Can't remove burner


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Old 09-19-18, 08:02 AM
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Can't remove burner

Hello, I own an AO Smith Promax gcv 40-200, installed around 2012, not working and pilot light not working. Everything I see online suggests maybe a bad thermocouple and to remove the burner assembly to replace it. I've shut off the gas, disconnected the thermocouple and other connections, and unscrewed the door, but it won't budge.

I downloaded the manual and the parts list shows a door "gasket." Does this mean the burner is sealed up and I need to get a professional to look at it?

Thanks!
 

Last edited by dto71; 09-19-18 at 08:02 AM. Reason: typo
  #2  
Old 09-19-18, 08:50 AM
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Update: okay, I did manage to get the burner assembly out, so I could replace the whole thing, but I don't see how the thermocouple can be removed separately from everything else.
 
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Old 09-19-18, 10:06 AM
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Yes there is a gasket around the door and the gasket sometimes sticks to the door or the side of the tank. You may need to scrape it away and put in a new gasket.

By the way the water heater will work equally well without the gasket. But there will be impaired ability to not ignite cleaning fluid or other flammable liquid that spilled on the floor nearby or not ignite gas that escaped in the basement from some other appliance damaged by too high pressure in the incoming gas line.

Do you have a picture of the door and burner assembly so it can be seen how easily another gasket or washer can be slipped out to separate the thermocouple from the rest of the assembly?
 
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Old 09-19-18, 10:27 AM
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A thermocouple only holds the gas valve open once heated.
As far as I know... even if it's bad.... the pilot will light and stay lit if the valve is held down manually.
Are you sure the spark ignition was working ? Many crap out.

If it's similar to my AO Smith..... only the burner assembly uses a gasket.

Depending on highboy or lowboy model.... the pilot and thermocouple is replaced as a unit. One of the listed assemblies is this.... 183824-190. With a superseded part number....9003542. When ordering you MUST confirm by full model number and possibly serial number. There are two assemblies listed.

Just as an example.... 9003542005-Heater-190-Degree-NaturalGas
Product support page.... hotwater.com/support/gcv-40/
 
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Old 09-19-18, 01:49 PM
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Thank you for the replies so far.

Ok, got the thermocouple out, took it to my local plumbing supply store, the guy tested it and said it was bad. I got a replacement and everything is back in EXCEPT the "third" line that screws into the gas control/thermostat.

I've screwed back in the new thermocouple, and the corrugated metal line which I assume is the gas line. There is a third, smooth metal flexible line. I don't know what it does but I've spent an hour trying to screw it back in and it's not threading. As you can see I'm starting to damage it.
 
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Old 09-19-18, 04:40 PM
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Is that the new pilot assembly ?
Did you use Vise Grips on the nut ?

That ferrule..... the little brass cone at the end.... looks like it wasn't on or set straight.
That pipe is the pilot light gas line.
The bigger line is the burner.
 
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Old 09-19-18, 08:45 PM
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It's the original line, the only thing I bought new was the replacement thermocouple.

I still don't know what the problem was with the pilot line, or how the ferrule got bent, but after another hour or so, I finally got it to thread in. With the new thermocouple the heater started right back up, total repair cost $11. Thanks to everyone who replied!
​​
 
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Old 09-19-18, 10:56 PM
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Just be sure to check for gas leaks using a little dishwashing soap in water with a brush.
 
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Old 12-08-18, 09:17 AM
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I’m having the same problem removing the burner assembly on my Promax 40 gallon. How were you able to remove it?

 
 

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