Weil-McLain GOLD GV Operating instructions

Part number 550-141-608/0908
Blower Assembly or Burner
Replacement Instructions
Hazard definitions
The following defined terms are used throughout these Instructions to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury or property damage.
Indicates special instructions on installation, operation or maintenance that are important but not related to
personal injury or property damage.
For use with Weil-McLain Kit part numbers:
382-200-340 — GV Blower housing assembly replacement kit
382-200-300 — GV Front section repair parts kit
382-200-320 — GV-3 Burner replacement kit
382-200-325 — GV-4 Burner replacement kit
382-200-330 — GV-5 Burner replacement kit
382-200-335 — GV-6 Burner replacement kit
GOLD GV
Recommended tools:
• 10”crescentwrench
• smallpipewrench
• 5 /16”nutdriver
• 5/16”socketwithextension
• ½”socketwithextension
Water Boiler — Series 1 – 4
To the installer:
These Instructions must only be used by a qualified installer/service technician. Read these Instructions completely before beginning
the installation. Failure to follow all instructions can cause severe personal injury, death or substantial property damage.

Part number 550-141-608/0908
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GOLD GV Series 1 – 4 Blower Assembly or Burner — Replacement Instructions
Item
number
Description Weil-McLain
kit part number
1Burner replacement kit
(includes: burner cone and ring assembly, blower flange
gasket, igniter, igniter screws, igniter washers, igniter
gasket)
GV-3
GV-4
GV-5
GV-6
382-200-320
382-200-325
382-200-330
382-200-335
2Blower flange gasket
3Air pressure switch (0-5,500 feet elevation)
4Blower motor replacement kit
(includes: blower motor, motor mount grommets,
screws, lock nuts, 9" Allen wrench)
382-200-345
5Blower housing assembly replacement kit
(includes: blower housing, observation port window,
blower housing cover plate, blower motor mounting
brackets, washer hold down bracket, lock nuts, motor
mount grommets, blower motor, blower wheel, mag-
netic washer, silicone sealant, screws, blower flange
gasket, igniter, igniter screws, igniter washers, igniter
gasket)
382-200-340
6Orifice plate
Item
number
DescriptionWeil-McLain
kit part number
7Gas/air manifold assembly
(includes: gas/air manifold, gas tubing,
washers, screws, gas valve o-ring)
8Condensate trap kit (includes: condensate trap, hoses)
9Gas valve tubing (turn clockwise to loosen)
10 Gas valve kit
(includes: gas valve, gas cock, ½" nipple, bracket, screws and o-ring)
10aGas cock, ½" NPT
11 Gas valve bracket with screws
12 Igniter replacement kit (includes gasket)
13 Igniter gasket
(included in item 12, above)
14 Inlet air fitting
15 Hose clamp, 3"
16 Inlet air hose
17 Front section repair parts kit (includes: square
cut seals - 2", silicone sealant, tie rod nuts, tie rod wash-
ers, water tubing male adapters - 1" NPT, water tubing,
pump to return, blower flange gasket, igniter, igniter
gasket, screws, studs, nuts, lock washers)
382-200-300
Parts

Part number 550-141-608/0908 3
GOLD GV Series 1 – 4 Blower Assembly or Burner — Replacement Instructions
Replacement instructions
Shut off main gas valve and disconnect electricity to boiler. Failure to do so can cause severe
injury, death or substantial property damage
Wait until igniter is cooled down before proceeding. Failure to do so can cause severe injury.
 Donotdisassembleblowerhousing.Areorexplosioncausingseverepersonalinjury,death
or substantial property damage could result.
To remove blower assembly or
burner
1. Removejackettopandfrontpanels.
2. Remove control tray shipping screw and lift up
controltray,settingitoutofyourway(Series1and
2). Remove gas supply piping.
3. Disconnect (refer to items identified on page 2):
a. gas tubing from gas valve (left-hand thread
-Series1-3)(4screws-Series4),item9
b. pressure switch hoses, item 3
c. hose from gas valve to gas/air manifold,
item 7
d. inletairhose,item16
e. blower motor wiring harness from control
module
f. igniter harness from igniter plug
g. blower support bracket
h. gas supply manifold with bracket from blower
housing
i. ground wire from blower housing
j. gas/air manifold and orifice plate, items 6
and 7.
4. Remove2ignitorscrewsandlockwashers.Carefully
removeigniter,item12.
Use care when removing and
handling igniter. Igniter is very
brittle and can break if not handled
carefully. Do not touch!
5. Remove nuts and washers from studs at blower
housing mounting bracket and casting.
6. Graspblowerassemblyandpullfreefromstuds.
Turn clockwise until blower assembly can be
removed safely from inside of boiler.
7. Pull out burner cone and ring assembly and old
gasket,items1and2,toinspectfordustorsoot
accumulation.Cleanorreplaceasnecessary.
To install blower assembly or
burner
1. Place new blower housing gasket over studs at
combustion chamber opening.
2. Re-install burner cone and ring assembly into
combustion chamber.
3. Position blower assembly over studs. Install nuts
and washers and tighten until blower housing
gasket starts to compress.
4. Installigniterandnewignitergasket.Fastenwith
screws and washers. Tighten until lockwasher starts
to compress.
Igniter body will crack if screws are
over-tightened.
5. Replace control tray.
6. Connect:
a. Gas/air manifold and orice plate (tighten
screws until metal-to-metal contact is made
around entire manifold)
b. Gastubing fromgasvalve(left-hand thread
-Series1-3)(4screws-Series4)
c. Pressure switch hoses
d. Hose from gas valve to gas/air manifold
e. Inlet air hose (tighten hose clamp)
f. Blower motor wiring harness to control
module
g. Igniter harness to igniter plug
h. Blower support bracket
i. Gassupplymanifoldwithbrackettoblower
housing
j. Groundwiretoblowerhousing.
k. Gassupplypiping
7. Be sure all wiring and hose connections are secure
and in their proper locations.
8. Turn on electrical power and gas. Check boiler
normal sequence of operation and follow check-out
procedure in Boiler Manual.
9. Replacejacketfrontandtoppanels.

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GOLD GV Series 1 – 4 Blower Assembly or Burner — Replacement Instructions
Part number 550-141-608/0908