GV BOILER
Intermediate or Back Section Repair Kit
Part Number 382-200-305
Replacement Instructions
The following terms are used in these instructions to bring attention to presence of hazards of various risk levels, or to important
information concerning the life of the product.
Indicates presence of hazard which
can cause severe personal injury,
death or substantial property damage.
Indicates presence of hazard which will
or can cause minor personal injury or
property damage.
WARNING
CAUTION
Failure to follow items below can cause severe personal injury, death or substantial property damage:
These instructions are for use by a qualified installer/service technician.Follow all instructions in proper order.
Shut off main gas valve and disconnect electricity to boiler.
WARNING
Wait until boiler is cooled down before proceeding with replacement.
Contents of Kit:
2” square cut seals
7. Remove section(s) to be changed.
Silicone sealant
Nuts and washers for draw rods
Instructions
Instructions for blower removal/replacement
8. Remove silicone sealant from mating sections.
9. Clean new section and mating sections of any oil
and dirt or silicone sealant will not adhere properly.
10. Clean square cut sealing surfaces on new and
mating sections.
1. Remove jacket top and front panels. Lay aside boiler
insulation.
2. Close isolation valves between boiler and system.
Drain boiler.
Do not use any cleaner containing
CAUTION
petroleum-based distillate (oil). Square
3. Remove:
cut seal failure will occur.
All wiring connectors from control tray.
Control tray (if applicable).
External system gas and water piping from boiler.
Thermostat wiring.
11. Apply bead of silicone sealant around perimeter of
intermediate or back section except on inside of
waterway holes (see Figure 1).
External vent piping.
External combustion air piping, if used.
Vent condensate drain hose.
Silicone
Sealant
Do Not
Apply
Silicone
Sealant
Here
Blower assembly and burner. See “Blower Assembly
or Burner Replacement Instructions,”part number
550-141-608, packed with kit.
High limit control bulb from well.
Relief valve and external piping (back section only).
External air vent piping.
Remaining outside and interior jacket panels.
Block temperature limit switch.
Circulator(s).
Do Not
Apply
Silicone
Sealant
Here
4. Tilt block assembly onto back section to rest on 2
short pieces of 2 x 4’s.
Section block is heavy - care must be
CAUTION
taken in moving to avoid personal
injury.
Figure 1
12. Insert new square cut seals.
13. Align new section and lay it on top of existing section.
Repeat steps 10-12 as necessary.
5. DO NOT remove drain valve and all other remaining
piping on front section.
6. Remove base rail assembly and tie rods from block
assembly.
Part number 550-141-588/0501
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