Lincoln Electric HELIX M45, 12885 Operator's Manual

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Page 1

Operator’s Manual

HELIX ® M45 WELD HEAD

For use with machines having Code Numbers:

12885

ORIGINAL INSTRUCTIONS

Authorized Service and Distributor Locator: www.lincolnelectric.com/locator

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Date Purchased

Code: (ex: 12735)

Serial: (ex: U1060512345)

IM6129 | Issue D ate 02/19

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08008 Barcelona

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HELIX® M45 WELD HEAD

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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.

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.

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.

SAFETY

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

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HELIX® M45 WELD HEAD

SAFETY

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.

)

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

WARNING: Cancer and Reproductive Harm www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

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HELIX® M45 WELD HEAD

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

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HELIX® M45 WELD HEAD

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

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HELIX® M45 WELD HEAD

SAFETY

ELECTROMAGNETIC

COMPATIBILITY (EMC)

CONFORMANCE

Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (2014/30/UE). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10

Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed

for industrial and professional use.

INTRODUCTION

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

INSTALLATION AND USE

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

ASSESSMENT OF AREA

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone cables; above, below

and adjacent to the welding equipment;

b. radio and television transmitters and receivers;

c. computer and other control equipment;

d. safety critical equipment, e.g., guarding of industrial equipment;

e. the health of the people around, e.g., the use of pacemakers and hearing aids;

f. equipment used for calibration or measurement and

g. the immunity of other equipment in the environment. The user shall ensure that other

equipment being used in the environment is compatible. This may require additional protection measures including:

h. the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

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HELIX® M45 WELD HEAD

SAFETY

Page 8

HELIX® M45 WELD HEAD

TABLE OF CONTENTS

Safety .............................................................................................................................................................. 3

Disposal Guide .......................................................................................................................................... 7

Dimensions ................................................................................................................................................A-1

Technical Specications ........................................................................................................................... A-2

Safety Precautions ...................................................................................................................................A-3

Proper handling ..................................................................................................................................... A-3

Operation .............................................................................................................................................. A-3

HELIX M45 WELD HEAD ........................................................................................................................... A-4

Basic Information .................................................................................................................................. A-4

Basic Components ................................................................................................................................ A-4

Body Assembly ..................................................................................................................................... A-4

Main Body Assembly ............................................................................................................................ A-4

Torch Height Assembly ......................................................................................................................... A-4

Work Angle Adjustment .........................................................................................................................A-5

Track Engagement ................................................................................................................................ A-5

Handle Adjustment ................................................................................................................................ A-5

Operational Safety Precautions ...............................................................................................................B-1

Operation Information ........................................................................................................................... B-1

External inputs ..................................................................................................................................... B-1

Control ...................................................................................................................................................B-1

Welding Power ......................................................................................................................................B-1

Manual Adjustments ............................................................................................................................. B-1

Accessories .........................................................................................................................................B-1

Maintenance ........................................................................................................................................D-1

Maintenance Schedule ..........................................................................................................................D-1

Every Shift ............................................................................................................................................. D-1

Monthly .................................................................................................................................................D-1

Semi Annually ........................................................................................................................................D-1

Tools ...................................................................................................................................................... D-1

Belt Change Adjustment .......................................................................................................................D-2

Trouble Shooting ....................................................................................................................................... F-1

Wiring Diagram ..........................................................................................................................................G-1

Helix M45 Parts Manual ............................................................................................................................H-1

Page 9

HELIX M45 Weld Head Dimensions

16.63 in

42.24 cm

14.96 in

38.99 cm

5.08 in

12.90 cm

INSTALLATIONHELIX® M45 WELD HEAD

15.22 in

38.65 cm

View Front

19.70 in±2.5 in

50.08 cm± 6.35 cm

10.35±2.5 in

26.28±6.35 cm

9.3 in

23.62 cm

View Side

A-1

Page 10

Technical Specications HELIX M45 Weld Head

HELIX M45 Weld head Product Number K52224-1

Input Power 24 VDC

Radial Clearance (on 8" Track Ring) 4.5" (114.3 mm)

Travel Speed 0.1 - 120 ipm

Max Oscillation Speed 150 ipm (381 cm/min)

Oscillation stroke 5" (49.78 mm)

Work Angle +45 degrees in / -45 degrees out

Pipe Sizes 8" OD to Flat Track

Weld Head Physical Dimensions

Depth (minus the torch): 19.70” (500.38 mm) Weight: 28 lbs (12.7 kg)

Environmental

Operating Temperature Range

32F to 140F (0C - 60C)

Ingress Protection - IP00

Storage Temperature Range

-22F to 140F (0C - 60C)

INSTALLATIONHELIX® M45 WELD HEAD

A-weighted emission sound pressure level: less than 70 db (A)

Explanation of Symbols

Electric Shock Warning Hot Surface Warning

A-2

Page 11

INSTALLATIONHELIX® M45 WELD HEAD

Safety Precautions

Read entire manual before installation or operation.

