PILOT LIGHT TROUBLESHOOTING CHART

Section A: Pilot light will not light.

 

 

 

 

 

 

 

Check the manual gas shut-off valve to

Is the gas turned on?

 

NO

 

 

see if it is in the open position, if it is open

 

 

 

 

 

 

 

 

 

then contact the gas utility company.

 

YES

 

 

 

 

 

 

 

 

 

 

 

Section B: Pilot light will not remain lit or repeatedly goes out.

Is the thermocouple securely

 

 

 

 

Make sure the thermocouple is securely

connected to the gas control

 

 

 

 

connected. Finger tighten then give a

 

 

NO

 

 

 

 

 

valve/thermostat?

 

 

additional 1/2 turn with a wrench.

Have you bled all the air

from the pilot tube and NO gas supply line?

YES

Is the igniter producing a

 

 

 

 

NO

 

 

spark?

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is the pilot tube and/or orifice

 

 

 

 

NO

 

 

free from dirt and debris?

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is the pilot free from dirt and

 

 

 

 

NO

 

 

 

debris?

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

While repeatedly depressing the igniter button, hold down the reset button until the pilot is lit and maintains a stable flame, then slowly release the reset button.

Follow the Testing the Igniter System instructions in this manual.

Follow the Replacing the Pilot Assembly instructions found in this manual to access pilot tube and orifice. Clean as needed and reinstall pilot tube and orifice.*

Follow the Cleaning the Pilot Assembly instructions found in this manual.*

YES

Test the thermocouple using the following procedure: Disconnect the thermocouple from the gas control valve/thermostat. Using a multimeter with alligator clip leads, attach the red lead to the body (copper part) of the thermocouple. Attach the black lead to the end (silver part) of the thermocouple that connects to the gas control valve/ thermostat. Follow the instruction to light the pilot and watch the voltage readings on the multimeter. After 45 seconds the meter should read 12 millivolts DC or more.*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is the thermocouple fully

 

 

Does the thermocouple pass the test?

 

NO

 

 

seated in the pilot bracket?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

YES

 

 

 

NO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Push the thermocouple

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

forward until it is fully seated in

 

 

 

 

 

 

 

Replace the thermocouple.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the pilot bracket and retest.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Follow the Replacing the Pilot Assembly

 

 

 

 

 

 

 

 

 

 

 

Is the pilot tube and/or orifice

 

 

instructions found in this manual to access

Is the pilot protected from cold

 

 

 

 

Eliminate any drafts. See the

drafts that could prevent it

 

 

 

 

 

“Site Location” instructions found

 

 

NO

 

 

 

 

 

 

 

from lighting.

 

 

 

 

in this manual.

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove the burner door assembly.

 

 

 

 

 

Is the flame arrestor free from dirt or

 

 

 

 

Clean the flame arrestor

debris? See “Removing the Burner

 

 

 

 

with a soft bristle brush

 

NO

 

 

 

 

Door Assembly” section of the manual

 

 

 

 

or vacuum cleaner.

 

 

 

 

for removal instructions.*

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

Check the water heater for a Flammable Vapor (FV) event.

If the flame arrestor show signs of discoloration, shut-off the gas supply to the water heater at the manual gas shut-off valve, then contact Sears Service at: 1-800-4-MY-HOME®(1-800-469-4663).

 

 

 

 

 

 

 

 

 

 

 

NO

 

 

pilot tube and orifice. Clean as needed and

 

 

 

 

 

 

 

 

 

 

 

 

 

free from dirt and debris?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

reinstall pilot tube and orifice.*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Follow the Cleaning the Pilot Assembly

Is the pilot free from dirt and debris?

 

NO

 

 

instructions found in this manual.*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check for insufficient combustion air.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Install correct size make-up air openings per the

Are there openings for

 

 

 

 

make-up air to enter the

 

NO

 

 

Combustion Air and Ventilation section in this

 

 

 

 

room?

 

 

 

 

 

 

 

manual.

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Are the openings of sufficient size?

 

 

 

 

 

 

 

 

 

Correct size of openings to

 

See Combustion Air and Ventilation section in

 

NO

 

 

allow sufficient air.

 

 

 

 

 

 

 

 

 

 

 

 

this manual for requirements.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NO Is there a furnace/air handler in the same room as the water heater?

YES

Does the return air duct for the furnace/ air handler draw its air from a separate location than the water heater? See Facts to Consider About the Location section and the Combustion Air section.

YES

Is there proper drafting at the

draft hood? See Draft Hood NO Operation section in this manual.

YES

Contact a local Heating, Ventilation, Air-Conditioning

NO & Refrigeration authorized service provider.

Check the vent system for restrictions/obstructions and check the vent termination height. Refer to the Installation Instructions section of this manual for specific requirements.

* This procedure requires the removal of water heater components.

Remove the burner door

 

 

 

 

 

assembly. Is the flame arrestor

 

 

 

 

Refer to the Service and Adjustment

 

 

 

 

section of this manual for information on

and burner free from debris due to

 

NO

 

 

 

 

 

 

 

 

cleaning the flame arrestor and burner.

 

 

 

 

excessive lint, dirt, dust or oil?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

Does the flame arrestor show signs of discoloration. NO

YES

Replace the gas control

Shut-off the gas supply to the water heater at the valve/thermostat.* manual gas shut-off valve, then contact Sears

Service at: 1-800-4-MY-HOME®(1-800-469-4663).

30