Whirlpool Essential Parts and Maintenance for Gas Water Heater – SG1J4040T3NOV and SG1J5040T3NOV

Figure 22

Gas Valve Connections

Replacement Parts

IMPORTANT: The following maintenance procedures are for the Flame Lock™Safety System components and should be performed by a qualified person.

Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly. When ordering replacement parts, always have the following information ready:

1.model, serial, and product number

2.item number

3.parts description

See “Repair Parts” section for a list of available repair parts.

Removing the Burner Door Assembly

1.Turn off the gas to the water heater at the manual gas shut-off valve (Figure 3).

2.Turn the gas control knob on the combination gas control valve/thermostat clockwise to the “OFF” position (Figure 19). NOTE: Depress the dial stop on Robertshaw valves before turning the gas control

knob. See Lighting Instructions on the water heater.

3. Remove the outer door. Robertshaw Gas Valve

4. Remove the two screws

securing the burner door	Pilot
assembly to the combustion
	Tube
chamber. (Figure 23).	Thermocouple

5. Disconnect the thermocouple	Manifold Tube
(right-hand thread), pilot	White Rodgers Gas Valve
tube, the igniter wire from the
igniter button, and manifold
tube at the thermostat.	Pilot
(Figure 22).
	Tube
6. Grasp the manifold tube and	Thermocouple
push down slightly to free the
	Manifold Tube
manifold tube, pilot tube, and

thermocouple.

7.Carefully remove the burner door assembly from the combustion chamber. Be sure not to damage internal parts.

Figure 23	Gas Valve /
Burner Door
	Thermostat
Assembly Removal		Piezo
		Igniter
		Button
Thermocouple
Manifold
Tube
Viewport		Pilot Tube
		Burner
		Door
	Door	Two Piece Wire
	Screw (2)	Connector

Natural Gas Burner (Ultra Low Nox)

Check the burner to see if it is dirty or clogged. The burner may be cleaned with soft paint brush (Figure 24). Do not use a wire brush or any tool that may damage the burner screen. Important: Do not use the burner if the burner screen is damaged. NOTE: Damage may be rips or holes in the burner screen. Discoloration is normal.

Figure 24

Natural Gas (Low Nox)

Burner Door Assembly

Pilot Assembly

Burner

Use brush on this surface.

Replacing the Pilot Assembly

1.Follow the instructions in “Removing the Burner Door Assembly” section to remove the assembly.

2.Remove the retainer clip securing the two piece wire connector to the burner door assembly. (Note the orientation of the retainer clip). Insert the tip of a large flat head screwdriver between the clip and the top of the two piece wire connector. Carefully rotate the screwdriver to raise the clip. It may be necessary to remove the connector one side at a time. (See Figure 25.)

3.Locate where the thermocouple connects to the rear of the pilot assembly, and pull the thermocouple tip from the rear of the pilot assembly.

4.Remove the nut securing the pilot assembly to the burner and keep it for reuse later.

5.Use a 1/2” open end wrench, to loosen the nut securing the pilot tube to the pilot. To prevent any bending use a pair of pliers to steady the pilot bracket.

6.Remove the old pilot assembly (including the igniter wire) from the burner door assembly.

7.Insert the pilot tube into the new pilot assembly. Important: The new pilot assembly comes with an orifice. This orifice must be installed when replacing the pilot assembly.

IMPORTANT: Do not operate this water heater without the orifice in place.

8.Use a 1/2” open end wrench, to tighten the nut securing the pilot tube to the pilot. To prevent any bending use a pair of pliers to steady the pilot bracket.

9.Use the nut removed in a previous step to secure the new pilot assembly to the burner.

10.Insert the igniter wire through the burner door and reconnect the thermocouple to the pilot assembly. See “Replacing the Thermocouple” section.

11.Reinstall the two piece wire connector. NOTE: The pilot tube must be at the top followed by the igniter wire then the thermocouple.

12.Follow the instructions in “Replacing the Burner Door Assembly” section to reinstall the assembly.

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