Lincoln Electric BURNY KALIBURN Spirit II 275 User Manual page 102

Section 6: Maintenance &Troubleshooting
Manual Gas Console (MGC)
1. Remove the cover of the manual gas console. Using clean, dry, compressed air,
blow out all accumulated dust inside the unit. In an excessively dirty environment,
blow out the unit on a weekly basis.
2. Verify that all PC board connectors are installed securely.
3. Verify that all gas hose connectors are tight and that there are no leaks. Only
tighten the gas fittings enough to make a gas seal. The fittings are subject to
damage if over tightened.
4. Inspect all gas hoses to ensure no damage exists.
damaged gas hoses.
Torch, Torch Leads, and Gas Hoses
1. Verify that all torch lead and gas hose connections are tight and that there are no
gas or water leaks. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened.
2. Verify that the braided shield of the torch leads is fastened securely to the brass
shield adapter that connects to the impulse start console. Also, make sure the
shield adapter is secured tightly to the impulse start console enclosure.
3. Inspect the braided shield for nicks or cuts and replace if necessary.
4. Remove the torch handle and verify that the connections at the torch base are
tightened securely. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened. Coolant leaking from
the drain hole in the torch handle indicates damaged or loose torch leads.
5. Make sure the torch lead insulating sleeves are positioned to properly cover the
brass torch fittings at the torch base.
6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If
nicks, cuts or holes are found, replace the torch base.
7. Remove the torch consumables from the torch head and inspect all o-rings.
Replace any o-rings with cuts, nicks, abrasions, or any other signs of wear.
Faulty o-rings may cause gas or water leaks, which will affect cut quality.
8. With the electrode removed, inspect the cooling tube in the torch head for
damage.
If using the copper electrode, the torch head uses cooling tube P/N BK277007. If
replacement is required, use tool P/N BK200109.
If using the silver electrode, the torch head uses cooling tube holder assembly
P/N BK279216. Remove this using the tool (socket P/N BK277087 & driver P/N
BK277086) and inspect the o-rings for damage. Apply a small amount of o-ring
lubricant before re-installing in the torch head.
9. Wipe any excess o-ring lubricant off of the torch base and head.
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Spirit II User's Manual
Immediately replace any