WARNING

ELECTRIC SHOCK CAN KILL

• Only qualied personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the power supply grounding lug to a proper safety (Earth) ground.

Operation

Read entire manual before operation.

Only operate the HELIX M45 weld head while it is rmly attached to the track ring with the clutch engaged. Always verify that the track is properly attached to the work surface before operating.

Keep hands away from weld head while in operation.

Verify that the system cable assembly is free from obstruction before operating. While welding, the weld head will rotate around the pipe. Be certain that there is plenty of play in weld cable. If the cable binds up during welding, parts of the weld cable or the weld head assembly may become damaged.

Never unplug or plug in control cables to the weld head while the system is powered on.

Verify that the system is properly grounded before beginning to weld.

Proper Handling

The HELIX M45 weld head is only meant to be picked up and supported by the handles. Only attempt to attach the weld head to the track ring while the clamp mechanism and clutch are disengaged.

Do not hang persons or objects from the handles of the weld head while operating.

Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.

Always place the weld head on a steady, at level surface when not in use or not clamped onto a track ring. Always be sure to engage the clutch when the weld head is left on the track.

Do not force the torch motion assembly in or out manually. Manually adjusting the torch in this manner can cause undue wear and tear on the gear and motors.

After welding allow adequate time for the weld head to cool before moving, making adjustments or putting into storage.

A-3

Page 12

INSTALLATIONHELIX® M45 WELD HEAD

HELIX M45 Weld Head

Basic Information

The HELIX M45 weld head is the second weld head in the APEX 3 world of digitally controlled, precision

welding. Designed with a low prole, this device also oers a pivoting torch height assembly, providing

perpendicular height control to the puddle face.

The handles on the HELIX M45 weld head rotate, allowing for optimized clearance. Designed to work with the APEX® 3 Series Orbital Controllers, the HELIX M45 weld head uses cross-roller bearings for rigid clamping and is able to change weld parameters based on its orientation in space.

The HELIX M45 weld head has automatic height control, oscillation capabilities, and multiple toolless torch adjustment options. These give the operator greater control of the weld puddle for complex welds in limited space.

Basic Components

The three basic components of the weld head are:

• Body Assembly

• Torch Clamp

• Torch Height Assembly

See FIGURE 1 - Weld Head Components – for the dierent weld head parts. Each piece of the machinery is discussed separately.

CLUTCH HANDLE

Adjustments and controls located on the body include:

• Clutch Handle

This handle is engaged with a pushing motion

and disengaged by a pulling motion. Pushing the weld head back and forth along the track makes the engagement of the clutch easier.

• Clamp Latch

Using a compression spring to add force to

the clamp, this latch engages or disengages the clamp which secures the weld head onto the track.This compensates for variance in track width dimension and maintains weld head position.

CONTROL CABLE INPUT

CLAMP LATCH

FIGURE 2 - Rear Weld Head Components

ACCESSORY CABLE

BODY

FIGURE 1 - Weld Head Components

Body Assembly

The body assembly is the main component for the HELIX M45 weld head. It contains the gears, motors and belts that provide travel and oscillation for the weld head – see FIGURES 1 and 2 - Weld Head

Components and Rear Weld Head Components.

TORCH CLAMP

• Control Cable Input

A connecting point for the control cable which

delivers all signals to the weld head.

• Accessory Cable

TORCH

This cable connects the onboard wire feeder and

HEIGHT

the torch height assembly.

Torch Height Assembly

The torch height assembly holds the torch and provides vertical motion to the torch. It also allows for toolless work angle adjustment.

A-4

Page 13

INSTALLATIONHELIX® M45 WELD HEAD

HANDLE ADJUSTMENT THUMB SCREW

Work Angle Adjustment

The HELIX M45 weld head allows for 45 degrees of outward adjustment and 45 degrees of inward adjustment. This angle is changed by using the work angle adjustment handle shown in FIGURE 3 - Work Angle Adjustment.

FIGURE 3 - Work Angle Adjustment

Track Engagement

Once the weld head is on the track, secure the clamp latch – see FIGURE 5 - Secure to Track. Move the tractor slowly on the track and push the clutch in to engage drive gears.

FIGURE 5 - Secure to Track

Before placing on th HELIX M45 weld head on the track, verify that the clamp latch is open and the clutch is pulled out – see FIGURE 4 - Clamp Latch and Clutch.

FIGURE 4 - Clamp Latch and Clutch

Handle Adjustment

The handles on the HELIX M45 weld head oer a

3-way toolless adjustment thumb screw, as shown in FIGURE 6 - Handle Adjustment Screw.

