Hayward FD Heater Header O-Ring Kit FDXLFOR1930

REPLACEMENT PROCEDURE FDXLFOR1930 (Header O-Ring Kit):

1. Turn pump, main gas valve, and heater power off.
2. Remove drain plug and drain water out of heat exchanger.
3. Remove 7 screws and remove the upper plastic heater side panel and black sheet metal trim panel, to allow access to the header (see Figure 1 for screw locations).
4. Disconnect wires on pressure switch, temperature sensor, and temperature limits (see Figure 2).
5. Remove 8 5/16" bolts, washers, and spacers, and remove header and mounting bases by pulling straight out from heater (see Figure 2).
6. Remove bypass cartridge from the header.
7. Replace all o-rings with the new ones in this kit. Apply silicone o-ring grease (Hayward Jacks 327 Multilube P/N SP032712, or equivalent) on o-ring seals on bypass cartridge, mounting bases, and heat exchanger tubes before re-assembly.
8. Insert bypass cartridge into header with the arrow on the end of the cartridge pointing up.
9. Re-install cartridge retaining nut. Nut should be tightened hand-tight only. D0 NOT OVER-TIGHTEN.
10. Re-install header assembly on heater.
11. Tighten 5/16" bolts to a torque of 75-100 in-lbs (6-8 ft- lbs).
12. Re-install upper plastic heater side panel and black sheet metal trim panel.