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6. Position the new thermocoupte through the bottom opening
of the two piece wire connector (Figure 34). Be sure igniter
wire is positioned through the small opening of the two
piece wire connector.
7. Re-attach the burner. Note the orientation of the burner
(Figure 33.)
8. See "Replacing the Manifold/Burner Assembly."
FERRULE NUT
THERMOCOUPLE
MANIFOLD TUBE
TWO PIECE
WIRE CONNECTOR ........... (_,_ i_;
Li
IGNITER WIRE
PILOT PILOT BRACKET
__ _ OTHER FITTINGS
',-=_ '_.... NOT SHOWN
R CLARITY
:' =i RETAINER
RLETpAIN|
' CLiP
PILOT TUBE _ MANIFOLD/BURNER
DOOR OPENING
Replacing the Pilot/Pilot Tube Assembly
Remove the manifold/burner assembly. See "Removing
the Manifold/Burner Assembly."
2. Lift the retainer clip straight up from the back of the two
piece wire connector (using a flat-blade screwdriver), then
remove the two piece wire connector from the manifold
door (Figure 34.)
IMPORTANT: Be careful not to bend or alter the position of the
pilot tube. It will be used as a bending template for the new
pilot assembly.
3. Take off the burner by removing the two (2) screws located
underneath the burner. See Figure 33.
4. Remove and keep the screw securing the pilot assembly to
the pilot bracket. (Figure 36)
5. Remove and keep the old pilot tube and thermocouple.
6. Using the old pilot tube as a guide, bend the new pilot tube
to match the old one. NOTE: Make only the bends closest
to the pilot before going to the next step. (Figure 36)
OLD PILOT ASSEMBLY
PILOT TUBE
SCREW
OTHER FITTINGS
NOT SHOWN
FOR CLARITY
7.
8.
g.
10.
11.
12.
13.
14.
15.
Route the new pilot tube, thermocoupte, and igniter wire
through the manifold/burner door opening. (Figure 34)
Connect the new pilot tube and tighten the nut securing it
to the pilot assembly. IMPORTANT: Keep the pilot orifice in
the pilot when making the connection. Do not operate the
water heater without the pilot orifice installed.
Install the thermocoupte, making sure that itisfully seated.
Re-attach the pilot assembly to the pilot bracket and secure
using the screw removed earlier.
Re-attach the burner. Note the orientation of the burner
(Figure 33).
Position the new pilot tube through the largest opening of
the two piece wire connector. NOTE: The largest opening
should be located at the top position. The igniter wire
should be located in the middle opening and thermocouple
in the bottom opening (Figure 37).
THERMOCOUPLE \\
TWO PIECE WIRE CONNECTOR
FIGURE 37.
Reposition the two piece wire connector in the manifold
door opening and secure it with the retainer clip.
Carefully bend the new pilot tube and thermocoupte to
match the bend of the manifold tube. NOTE: When bending,
DO NOT crimp or crease the pilot tube or thermocouple.
(Figure 34)
Before you proceed to the next step, install the new brass
ferrule nut in the gas control valve/thermostat's pilot tube
opening. HAND TIGHTEN ONLY.
16. See "Replacing the Manifold/Burner Assembly."
Cleaning the Combustion Chamber and
Flame-arrestor
1.
2.
Follow procedure outlined in "Removing the Manifold/
Burner Assembly."
Use a vacuum cleaner/shop vac to remove all loose debris
in the combustion chamber (Figure 38). Use compressed
air to clear any dust or debris that may have accumulated
in the flame-arrestor.
COMBUSTION CHAMBER
IGNITER WIRE
THERMOCOUPLE FIRST BEND(S)
FIGURE 36.
3O
FIGURE 38.
3. Reassemble by following the procedure under "Replacing
the Manifold/Burner Assembly."