FIGURE 6 - Handle Adjustment Screw

A-5

Page 14

HELIX® M45 WELD HEAD

OPERATION

Operational Safety Precautions

Read and understand this entire section before operating the machine.

WARNING

ELECTRIC SHOCK CAN KILL.

• Only qualied personnel should perform the installation.

• Turn the input power OFF at the disconnect switch or fuse box.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always dry insulating gloves.

• Read and follow “Electric Shock Warnings” in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the work pieces.

FUMES AND GASES can be dangerous. * Keep your head out of fumes. * Use ventilation or exhaust to remove fumes from breathing zone.

Operation Information

The HELIX M45 weld head is designed for multiprocess welding and will work with any APEX® 3 Series Orbital Control System. For complete instal-

lation and operational instructions, see the specic

controller manual and the applicable process manual.

External Inputs

The external inputs for the HELIX M45 weld head are control signals, and 24V DC.

Control

Control of the weld head and wire feeder is provided by the APEX 3 Series controller. Through the use of a handheld pendant, the operator is able to control and monitor all aspects of the weld and change parameters while welding.

Welding Power

Welding power is provided by a standard Lincoln Electric Power Wave® or a Vantage® power source. An ArcLink® connection is required.

Accessories

HELIX M45 Weld Head Accessories and Consumables

WELDING SPARKS can cause re and explosion * Keep ammable material away. * Do not weld on containers that have held combustibles.

ARC RAYS can burn. * Wear eye, ear and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

Refer to control system manual for all operational instructions.

Accessory

Weld Head Control Cable 25’ K52107-25

Weld Head Control Cable 50’ K52107-50

HELIX SF70C Onboard Wire Feeder 1 K52248-1

HELIX SF70C Onboard Wire Feeder 2 K52248-2

Low Prole Mechanized TIG Torch, 25’ K52249-25

Low Prole Mechanized MIG Torch, 25’ K52250-25

HELIX M45 Oscillation Arm Extension 6” K52251-06

HELIX M45 Oscillation Arm Extension 12” K52251-12

HELIX M45 Oscillation Arm Extension 18” K52251-18

HELIX M45 Oscillation Arm Extension 24” K52251-24

B-1

Part Number

Page 15

HELIX® M45 WELD HEAD

Maintenance

The HELIX M45 weld head is designed for trouble-free operation and normally requires minimal preventive care and cleaning. This section provides instructions for maintaining user-serviceable items. The suggested repair procedure for all such items is to remove and replace defective assemblies or parts.

When users and/or service personnel are not familiar with electrical and electronic equipment, the product should be returned to the factory or serviced by factory authorized representatives.

Maintenance Schedule

The maintenance schedule is suggested as a guideline for proper system maintenance. More stringent maintenance requirements may be required depending on the work being performed and the requirements of the customer for whom the work is performed. All maintenance schedules are based on a 40-hour work week.

Any excess play in parts or equipment should be noted and reported to an authorized repair facility. Any anomalous activity, such as motor hesitation, clicking or other noises, or anything out of the ordinary should be noted and reported to an authorized repair facility.

MAINTENANCE

• Check over all the weld head components for any signs of damage or wear.

• Ensure track ring gears and weld head gears are clean and clear of debris.

• Check for wear of drive rolls on wire feeder.

Semi Annually

• Based on a 40-hour work week it is recommended that the belts be replaced every six months.

• Verify that all motors are working correctly without strain. Listen to the motors to conrm that there is no excess noise or grinding.

Tools

Required tools to operate and repair the HELIX M45 weld head:

• 2.5 mm hex key

• 3 mm hex key

• 4 mm hex key

• wire cutters

Further tools are required for in depth maintenance which is only authorized at local repair facilities.

Every Shift

• Check lines, cables, and drive belts for loose connections and worn areas.

• Change out consumables as needed.

• Check torch height motion and travel for slop or wearing parts. NOTE: Do not force the oscillator in or out while checking for worn parts.

• Inspect torch cable for wear or damage.

Monthly

• With the clutch and clamp latch engaged, grab the weld head by the handles and gently move back and forth to check for excess play in the weld head along the track.

• Release the clutch latch and verify that the weld head moves smoothly along the track without rubbing or binding.

• Examine all cable connections to verify that there are no gas leaks, and that all cables are seated correctly and that there is no visible wear and tear to any connector or associated cables.

D-1

Page 16

HELIX® M45 WELD HEAD

Belt Change Adjustment

There are two belts that will require changing with frequent use: the Torch Height Belt see FIGURE 6

- Changing Torch Height Belt – and the oscillator

belt – see FIGURE 5 - Changing Oscillator Belt.

MAINTENANCE

DO NOT LOOSEN

Loosen Screw

Belt

FIGURE 6 - Changing Torch Height Belt

To change the Torch Height Belt:

1. Remove the bottom cover using a 2.5 mm

Hex Driver.

