27
10. Reposition the t wo piece wire connector in the manifold
door opening and secure it with the retainer clip.
11. Carefully bend the new pilot tube and thermocouple
to match the bend of the manifold tube. NOTE: When
bending DO NOT crimp or crease the pilot tube or
thermocouple. (Figure 25)
12. Before you proceed to the next step, install the new
brass ferrule nut in the gas control valve/thermostat’s
pilot tube opening. HAND TIGHT ONLY.
13. See Replacing the Manifold/Burner A ssembly.
External Inspection & Cleaning of the Base-Ring Filter 1. At least annually check the base-ring filter (Figure 29)
for any dust or debris that may have accumulated on
the filter screen. NOTE: If the water heater is located
in an area that is subjected to lint and dirt, it may be
necessary to check the base-ring filter m ore frequently.
2. Follow the Lighting Instructions to turn off the water
heater and allow it to cool for 10 minutes before
attempting to clean the base-ring filter.
3. Use a vacuum cleaner with a hose attachment to
remove any dust or debris that may have accumulated
on the filter. NOTE: If unable to inspect or clean the
base-ring filter, follow the “Cleaning the Combustion
Chamber and Flame-arrestor” instructions.
4. After the base-ring filter has been cleaned, follow
the Lighting Instructions to return the water heater to
service.
Cleaning the Combustion Chamber and Flame-arrestor 1. Follow procedure outlined in “Removing the Manifold/
Burner Assembly”.
2. Use a vacuum cleaner/shop vac to remove all loose
debris in the combustion chamber (Figure 29). Use
compressed air to clear any dust or debris that may
have accumulated in the flame-arrestor.
DOOR GASKET
FLAME ARRESTOR
COMBUSTION CHAMBER
BASE-RING
FILTER
FIGURE 29.
3. Reassemble following the procedure under “Replacing
the Manifold/Burner Assembly”.
Replacing the Manifold/Burner Assembly WARNING
Explosion Hazard
• Tighten both manifold door screws securely.
• Remove any fiberglass between gasket and
combustion chamber.
• Replace viewport if glass is missing or damaged.
• Replace two piece wire connector if missing or
removed.
• Replace door gasket if damaged.
• Failure to follow these instructions can result in
death, explosion, or fire.
1. Check the door gasket for damage or imbedded debris
prior to installation.
2. Inspect the view port for damage and replace as
required.
3. Insert the manifold/burner assembly into the burner
compartment making sure that the tip of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figures 30 & 31).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
5. Replace the two screws, which secure the manifold/
burner assembly door to the combustion chamber
and tighten securely. Once the manifold/burner
assembly door is tightened, visually inspect the door
gasket between the manifold/burner assembly door
and the combustion chamber for spaces or gaps that
would prevent a seal. IMPORTANT: Do not operate
the water heater if the door gasket does not create a
seal between the manifold door and the combustion
chamber.
6. During the following procedure, do not cross-thread
or apply any thread sealant to any of the fittings listed
below. First, reconnect the manifold tubing to the gas
control valve/thermostat. NOTE: L.P. gas systems use
reverse (left-hand) threads on the manifold tube.
NOTE: If a ferrule nut needs to be installed for the pilot
tube, locate the one provided with your parts kit. Install
it in the gas control valve/thermostat at the pilot loca-
tion, hand tight only. Next, insert the pilot tube into the
ferrule nut until it bottoms out.
NOTE: Hold the tube in this position. Tighten the fer-
rule nut with a wrench until the crimp connection seals
to the pilot tube. Continue to tighten until the nut is