Weil-McLain SERIES 1 Replacement Instructions

This symbol is used in these instructions to indicate presence of hazards which can cause severe personal injury,
WARNING
death or substantial property damage.
These instructions are for use by a qualified installer/service technician. Failure to follow all instructions in proper
WARNING
order can cause severe personal injury, death or substantial property damage.
Shut off main gas valve and disconnect electricity to boiler. Failure to do so can cause severe personal injury, death
or substantial property damage.
Contents of Kit:
Gas/Air Manifold
O-ring for manifold
Gas valve fitting
Miscellaneous hardware: screws to mount manifold to
inducer housing, to mount gas valve to inducer housing,
to mount manifold fitting to gas valve, plastic tie wrap to
re-attach condensate trap to manifold.
Instructions
1. Remove:
Jacket top and front panels.
All hoses from gas/air manifold assembly (save to re-
install). See Figure 1.
For Series 1, 2 & 3, remove left-handed threaded fitting
from gas valve.
OR
For Series 4, remove the gas valve to manifold fitting
by removing four screws (#7 metric head) from fitting.
Gas/air manifold assembly.
Gas orifice plate (save to re-install).
2. Install new gas/air manifold assembly. Loosely screw
in 2 back screws to support assembly.
3. For Series 1, 2 & 3, align left-hand threaded fitting to
gas valve and tighten.
a. Do not clamp gas tubing with excessive force, as it
will deform.
b. Do not apply excessive force to gas valve.
OR
For Series 4, align gas valve manifold fitting to gas
valve with new O-ring in place and replace four screws
in the gas valve fitting.
Carefully seat O-ring in manifold fitting
WARNING
groove to insure proper fit as manifold
fitting is mated to gas valve. Failure to do
so can result in a fire or explosion causing
severe personal injury or property
damage.
4. Slide in gas orifice plate and re-install two front screws
in gas/air manifold assembly.
GV BOILER GV BOILER
GV BOILER
GV BOILER GV BOILER
Gas/Air Manifold Assembly
Part Number 382-200-355 for Series 1, 2 & 3
Part Number 382-200-362 for Series 4
Replacement Instructions Replacement Instructions
Replacement Instructions Replacement Instructions Replacement Instructions
5. Tighten all four screws in gas/air manifold assembly
evenly, until metal-to-metal contact is made around
entire manifold.
6. Re-connect hoses as shown in Figure 1. Secure wire
tie or hose clamp on air inlet hose.
7. Turn on electric and gas to boiler. Check boiler normal
sequence of operation and follow checkout procedure
in Boiler Manual.
8. Replace jacket front and top panels.
RECOMMENDED TOOLS:
10" CRESCENT WRENCH
SMALL PIPE WRENCH
5/16" NUT DRIVER
5/16" SOCKET WITH EXTENSION
#7 METRIC WRENCH OR SOCKET
1/4" SLOTTED SCREWDRIVER
Do not disassemble blower housing. A
WARNING
fire or explosion causing severe
personal injury or property damage can
result.
Figure 1
Michigan City, IN 46360-2388
Part number 550-141-607/0601
Weil-McLain
500 Blaine Street
http://www.weil-mclain.com