2. Loosen (DO NOT REMOVE) the two screws

shown in FIGURE 6 using a 3 mm Hex Driver and slide the motor pulley towards the middle of the Torch Height.

3. Remove the belt

4. Replace with a new belt (KP52252-1, see Parts

Manual on page H-9). Check that the belt is straight and avoid over tightening to prevent machine malfunction. Push the motor pulley back into place and tighten the two screws.

5. Replace the bottom cover.

Back Cover

Motor Pulley

FIGURE 7 - Changing Oscillator Belt

To change the Oscillator Belt:

1. Remove the back cover using a 2 mm Hex Driver.

2. Loosen (DO NOT REMOVE) the screw shown in FIGURE 7 using a 3 mm Hex Driver.

3. Push the motor pulley toward the center of the

weld head.

4. Replace with a new belt (KP52137-1, see Parts

Manual on page H-7). Check that the belt is straight and avoid over tightening to prevent machine malfunction. Push the motor pulley back into place and tighten the screw.

5. Replace the back cover.

D-2

Page 17

HELIX® M45 WELD HEAD

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS

(SYMPTOMS)

Auto Height does not operate / operates incorrectly.

Travel is inconsistent.

No oscillation / inconsistent oscillation.

Wire does not feed properly.

POSSIBLE

CAUSE

1. Weld settings are incorrect.

2. Auto height is disabled.

3. Inconsistent wire feeding

4. Wire binding in contact tip.

1. Clutch is not fully engaged.

2. Loose communication cable.

3. Step travel is engaged.

1. Loose communication cable.

2. Oscillation settings are incorrect

3. Oscillation arms binding on wipers.

4. Worn oscillator belt.

1. Drive rolls are worn/damaged

2. Wire guides are restricting wire passage.

3. Wire binding in contact tip.

4. Wire liner is kinked.

RECOMMENDED

COURSE OF ACTION

1. Check WFS/Amps

2. Check auto height is on.

3. Check wire.

4. Check contact tip.

1. Check clutch latch to ensure it is engaged (locked).

2. Check all cable connections.

3. Check travel settings.

1. Check all cable connections.

2. Check oscillator settings on jog screen.

3. Check wipers for free movement.

4. Check oscillator belt.

1. Check drive rolls

2. Check wire feed for blockage.

3. Check contact tip.

4. Check for kinks or obstructions in the torch or wire liner.

1. Verify gas is turned on.

1. Gas supply is shut o.

Gas issues

Tractor drags on work surface 1. Track is improperly installed.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Services Facility.

2. Gas tank is empty.

3. Gas hose is kinked.

2. Verify there is gas present in the tank.

3. Check the gas line for kinks or obstructions.

1. Check that the shoes are all equally spaced around the track.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

F-1

Page 18

HELIX® M45 WELD HEAD

123456789

RIBBON

BLK

1234567

DIAGRAMS

RED

4503A

4504A

123456789

123

4J2123

4502B

4501B

123456789

J11

USB

Height Module

4525

2 3 41

CON3

4526

G8985-1

INCLINOMETER

4509

4510

RIBBON

BLK

1234567

Tractor Body

4525

4526

4527

4528

RECEPTACLE

4509

S32522

ABC

4510

PANEL MOUNT

4507

4508

PANEL MOUNT

RECEPTACLE

4506

1 2

4505

1234

BLK

RED

RIBBON

1 2 3 4 5 6

J4J5

S32512

M23647

RED

HEIGHT CONTROL

J10

4527 4528

J14

123 4 5 6 789 10111213141516

J11

USB

4502B

4501B

4502A

4501A

CON3

1 432

OSCILLATION CONTROL

J10

J14

OSCILLATION

4504A

4503A

4504

4503

1 234 56789 10 111213141516

4700pF

3000V

4502

4507

4501

M23647

4503

4508

BHEFC

4504

4505

4506

RECEPTACLE

PANEL MOUNT

123 4 5 6 789 10111213141516 1 2 3 4 5 6 789 10

4501A

4502A

4502

CON3

123

4501

TRAVEL CONTROL

USB

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

G-1

Page 19

HELIX® M45 WELD HEAD

PARTS

PARTS MANUAL

This parts list is provided as an informative guide only.

H-1

Page 20

HELIX® M45 WELD HEAD

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-2

Page 21

HELIX® M45 WELD HEAD

GENERAL ASSEMBLY

PARTS

HELIX® M45 WELD HEAD

For Codes: 12885

Do not use this Parts List for a machine if its code number is not listed. Contact the Service Department for

Use the illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item Number

SUB ASSEMBLY PAGE NAME

PAGE NO.

CODE NO.

