Weil McLain GV Boiler User Manual

GV BOILER  
Front Section Repair Kit  
Part Number 382-200-300 for Series 1 & 2  
Part Number 382-200-300 for Series 3 & 4  
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:  
Ignitor Replacement Kit  
7. Remove base rail assembly and tie rods from block  
assembly.  
Studs, nuts, washers, adapters, flange gaskets pump/  
return water tubing  
Square cut seals, silicone sealant  
Instructions  
8. Remove front section from block and remove  
silicone sealant from mating intermediate section.  
9. Clean new front section and mating intermediate  
section of any oil and dirt - silicone sealant will not  
adhere properly.  
Instructions for blower motor/replacement  
1. Remove jacket top and front panels. Lay aside boiler  
insulation.  
2. Close isolation valves between boiler and system.  
Drain boiler.  
10. Clean square cut sealing surfaces on new and  
mating sections.  
Do not use any cleaner containing  
CAUTION  
3. Remove:  
petroleum-based distillate (oil). Square  
All wiring connectors from control tray.  
Control tray (if applicable).  
cut seal failure will occur.  
External system gas and water piping from boiler.  
Thermostat wiring.  
External vent piping.  
External combustion air piping, if used.  
Vent condensate drain hose.  
11. Apply bead of silicone sealant around perimeter of  
intermediate section, NOT on inside of waterway holes  
(see Figure 1).  
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 and well.  
External relief valve piping.  
External air vent piping (if used).  
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  
5. Remove drain valve and all other remaining piping on  
front section.  
6. Remove vent ell and clean silicone sealant from vent  
ell (Series 1 & 2 only).  
12. Insert new square cut seals.  
13. Align front section and lay it on top of intermediate  
section.  
Part number 550-141-589/0501  

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