / ZIPLINE BOOM PACKAGE