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PILOT REMOVAL AND CLEANING
1. Disconnect pilot tubing and wires from gas valve.
2. Remove pilot assembly from burner tray.
3. Remove pilot from bracket.
4. Remove pilot orifice and air opening (Honeywell MV
unit only), and clean with wire or small brush.
CAUTION! Do not enlarge hole in pilot orifice.
5. Reverse above procedure to reinstall.
HONEYWELL PILOT ROBERTSHAW PILOT
Pilot Pilot
Air
Opening
Orifice
Orifice
Fig. # 8045.1 Fig. # 8102.0
HEAT EXCHANGER REMOVAL
1. Shut water, gas and electricity off, close valves and
relieve pressure and remove relief valve. Remove side
inspection panels.
2. Remove top holding screws.
3. Remove draft diverter, lift and remove top and flue
collector. Remove inspection panels.
4. Disconnect wires from high limits and pressure
switch. Remove temperature sensor.
5. Disconnect flange nuts on inlet-outlet header, loosen
union(s) at gas pipe and slide boiler away from piping.
6. Lift heat exchanger straight up using caution not to
damage refractory.
7. Reverse above procedure to reinstall. Make sure the
insulation strips are properly replaced on top of the
refractory retainer.
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BURNER DRAWER REMOVAL
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit,
and (2) screws that secure gas valve to jacket.
6. Disconnect wires that terminate at gas valve.
7. Slide out burner tray.
8. Reverse above procedure to reinstall.
GAS VALVE REMOVAL
1. Shut off gas supply to the heater. Remove gas piping
to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Reverse above procedure to reinstall.
MAIN BURNER AND ORIFICE REMOVAL
1. Remove burner drawer, following procedure above.
2. Remove screws and burner hold-down bracket.
NOTE: If the heat exchanger is sooted badly, the
burner hold-down bracket and spacer can become dis-
torted from direct flame impingement and this usually
necessitates replacement of these parts.
3. Lift burners from slotted spacers and slide from
orifices. Clean with a wire brush.
4. Orifices usually do not need to be replaced. To clean,
run either copper wire or wood toothpick through
orifice. Do not enlarge hole. To remove orifice, use
a socket wrench and remove from manifold. DO NOT
overtighten when reinstalling.
Burners
Burner Hold-Down Bracket
Fig. # 9479