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Part two of how to repair a Burnham Holiday gas fired boiler. 

This is part two of the instructions on how to clean and replace thermocouple on a Burnham Holiday gas fired hot water boiler, to see the first page please click here.

 

This pilot assembly was not installed properly (possible because the home owner did not know how to remove the burner tray. It is very hard to do with out removing the tray. Remove the pilot assembly I have decided to replace it.
With the tray out of the boiler vacuum all the burners and around the front of the boiler You can remove all the burners and wash them in a bucket or a sink. Note: Cast iron burners stay hot for a very long time.
So I get a new pilot assembly out of my truck, i remove the pilot tubing from the old one and put it on the new one Make sure the little orifice does not fall out of the new pilot assembly. and make sure the pilot tubing compression nut is tight. It is easer to do this with the pilot assembly off the burner and with out the thermocouple in place. after it is tight it is time to install the new thermocouple.
Some pilot assemblies require the threaded adaptor that comes with the new thermocouple others do not, this one does, so I use it. It just pushes on to the thermocouple.
Now I just screw it into the pilot assembly just snug is all that is needed, it is a fine thread and it can't be made tight, and does not need to be.
Now I attach it to the burner with the 2 screws. and the thermocouple is replaced.
When putting the burners back make sure the center of the back of the burner goes over the orifice nipple. and the front little pimple goes into the little dimple on the tray.
If it is in correctly it will not move side ways. then put the screw back. now the tray and burners should feel like one piece the burners should no have any play in them at all. Make sure the pilot tube and the thermocouple are facing towards you. Now slide the tray back in. Line the union up and make sure both tabs drop back in there slots on the left and right side of the tray. Now normally I would just say tighten up the union but we have to replace the gas valve first.

 

This is what the burner tray looks like when removed.
We need to remove the burner with the pilot assembly on it. So remove the screw on the top of the burner and the burner lifts up from the top. See pictures.
We need to remove the burner with the pilot assembly on it. So remove the screw on the top of the burner and the burner lifts up from the top. See pictures.
 
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