Weil-McLain GV BOILER 382-200-305 User Manual

Gv boiler, Replacement instructions

Part number 550-141-588/0501

Intermediate or Back Section Repair Kit

Part Number 382-200-305

GV BOILER

Replacement Instructions

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.
Wait until boiler is cooled down before proceeding with replacement.

WARNING

Indicates presence of hazard which
can cause severe personal injury,
death or substantial property damage.

WARNING

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.

2” square cut seals
Silicone sealant
Nuts and washers for draw rods
Instructions
Instructions for blower removal/replacement

Contents of Kit:

CAUTION

Indicates presence of hazard which will
or can cause minor personal injury or
property damage.

Remove jacket top and front panels. Lay aside boiler
insulation.

Close isolation valves between boiler and system.
Drain boiler.

Remove:
All wiring connectors from control tray.
Control tray (if applicable).
External system gas and water piping from boiler.
Thermostat wiring.
External vent piping.
External combustion air piping, if used.
Vent condensate drain hose.
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).

Tilt block assembly onto back section to rest on 2
short pieces of 2 x 4’s.

DO NOT remove drain valve and all other remaining
piping on front section.

Remove base rail assembly and tie rods from block
assembly.

CAUTION

Do not use any cleaner containing
petroleum-based distillate (oil). Square
cut seal failure will occur.

11. Apply bead of silicone sealant around perimeter of

intermediate or back section except on inside of
waterway holes (see Figure 1).

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.

Remove section(s) to be changed.

Remove silicone sealant from mating sections.

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.

CAUTION

Section block is heavy - care must be
taken in moving to avoid personal
injury.

Silicone

Sealant

Do Not

Apply

Silicone

Sealant

Here

Do Not

Apply

Silicone

Sealant

Here