12885 1 1 1 1 1 1 1 1

1 2 3 4 5 6 7 8

Control Box Assembly

H-4 H-6 H-8 H-12 H-14 H-16 H-18 H-20

Top Plate Assembly

Torch Height

RIght Side Plate

Left Side Plate

Torch Clamp

Transmission Drive

Inboard Side Plate

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-3

Page 22

HELIX® M45 WELD HEAD

Control Box Assembly

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

H-4

Page 23

HELIX® M45 WELD HEAD

PARTS

Control Box Assembly

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

1 HELIX M45 Input Output Wire Harness Kit, includes: 1A HELIX M45 Input Output Wire Harness

9SS32513 NSS

1 X

1 X 1B SHCS M3 X 0.5 X 6, Stainless Steel NSS 1 X 2 Travel Controller Kit, includes: 9SM23203-2 1 X 2A Travel Controller 2B Pan Head Screw Phillips M3 X 0.5 X 6, Steel, Zinc Plated 3 Oscillation Controller Kit, includes: 3A Oscillation Controller 3B SHCS M2.5 X 0.45 X 8, Stainless Steel 4 Inclinometer PCB Kit, includes: 4A Inclinometer PCB 4B Pan Head Screw Phillips M2.5-0.45 X 4, Stainless Steel 5 Slide Support Kit 5A Slide Support 5B FHCS M5 X 0.8 X 12, Steel, Zinc Plated 5C Compression Spring 6 Clamp Handle Kit, includes: 6A Clamp Handle 6B Clamp Barrel 6C Set Screw Cup Point M5 X 0.8 X 8, Stainless Steel 6D Clamp Shaft 6E Push Washer 6F Compression Spring 6G Thin Hex Nut, M10 X 1.5, 18-8 Ss 7 Cross Roller Bearing Kit (2 Sets), includes: 7A Cross Roller Bearing 7B SHCS M3 X 0.5 X 10, 316 Stainless Steel 7C SHCS M4 X 0.7 X 14, 316 Stainless Steel 8 Outboard Plate Assembly, includes: 8A Outboard Plate Roller 8B Roller Pivot Bushing 8C Roller Pivot

NSS NSS 9SM23204-6 NSS NSS 9SS32526 NSS NSS 9SS32292 NSS NSS NSS 9SS33201 9SS32287 9SS32289 NSS 9SS32293 9SS32290 9SS32486 S32482-25 9SS32559 NSS NSS NSS 9SM23604 NSS NSS 9SM23184

1 X

2 X

1 X

5 X

1 X

2 X

1 X

2 X

1 X

2 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-5

Page 24

14A

14B

10A

10B

12A

12B

15A

15B

17A

17B

TOP PLATE ASSY

ITEM

PART NO

9SM23603

9SS32271-1

NSS

9SS32285

NSS

9SS32524

9SS32265

NSS BACK COVER

NSS

9SS32454

NSS

9SS32295

9SS32515

9SS32297

9SS32264

10A

NSS

10B

NSS

9SS32286

9SS32268

12A

NSS

12B

NSS

9SS32453

9SS32271-2

14A

NSS

14B

NSS

9SS32494

15A

NSS

15B

NSS

9SS32490

9SS32263

17A

NSS

17B

NSS

HELIX® M45 WELD HEAD

Top Plate Assembly

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-6

Page 25

HELIX® M45 WELD HEAD

PARTS

Top Plate Assembly

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

1 Top Plate Assembly 2 Rear Screw Mount Kit, includes: 2A Rear Screw Mount 2B SHCS M4 X 0.7 X 22, Stainless Steel 2C FHCS M4 X 0.7 X 10, Stainless Steel 3 OSC Shaft Kit, includes: 3A OSC Shaft 3B SHCS M4 X 0.7 X 8, Stainless Steel 4 60 Tooth MXL Belt 5 Back Cover Kit, includes 5A Back Cover 5B BHCS M3 X 0.5 X 4, Stainless Steel 6 Slide OSC Motor Assembly Kit, includes 6A Slide OSC Motor Assembly

9SM23603 9SS32271-1 NSS NSS NSS 9SS32285 NSS NSS KP52137-1 9SS32265 NSS NSS 9SS32454 NSS

1 X 1 X 1 X 1 X 1 X 1 X 1 X 1 X 1 X 1 X 1 X 4 X 1 X

1 X 6B SHCS M4 X 0.7 X 22, Stainless Steel NSS 1 X 6C Nut M4, Stainless Steel 7 Spring Retainer 8 Compression Spring 9 Shim 10 OSC Shield Kit, includes: 10A OSC Shield 10B FHCS M3 X 0.5 X 6, Stainless Steel 11 OSC Carriage Assembly 12 Shaft Support Kit, includes: 12A Shaft Support 12B SHCS M3 X 0.5 X 10, Stainless Steel 13 Clutch Retainer 14 Front Screw Mount Kit, includes: 14A Front Screw Mount 14B SHCS M4 X 0.7 X 8, Stainless Steel 15 Linear Sleave Bearing 3/8 Kit, includes: 15A Linear Sleave Bearing 3/8 15B Retaining Clip 16 Shaft Wiper 17 Shaft Wiper Retainer Kit, includes: 17A Shaft Wiper Retainer 17B SHCS M3 X 0.5 X 6, Stainless Steel

