Tools/Parts Required
Flat Screwdriver, Phillips Screwdriver
1/4” and 3/8” Socket Sets with Extenders
Sockets needed:1/4”, 5/16, 11/32, 7/16, 1/2, 9/16, 7/8
Rubber Mallet
Torque Wrench calibrated in
Inch-Lbs.
High Temperature RTV (600° F. Cont.; 700° F. Intermittent)
Flame Holder/Adapter Plate Gaskets
(2 - Part No. 42001-0065)
14” & 12” Pipe Wrenchs (1 Each) or 2 Channel-Lock Pliers
Optional:
Lifting Gear capable of handling 150 Lbs.
Safety Precautions:
Risk of electrical shock, fire or explosion.
Disconnect all power to the heater and close the external
manual gas valve at start of this procedure. Check for gas
leaks with a soapy water solution after reassembly.
Risk of carbon monoxide poisoning from
indoor units if exhaust vent joints are not sealed.
Check
all vent joints for leakage after reassembly.
Heavy parts; can cause personal injury.
When lifting, use all proper precautions for the weights
involved.
Uncured RTV sealants can cause eye irrita-
tion.
Follow manufacturer’s instructions when using RTV
sealants.
Location
The Insulation is located inside the Combustion Chamber.
Function
The insulation increases the thermal efficiency of the
heater and prevents overheating of parts outside the com-
bustion chamber.
Servicing Procedure (See Figure 1):
Heavy parts; can cause personal injury.
When lifting, use all proper precautions for the weights
involved.
1. Turn off the filter pump and all electrical power to the
heater. Close the external Manual Gas Valve.
2. If the heater is below the water level of the pool, close
the isolation valves to avoid draining the pool.
3. Remove the drain plug under the manifold and drain
the heater.
4. While the heater is draining, remove the upper left and
upper right jacket halves.
5. Remove the switch covers on both sides of the mani-
fold and unplug the wires from the Automatic Gas
Shutoff, the High Limit Thermostat, and the Thermistor
(See Figure 2, Key No. 1). If necessary, disconnect the
Water Pressure Switch and remove it.
6. Disconnect exhaust vent from indoor units.
7. Disconnect the gas pipe at the external union between
the heater and the external manual gas valve.
8. Disconnect the incoming electrical wires at the junction
box and cut the wire tie holding the Wiring Harness to
the Lower Enclosure (See Figure 2, Key No. 2).
9. Disconnect the inlet and outlet unions and move the
heater enough to allow removal of the manifold
adapter and the inlet/outlet manifold as a unit (See
Figure 2, Key No. 3).
1/2" Insulation
Blanket
1/2" Insulation
Blanket
1" Insulation
1" Insulation
Flameholder Insulation
Cap
Condensate
Evaporator
3120 1197
PRE
SS
TA
B
VE
NT
PIL
OT
OF
F
OFF
ON ON
Open
Manual/Gas Valve OFF
Power
Combination Gas Control Valve OFF
Close Isolation Valves
Turn Clockwise
and press down
to turn off gas.
Drain Cock(s) and Plugs
OPEN
2704 1196
PRESS
TAB
VENT
PILOT
O
FF
OFF
O
N
ON
Remove Water Pressure
Switch to help Manifold
Drain
Outlet
Inlet
Drain Inlet/Outlet
Manifold
Figure 1: Isolate and Drain Heater; Disconnect Power
2
