CLEANING THE PILOT ASSEMBLY
AquaStar models 80/125/170
A. Removing Pilot
1.Hold Gas Pilot Filter Housing in place with one wrench.
2.Unscrew Pilot Tube nut with second wrench.
3.Save the little white Gasket for reassembly.
4.Pivot the tube to the left (loosen base fitting if needed).
5.Remove upper “hairpin” retaining clip.
6.Pull Pilot Assembly downward out of bracket.
B. Cleaning the Pilot
1.Separate the chrome Pilot Burner from the brass Gas Pilot Filter Housing. Save the white Gasket for reassembly.
2.Examine the Filter material for dirt. Blowing from the top gets the filter material out of the brass housing. Since the material is layered; dirty layers can be removed. The remaining portion of the filter can be loosely reinserted into the housing. Do not pack the material into the housing as this can obstruct gas flow to the pilot.
3.Check that the
4.The pilot injector (orifice) must not be enlarged. The natural gas orifice is large enough that you can visually inspect and clean it. The LP orifice, however, is so small that it is difficult to inspect or clean. We recommend that you change the LP orifice if you
suspect that it might be partially obstructed. If you do not have a replacement orifice, you may blow through it or use a
5.Clean any combustion residue from the Pilot Burner tip. Make certain that both holes and the slit are clean.
C.Reinstalling Pilot Burner to Main Burner Bracket 1. Insert injector into base of Pilot Burner. Reattach
Filter Housing to base of Pilot Burner, making sure to have the Gasket in between.
Be certain that the brass Gas Pilot Filter Housing is snug to the Pilot Burner — use two wrenches to tighten.
2. Pilot holes face in towards Main Burners. Slide Pilot Burner ALL the way up into the bracket.
a)Insert Hairpin Retaining Clip to hold Pilot Burner in bracket. Pivot the Pilot Tube back into position below Filter Housing.
b)Insert the other Gasket between tube and Filter Housing.
c)Use two wrenches to tighten Pilot Tube to Filter Housing.
1)One wrench should hold Pilot Burner in right most position, making sure right side flame is aimed precisely on tip of Thermocouple.
2)Use second wrench to tighten Pilot Tube nut — DO NOT
Thermocouple
To E.C.O.
Main
Burners
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Pilot | Pilot Injector |
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Assembly | Screen |
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Pilot Burner
Retaining Bracket
To Electromagnet 
Pilot Flames
Pilot Burner
Air Screen
Thermocouple
Screen
Retaining
Clip
View of Pilot Flame as seen from above
NOTE: Pilot flame must be sharp blue, not soft and yellow
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