NSS 9SS32295 9SS32515 9SS32297 9SS32264 NSS NSS 9SS32286 9SS32268 NSS NSS 9SS32453 9SS32271-2 NSS NSS 9SS32494 NSS NSS 9SS32490 9SS32263 NSS NSS

1 X

5 X

1 X

2 X

1 X

4 X

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

H-7

Page 26

HELIX® M45 WELD HEAD

Torch Height

PARTS

21D

20A

19A

20B

21B

16E

21C

17B

21D

16D

13A

23A

13B

16D

14A

16C

16B

15C

16A

23B

15A

14B

15B

22A

10B

12B

17A

12A

10A

19B

21D

21A

22B

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-8

Page 27

HELIX® M45 WELD HEAD

PARTS

Torch Height 1

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY.

1 AVC Housing 2 AVC Cover Kit, includes: 2A AVC Cover 2B SHCS M3 X 0.5 X 6, 316 Stainless Steel 3 Bottom Cover Kit, includes: 3A Bottom Cover 3B SHCS M3 X 0.5 X 6, 316 Stainless Steel 4 MXL 80 Tooth Belt 5 Torch Height Controller Kit, includes: 5A Torch Height Controller 5B SHCS M2.5 X 0.45 X 8, 316 Stainless Steel 6 Torch Height Motor Kit, includes:

9SM23591 KP52253-1 NSS S30962-17006 9SM23590 NSS NSS KP52252-1 9SM23204-7 NSS NSS

9SS30308-2 6A Torch Height Motor NSS 6B AVC Motor Mount

9SS32251 6C Flat Head Screw Phillips M2-0.4 X 8, Stainless Steel NSS 6D SHCS M4 X 0.7 X 10, Stainless Steel 7 AVC Screw 8 Angular Contact Bearing 6 X 17 X 6 9 Bearing Retainer Kit, includes: 9A Bearing Retainer 9B FHCS M3 X 0.5 X 6, Stainless Steel 10 6mm X 22 Tooth Pulley Kit, includes: 10A 6mm X 22 Tooth Pulley

Set Screw Cup Point M3 X 0.5 X 3,

10B

316 Stainless Steel 11 Angular Contact Bearing 6 X 17 X 6 12 Bearing Retainer Kit, includes: 12A Bearing Retainer

NSS 9SS32294 9SS32493 9SS32257-2 NSS NSS 9SS30524 NSS NSS

9SS32493 9SS32257-1 NSS

12B SHCS M3 X 0.5 X 6, 316 Stainless Steel NSS

9mm Linear Rail Assembly Kit, includes: 13

(Kit Is One Rail. Two Required Per Assembly)

9SS32509

13A 9mm Linear Rail Assembly NSS 13B SHCS M3 X 0.5 X 6, 316 Stainless Steel

NSS 14 AVC Carriage Kit, includes: 9SS32253 14A AVC Carriage 14B SHCS M3 X 0.5 X 6, Stainless Steel

NSS

1 X

1 X 1 1 6 2

1 X

1 4

2 X

2 4 1 X 1

8 X

X X

X X X

X X

X X X X X X

X X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-9

Page 28

HELIX® M45 WELD HEAD

Torch Height

PARTS

21D

20A

19A

20B

21B

16E

21C

17B

21D

16D

13A

23A

13B

16D

14A

16C

16B

15C

16A

23B

15A

14B

15B

22A

10B

12B

17A

12A

10A

19B

21D

21A

22B

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-10

Page 29

HELIX® M45 WELD HEAD

PARTS

Torch Height 2

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

15 Torch Mount Kit, includes: 15A Torch Mount 15B SHCS M4 X 0.7 X 10, 316 Stainless Steel 15C Dowel Pin M3 X 10, 316 Stainless Steel 16 AVC Arm Kit, includes: 16A AVC Arm

16B

Shoulder Screw 6mm X 10mm,

M5, Low-Prole, Stainless Steel

16C Washer 1/4, Narrow, Stainless Steel 16D PTFE Washer 16E SHCS M4 X 0.7 X 10, Stainless Steel

9SS32556 NSS NSS NSS 9SS32261-1 NSS 9SS32508-06010

9SS29124-29 9SS32506

NSS 17 Back Cover Kit, includes: 9SS32260 1 X 17A Back Cover 17B SHCS M3 X 0.5 X 6, 316 Stainless Steel

