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
OPERATOR’S MANUAL
• Sales and Service through Subsidiaries and Distributors Worldwide •
• World's Leader in Welding and Cutting Products •
Page 2
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.
Page 3
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.
Page 4
iii
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
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, (814)288-3641, 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
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.
CONNECT
ELECTRODE
WELD CABLE
FROM POWER
SOURCE HERE
MOUNTING SLOT
CONNECT
CONTROL CABLE
ASSEMBLY TO WIRE
FEEDER HERE
LN-10 CONTROL BOX ASSEMBLY
FRONT VIEW
CONNECT
POWER INPUT
CONTROL CABLE
FROM POWER
SOURCE HERE
LN-10 / ZIPLINE BOOM PACKAGE
Page 11
A-7
INSTALLATION
A-7
INSTALLATION PROCEDURE
Assemble the Zipline boom according to the installation instructions provided with the boom. Next, install
and assemble the wire feeder boom package as follows:
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 provided. Screw the bolts and washers partially into the bottom 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
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
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.
be routed
INSTALL THE CONTROL CABLE ASSEMBLY
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.
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 fastened 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.
LN-10 / ZIPLINE BOOM PACKAGE
Page 12
A-8
INSTALLATION
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 different size conduit bushings are provided in the conduit bushing kit, .025 to .063 and .063 to .125. Based
on the wire used for your application, find two appropriate 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 electrode 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. Reinstall 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 provided 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 manual 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.
LN-10 / ZIPLINE BOOM PACKAGE
Page 13
B-1
DIMENSION PRINTS
12 FT. SPRING BALANCED ZIPLINE BOOM ASSEMBLY
B-1
60.00
48.00
60.00
46.00
R 144.0
(R 12'-0")
N.B.
165.6
(13'-10")
18.28
144.0
135.0
(12'-0")
(11'-3")
88.25
5.00
15.00
33.00
45.00
TYP.
.81
12.38
14.00
12.38
HOLE
.81
14.00
.81
TYP.
FOR 3/4" BOLTING
(4 PLACES)
MAST PEDESTAL DETAIL
N.A.
17.38
UPWARD 50 TO DOWNWARD 6.
46" X 48" OR 60" X 60".
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
7.75
38.25
52.25
LN-10 / ZIPLINE BOOM PACKAGE
Page 14
B-2
DIMENSION PRINTS
12 FT. HYDRAULIC ZIPLINE BOOM ASSEMBLY
B-2
XA
60.00
48.00
60.00
R 144.0
46.00
(12'-0")
N.B.
163.6
(13'-8")
16.45
144.0
133.0
(12'-0")
(11'-1")
N.A.
83.13
5.00
15.00
33.00
45.00
TYP.
.81
12.38
14.00
12.38
HOLE
.81
14.00
.81
TYP.
FOR 3/4" BOLTING
(4 PLACES)
MAST PEDESTAL DETAIL
LN-10 / ZIPLINE BOOM PACKAGE
17.38
UPWARD 50 TO DOWNWARD 18.
46" X 48" OR 60" X 60".
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
7.75
38.25
52.25
Page 15
B-3
DIMENSION PRINTS
16 FT. SPRING BALANCED ZIPLINE BOOM ASSEMBLY
XA
60.00
46.00
88.25
B-3
5.00
60.00
48.00
R 192.0
(R 16'-0")
N.B.
213.6
(17'-10")
18.28
192.0
183.0
(16'-0")
15.00
33.00
45.00
(15'-3")
TYP.
.81
12.38
14.00
12.38
HOLE
.81
14.00
.81
TYP.
FOR 3/4" BOLTING
(4 PLACES)
MAST PEDESTAL DETAIL
N.A.
17.38
UPWARD 50 TO DOWNWARD 6.
46" X 48" OR 60" X 60".
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
7.75
38.25
52.25
LN-10 / ZIPLINE BOOM PACKAGE
Page 16
B-4
DIMENSION PRINTS
16 FT. HYDRAULIC ZIPLINE BOOM ASSEMBLY
B-4
XA
60.00
48.00
60.00
R 192.0
46.00
(16'-0")
N.B.
211.6
(17'-8")
16.45
192.0
181.0
(16'-0")
(15'-1")
N.A.
83.13
5.00
15.00
33.00
45.00
TYP.
.81
12.38
14.00
12.38
HOLE
.81
14.00
.81
TYP.
FOR 3/4" BOLTING
(4 PLACES)
MAST PEDESTAL DETAIL
LN-10 / ZIPLINE BOOM PACKAGE
17.38
UPWARD 50 TO DOWNWARD 18.
46" X 48" OR 60" X 60".
N.B. PALLET BASE IS OPTIONAL. AVAILABLE SIZES ARE
N.A. BOOM ADJUSTS FROM THE HORIZONTAL POSTION
7.75
38.25
52.25
Page 17
B-5
DIMENSION PRINTS
B-5
10.92
4.27
5.252.80
WARNING
2.63
13.75
3
YEAR
WARRANTY
4.58
5-2-97
18299
M
CONTROL BOX DIMENSION PRINT
R .141
(3 SLOTS)
GRAPHICS SHOWN REPRESENT M17869-1.
14.67
10.10
12.75
14.65
LN-10 / ZIPLINE BOOM PACKAGE
Page 18
B-6
6.55
7.81
DIMENSION PRINTS
12.74
B-6
4-24-98
18904
M
5.25
4.44
WIRE DRIVE DIMENSION PRINT
2.42
4.08
14.71
2.25
10.40
11.00
5/16-18UNC-2B
(4 PLACES)
LN-10 / ZIPLINE BOOM PACKAGE
3.00
6.00
Page 19
NOTES
LN-10 / ZIPLINE BOOM PACKAGE
Page 20
NOTES
LN-10 / ZIPLINE BOOM PACKAGE
Page 21
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A must for all welders, supervisors, engineers and
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$15.00 postage paid U.S.A. Mainland
How To Read Shop Drawings
The book contains the latest information and application
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New Lessons in Arc Welding
Lessons, simply written, cover manipulatory techniques;
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Need Welding T raining?
The Lincoln Electric Company operates the oldest and
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For details write: Lincoln Welding School
headquarters in Cleveland, Ohio. Over 100,000 stu-
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s
to visualize mechanically drawn objects as they will appear
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x
Durable, cloth-covered board binding.
$4.50 postage paid U.S.A.
ability
11”
Mainland
and ask for bulletin ED-80 or call 216-383-2259 and ask
for the
Welding School Registrar.
Lincoln Welding School
BASIC COURSE$700.00
5 weeks of fundamentals
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Page 22
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 23
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.