Lincoln Electric HELIX T55 User manual

HELIX™ T55 WELD HEAD
For use with machines having code Numbers: 70301 & 70300
Copyright © Lincoln Global Inc.
World’s Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX:[phone] WEB Site: www.lincolnelectric.com
OPERATOR’S MANUAL
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 READ-
ING THIS MANUAL,
AND
THE
SAETY PRECAUTIONS CON-
TAINED THROUGHOUT.
And,
most importantly, think before
you act and be careful.
IM6112
October, 2012

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TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS ................................. i
TABLE OF FIGURES.....................................ii
BASIC INFORMATION................................. 1
Toolbox........................................................ 1
Technical Specifications.............................. 2
Track Ring ................................................... 3
Shoe Placement........................................ 4
Shoe Extension ........................................ 4
Track Ring Installation ............................ 5
Weld Head................................................... 8
Weld Head Installation ............................ 8
Torch Setup.................................................. 9
Fillet Weld Angle .................................... 9
Lead Lag Angle ....................................... 9
Torch Stick Out........................................ 9
Tungsten Stick Out................................ 10
Torch Height.......................................... 10
Wire Feeder Angle................................. 11
Verify Drive Rolls ..................................... 12
Change Upper Drive Roll...................... 12
Change Lower Drive Roll...................... 13
Wire Feed Setup ........................................ 14
Wire Spool Installation.......................... 14
Feeding the Wire.................................... 14
Adjustments for Radial Clearance......... 15
OPERATION................................................. 16
MAINTENANCE.......................................... 17
Preventative Maintenance Schedule.......... 17
Track Ring ................................................. 17
Monthly Maintenance............................ 17
Quarterly Maintenance .......................... 17
Annual Maintenance.............................. 17
T55 Weld Head..........................................17
Daily Maintenance.................................17
Weekly Maintenance .............................17
Monthly Maintenance............................17
Quarterly Maintenance...........................17
PARTS LIST..................................................20
Index ..............................................................37

TABLE OF CONTENTS
TABLE OF FIGURES
Figure 1 –TRACK RING................................ 3
Figure 2 –SHOE PLACEMENT .................... 4
Figure 3 –SHOE EXTENSION...................... 5
Figure 4 –ASSEMBLY STEP 1..................... 5
Figure 5 –ASSEMBLY STEP 2..................... 6
Figure 6 –ASSEMBLY STEP 3..................... 6
Figure 7 –TRACK DISTANCE...................... 6
Figure 8 –TRACK PLACEMENT ................. 7
Figure 9 –WELD HEAD ................................ 8
Figure 10 –LATCH AND KNOB................... 8
Figure 11 –FILLET WELD ANGLE ............. 9
Figure 12 –FILLET WELD ANGLE 2 .......... 9
Figure 13 –TORCH LEAD/LAG ................... 9
Figure 14 –LEAD/LAG ADJUSTMENT....... 9
Figure 15 –TORCH STICK-OUT ................ 10
Figure 16 –BACK CAP................................ 10
Figure 17 –SLIDE CLAMP BOLTS............ 10
Figure 18 –TORCH HEAD REMOVAL ..... 10
Figure 19 –AVC PLATE.............................. 11
Figure 20 –WIRE GUIDE HEIGHT ............ 11
Figure 21 –WIRE GUIDE ADJUST ............ 11
Figure 22 –LOWER DRIVE ROLL............. 12
Figure 23 –TENSION KNOB ...................... 12
Figure 24 –SET SCREW.............................. 12
Figure 25 –DRIVE ROLL SHAFT............... 12
Figure 26 –ROLLER SET SCREW 2 .......... 13
Figure 27 –MOTOR KEY ............................ 13
Figure 28 –HUB NUT .................................. 14
Figure 29 –THUMB NUT ............................ 14
Figure 30 –WIRE 1 INSTALLATION......... 14
Figure 31 –WIRE 2 INSTALLATION......... 14
Figure 32 –INLET GUIDE........................... 15
Figure 33 –THUMB SCREW....................... 15
Figure 34 –WIRE ARMS ADJUSTED........ 15

Helix™T55

1BASIC INFORMATION 1
BASIC INFORMATION
The T55 Helix™ is a precision, gear driven weld
head designed for GTAW (TIG) welding. Paired
with the specifically designed steel and chromoly
track ring, the Helix™ provides strong, reliable
welds for a rugged and stable welding solution.
The T55 Helix™ tractor is controlled by a handheld
controller and AVC. It features an easy release
clutch which disengages the drive roll allowing free
movement along the track, without removing the
unit from the track ring. A heavy duty Nylon cover-
ing protects power, control, water and gas cables
from wear and tear; and a high temperature Teflon
coated sleeve protects the area closest to the weld
head.
The standard T55 weighs in at 35 lbs., without the
wire arms, and has two handles for easy carrying.
Two wire arms come standard with the option to
remove one of the arms for added versatility. The
Weld Head has 1”of oscillation stroke allowing the
operator flexibility when installing the Weld Head
and Track Ring. 3. 5” of AVC stroke allows the op-
erator to weld in deep groove applications. Torch
and Arc orientation can be adjusted 140° to adjust
for numerous weld parameters. Precision motors
allow for travel speeds from 0.5 IPM to 20 IPM.
The track ring is a low profile heavy duty track ring
stabilized at even intervals with cross braces.
Mounting shoes, containing spring cushions rated
to 800lb, attach to the cross braces and allow for
the work surface’s heat expansion which stops
binding and ring distortion. The geared system of
the track eliminates slippage and the angled section
interface prevents tractor jump.
The T55 Helix™ comes fully assembled in a rugged
waterproof case along with a gas line, water in and
water out, power cable, control cable, and a Helix™
tool box.
Toolbox
Included with the Helix™ is a toolbox of common
tools and consumables. These tools are for general
operation and maintenance; more in-depth mainte-
nance may require additional tools.
Tools
60” Flexible cloth Measuring tape
7/64” Hex Key (wire guide clamp)
1/8” Hex Key (wire guide angle adjust)
3/16” Hex Key (Oscillation plate, Lead/Lag Angle)
1/4” Hex Key (track shoes)
5/16” Hex Key (Weld Angle)
5/32” Hex Key (track clamp bolts, barrel clamp,
torch slide)
Wire Cutters
Consumables
Pyrex Cup (2)
1/8 Tungsten adapter (2)
Collet Body
1/8 Collet (2)
1/8 Tungsten (3)
Back Cap Long
Back Cap Medium
Optional Consumables not included
5/32 Tungsten Adapter
5/32 Collet
5/32 Tungsten