NSS

NSS 18 Front Plate 9SM23592 1 X 19 Mounting Brace Kit, includes: 19A Mounting Brace 19B SHCS M4 X 0.7 X 10, 316 Stainless Steel 20 Mounting Brace Kit, includes: 20A Mounting Brace 20B SHCS M4 X 0.7 X 10, Stainless Steel 21 AVC Arm Kit, includes: 21A AVC Arm

21B

Shoulder Screw 6mm X 10mm, M5, Low-Prole,

18-8 Stainless Steel 21C Washer 1/4 X 1, Stainless Steel 21D PTFE Washer 21E SHCS M4 X 0.7 X 10, Stainless Steel 22 Input Wire Harness Kit, includes: 22A Input Wire Harness 22B BHCS M3 X 0.5 X 6, Stainless Steel 23 4mm 22 Tooth Pulley Kit, includes: 23A 4mm 22 Tooth Pulley

23B

Set Screw Cup Point M3 X 0.5 X 3,

Stainless Steel 24 Handle

9SS32262-2 NSS NSS 9SS32262-1 NSS NSS 9SS32261-2 NSS S32508-06010

9SS32507-29032 9SS32481 S30962-19010 9SS32512 NSS NSS 9SS30525 NSS NSS

9SS32511-1

2 X 2 X 2 X 4 X 1 X 1 X

1 X

1 X 2 X 2 X

1 X 4 X

1 X 1 X 3 X 1 X 1 X 3 X 1 X 1 X

1 X

1 X 2 X 2 X 1 X 1 X 4 X 1 X 1 X

1 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-11

Page 30

HELIX® M45 WELD HEAD

Right Side Plate

PARTS

13B

13A

2B 2A

10B

10A

4B1A

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-12

Page 31

HELIX® M45 WELD HEAD

PARTS

Right Side Plate

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

1 Right Side Plate Kit, includes: 1A Right Side Plate 1B SHCS M4 X 0.7 X 10, Stainless Steel 2 Lower Seal Block Kit, includes: 2A Lower Seal Block 2B SHCS M4 X 0.7 X 10, Stainless Steel 3 Lower Seal 4 Lower Seal Plate Kit, includes: 4A Lower Seal Plate 4B SHCS M3 X 0.5 X 5, Stainless Steel 5 Linear Rail Assembly Kit, includes: 5A Linear Rail Assembly 5B SHCS M3 X 0.5 X 10, Stainless Steel 6 OSC Arm Kit, includes:

9SM23606 NSS NSS 9SS32237 NSS NSS 9SS32239 9SS32238 NSS NSS 9SS32483 NSS NSS 9SM23586

1 X 1 X 6 X 1 X 1 X 2 X 1 X 1 X 1 X 4 X 1 X 1 X 4 X

1 X 6A OSC Arm NSS 1 X 6B FHCS M3 X 0.5 X 6, Steel, Zinc Plated 7 Handle Assembly Kit, includes 7A Handle Assembly 7B PTFE Washer 8 Bearing Arm Plate Kit, includes: 8A Bearing Arm Plate 8B SHCS M4 X 0.7 X 10, Stainless Steel 9 Outer Wiper 10 Wiper Plate Kit, includes:

NSS 9SS32479 NSS NSS 9SM23587-1 NSS NSS 9SS32241 9SS32240

6 X

1 X

2 X

1 X

2 X

1 X

1 X 10A Wiper Plate NSS 1 X 10B SHCS M3 X 0.5 X 6, Stainless Steel

Shoulder Screw 6mm X 20mm,

M5, Low-Prole, Stainless Steel

12 Stop Knob 13 Arm Cover Assembly Kit, includes: 13A Arm Cover Assembly 13B SHCS M4 X 0.7 X 10, Stainless Steel

NSS S32508-06020

9SS32235 9SM23635-1 NSS NSS

4 X

1 X

6 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-13

Page 32

HELIX® M45 WELD HEAD

13A

12A

12B

13B

LEFT SIDE PLATE

ITEM

PART NO

9SM23607

NSS

9SS32237

NSS

9SS32239

9SS32238

NSS

9SS32483

NSS

9SM23586

NSS

9SS32479

NSS

9SM23587-2

NSS

9SS32241

9SS32235

S32508-06020

9SS32240

12A

NSS

12B

NSS

9SM23635-2

13A

9SM23635-2

13B

NSS

PARTS

Left Side Plate

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-14

Page 33

HELIX® M45 WELD HEAD

PARTS

Left Side Plate

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

1 Left Side Plate Kit, includes: 1A Left Side Plate 1B SHCS M4 X 0.7 X 10, Stainless Steel 1C Set Screw Cup Point M4 X 0.7 X 6, 316 Stainless Steel 2 Lower Seal Block Kit, includes: 2A Lower Seal Block 2B SHCS M4 X 0.7 X 10, Stainless Steel 3 Lower Seal 4 Lower Seal Plate Kit, includes: 4A Lower Seal Plate 4B SHCS M3 X 0.5 X 5, 316 Stainless Steel

