Lincoln Electric IM596-2A User Manual

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LN-10 / ZIPLINE BOOM PACKAGE

IM596-2A

March, 2001

For use with “K” Sales Spec Numbers:

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 thought­ful 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.

K1564-2
K1564-3
K1564-5

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2001 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

READ AND FOLLOW ALL WARNING INFORMATION IN THIS AND ALL OTHER MANUALS

WARNING

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

MOVING BOOM PARTS CAN CAUSE SERIOUS PERSONAL INJURY.

i

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

WARNING

FALLING BOOM CAN CAUSE SERIOUS PERSONAL INJURY AND EQUIPMENT
DAMAGE.

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

WARNING

UNBALANCED BOOM CAN CAUSE SERIOUS PERSONAL INJURY AND
EQUIPMENT DAMAGE.

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

CAUTION

ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS
EQUIPMENT.

READ AND FOLLOW THE MANUFACTURER’S INSTRUCTIONS AND YOUR
EMPLOYER’S SAFETY PRACTICES.

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

iiii

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.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

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

iii

A-1

INSTALLATION

A-1

PRODUCT DESCRIPTION

This wire feeder boom package comprised of Lincoln
equipment will allow you to setup a boom welding sys­tem 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 prod­ucts from Bird Machine and Repair, Inc., 100 Station
St., Johnstown, PA. 15905, [phone], the manu­facturer 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.

DESCRIPTIONITEM

12PALLET BASE ASSEMBLY (OPTIONAL)

PEDESTAL ASSEMBLY
BOOM MAST & SPRING RETAINER HOUSING ASSY

3
4

SPRING ROD CLEVIS

5

MAIN SWIVEL PIN

6

FRICTION CONTROL KNOB

7

SPRING ROD SHIPPING SUPPORT
CONDUIT BUSHING BRACKET

8
9

CONTROL BOX SUPPORT ASSEMBLY (OPTIONAL)

10

BOOM ARM ASSEMBLY

11

CABLE & HOSE TROUGH
FEEDER MOUNT BRACKET & CAGE ASSEMBLY (OPTIONAL)

12

12

QTY.

4

1
1
1
1
1
1
1
2
1
1
2
1

11

6

10

1

3

ZIPLINE BOOM PACKAGES

8

S

5

7

9

2

24078

24078

A

FIGURE A.1

LN-10 / ZIPLINE BOOM PACKAGE

A-2

INSTALLATION

A-2

RECOMMENDED WIRE FEEDER ­POWER SOURCE COMBINATIONS

The Zipline booms have been designed to integrate
with newer wire feeders and power sources. The fol­lowing 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

See the appropriate Dimension Print in Section B of
this manual for details on the physical size of the
equipment.

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

LN-10 / ZIPLINE BOOM PACKAGE

A-3

REQUIRED TOOLS

UNPACK THE BOOM PACKAGE

CHECK YOUR BOOM PACKAGE
FOR THE FOLLOWING:

INSTALLATION

K1564-2 LN-10 B00M PACKAGE - 12' ZIPLINE BOOM
K1564-3 LN-10 B00M PACKAGE - 16' ZIPLINE BOOM

ITEM

1

2

L9776-C-18 L9776-C-22

3

4

5

6

7

8

9

10

11

12

13

INSTRUCTION MANUAL

11/16" WRENCH7/16" WRENCH 3/4" WRENCH
1/2" WRENCH

K1564-3K1564-2

PART NO.PART NO.

M18899-1
M17869-5

M18298-2-10

CL012325

CL012326

S18453-3

S20023-A-21S20023-A-17

M14935-1

S23858-2

S23859

M15608

L3326-169
L2213-528

FLAT HEAD SCREWDRIVERPHILLIPS HEAD SCREWDRIVER

DESCRIPTION

WIRE DRIVE ASSEMBLY

CONTROL BOX ASSEMBLY

CONTROL CABLE ASSEMBLY

POWER INPUT CABLE ASSEMBLY

ELECTRODE WELD CABLE

GAS HOSE

ELECTRODE CONDUIT

2" SPINDLE ASSEMBLY

HARDWARE KIT

CONDUIT BUSHING KIT

GUN CONTROL ASSEMBLY

BOOM PACKAGE INSTRUCTION MANUAL

WIRE FEEDER INSTRUCTION MANUAL

A-3

REQ'D

1

1
1

1

1

1

1

1

1

1

1

1

1

1

(1) WIRE DRIVE ASSEMBLY

4

(1) POWER INPUT CABLE ASSEMBLY

2

(1) CONTROL BOX ASSEMBLY

5

(1) ELECTRODE WELD CABLE

8

3

(1) CONTROL CABLE ASSEMBLY

6

(1) GAS HOSE

11

7

(1) ELECTRODE CONDUIT

(1) 2" SPINDLE ASSEMBLY

LN-10 / ZIPLINE BOOM PACKAGE

(1) GUN CONTROL ASSEMBLY

A-4

ITEM 9 S23858-2

INSTALLATION

K1564-2 LN-10 B00M PACKAGE - 12' ZIPLINE BOOM
K1564-3 LN-10 B00M PACKAGE - 16' ZIPLINE BOOM

INSTRUCTION MANUAL

A-4

1

(3) 1/4-20X.75 HHCS-GR2

4

(4) 5/16-18X.75 HHCS-GR2

ITEM

PART No.

CF000014

1
2

S9262-98

3

E106A-2
CF000040

4
5

S9262-30

6

E106A-14
S9262-14

7
8 T8833-64
9

S9262-1
10 E106A-15
11 T11563-2
12 T11563-3

M18223-113

HARDWARE KIT

DESCRIPTION

1/4-20X.75 HHCS-GR2
PLAIN WASHER
LOCKWASHER
5/16-18X.75HHCS-GR2
PLAIN WASHER
LOCKWASHER
PLAIN WASHER
1/2-13X3.00HHCS-GR8
PLAIN WASHER
LOCKWASHER
1/8 ALLEN WRENCH
3/16 ALLEN WRENCH
LOW SPEED PINION

2

(3) PLAIN WASHER

5

(4) PLAIN WASHER

QTY.

3
3
3
4
4
4
1
1
1
1
1
1
1

B-RW

S23858-2

(3) LOCK WASHER

(4) LOCK WASHER

3

6

(1) PLAIN WASHER

(1) SOCKET KEY-1/8 ALLEN WRENCH

11

(1) 1/2-13X3.0 HHCS-GR8

7

9

(1) PLAIN WASHER

(1) SOCKET KEY-3/16 ALLEN WRENCH

12

LN-10 / ZIPLINE BOOM PACKAGE

8

10

(1) LOCK WASHER

13

(1) LOW SPEED PINION