5 Linear Rail Assembly Kit, includes:

5A Linear Rail Assembly 5B SHCS M3 X 0.5 X 10, Stainless Steel

9SM23607 NSS NSS NSS 9SS32237 NSS NSS 9SS32239 9SS32238 NSS NSS 9SS32483

NSS

NSS 6 OSC Arm Kit, includes: 9SM23586 1 X 6A OSC Arm 6B FHCS M3 X 0.5 X 6, Steel, Zinc Plated 7 Handle Assembly Kit, includes: 7A Handle Assembly 7B PTFE Washer 8 Bearing Arm Plate Kit, includes: 8A Bearing Arm Plate 8B SHCS M4 X 0.7 X 10, 316 Stainless Steel 9 Outer Wiper 10 Stop Knob

Shoulder Screw 6mm X 20mm, M5, Low-Prole,

Stainless Steel 12 Wiper Plate Kit, includes: 12A Wiper Plate 12B SHCS M3 X 0.5 X 6, 316 Stainless Steel 13 Arm Cover Assembly Kit, includes: 13A Arm Cover Assembly 13B SHCS M4x0.7x10, Stainless Steel

NSS NSS 9SS32479 NSS NSS 9SM23587-2 NSS NSS 9SS32241 9SS32235 9SS32508-06020

9SS32240 NSS NSS 9SM23635-2 NSS NSS

1 X 1 X 6 X 4 X 1 X 1 X 2 X 1 X 1 X 1 X 4 X

1 X

1 X 5 X

1 X 6 X 1 X 1 X 2 X 1 X 1 X 2 X 1 X 1 X

1 X

1 X 1 X 4 X 1 X 1 X 6 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-15

Page 34

HELIX® M45 WELD HEAD

Torch Clamp

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

H-15

Page 35

HELIX® M45 WELD HEAD

PARTS

Torch Clamp

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY.

1 Back Slide Plate Kit, includes: 1A Back Slide Plate Assy 1B SHCS M3 X 0.5 X 6, 18-8 Stainless Steel 2 Dove Tail Clamp Kit, includes:

9SS30987 NSS NSS

9SS32566 2A Dove Tail Clamp Set NSS 1 X 2B SHCS M5 X 0.8 X 18, 316 Stainless Steel 3 Handle 4 Disc Spring Kit (8 Pieces)

NSS

9SS32511-1

9SS30986

1 X 1 X 4 X 1 X

1 X 1 X 1 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

H-16

Page 36

HELIX® M45 WELD HEAD

Transmission Drive

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

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HELIX® M45 WELD HEAD

PARTS

Transmission Drive

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

Transmission Drive, includes: 1 Travel Motor Assemby Kit, includes: 1A Travel Motor Assembly 1B SHCS M3 X 0.5 X 10, Stainless Steel 2 Transmission Housing Assembly 3 Transmission Cap Kit, includes: 3A Transmission Cap 3B FHCS M3 X 0.5 X 5, 316 Stainless Steel 4 Travel Gear Shaft 5 Pressure Plate Kit, includes: 5A Pressure Plate 5B BHCS M3 X 0.5 X 4, Stainless Steel 6 Angular Contact Bearing 6 X 17 X 6 7 Travel Gear Assembly Kit, includes: 7A Travel Gear Assembly

9SM23643 9SS32504 NSS NSS 9SM23641 9SS32518 NSS NSS 9SM22942 9SS32249 NSS NSS 9SS32493 9SM24544

NSS 7B Spring Pin Coiled 1/8 X 1, Stainless Steel NSS 1 X 8 Pivot Arm Kit, includes: 8A Pivot Arm 8B SHCS M5 X 0.8 X 14, Stainless Steel 9 Brass Shim 10 E-Clip Retaining Ring 7/16, Steel

9SM23605

NSS

9SS29130

9SS32184-028

1 X 1 X 1 X 4 X 1 X 1 X 1 X 5 X 1 X 1 X 1 X 4 X 1 X 1 X 1 X

1 X 1 X 2 X 2 X 1 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

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HELIX® M45 WELD HEAD

Inboard Side Plate

PARTS

02-04-19

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts, always refer to the

Lincoln Electric Parts List.

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HELIX® M45 WELD HEAD

PARTS

Inboard Side Plate

# Indicates a change in this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1

1 Inboard Plate Assembly Kit, includes: 1A Inboard Plate Assembly 1B Roller Pivot 1C Roller Pivot Bushing

9SM23632 NSS 9SM23184 NSS

1 X 1 X 2 X 2 X

NOTE: This Parts Manual is provided as an informative guide only. When ordering parts always refer to the

Lincoln Electric Parts List.

02-04-19

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CUSTOMER ASSISTANCE POLICY

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

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

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

Lincoln Electric HELIX M45, 12885 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual