17
103536-13 - 2/24
MegaSteam
Installation & Service Manual
8. Align upper panel attachment holes with
smokebox upper attachment bosses and install
5/16-18 in. x ½ in. Phillips pan head machine
screws hand tight.
9. Securely tighten rear jacket panel mounting
hardware.
10. Locate/remove four #8 x ½ in. shoulder sheet
metal screws from Hardware Bag, then, install
them into rear panel flange holes.
H. FLUE CLEANOUT COVERS AND SMOKEBOX
COLLAR INSTALLATION.
1. Remove two cast iron Cleanout Covers, cast
iron Smokebox Collar and the tube of hi-
temperature silicon adhesive sealant from
Part Carton. See also “Service Parts” Section,
“Bare Boiler Assembly” illustration for part
identification.
2. Check the rope gasket factory attached to
the covers. Repair or replace, if the rope is
damaged, or, there is a gap between the rope
ends.
3. Locate/remove four 5/16-18 in. – 7/8 in. hex
head cap screws from Hardware Bag.
4. Apply a drop of supplied Anti-seize (pouch
provided in Part Carton) to each of four (4)
5/16-18 in. x 7/8 in. hex head cap screws for
rust protection and to facilitate easy removal
for future service.
5. Position left Cleanout Cover over rear section
cleanout opening, align section boss holes
with Cleanout Cover holes, install both 5/16-18
in. – 7/8 in. hex head cap screws hand tight,
then, alternately tighten them with open end or
socket wrench.
6. Repeat above steps with right Cleanout Cover.
7. Apply the adhesive sealant to the underside
of the collar, all around, at the inside corner of
the collar outer ring. Insure adhesive bead is
complete all around and without gaps.
8. Place the collar over smokebox tongue and
align collar integral mounting ear slots with
smokebox bosses.
9. Thread-in both 5/16-18 in. – 7/8 in. hex head
cap screws hand tight, then, alternately tighten
them with open end or socket wrench.
I. INSULATION WRAPPER AND BURNER POWER
OUTLET RECEPTACLE WITH HARNESS
INSTALLATION.
1. Insulation Wrapper is vacuum packed/sealed
in plastic bag at the factory.
2. Carefully cut the plastic bag and remove
Insulation Wrapper. The wrapper will expand
upon removal.
3. Unfold Insulation Wrapper, position it over
section assembly centered left to right and
align two wrapper upper holes with 2 in. NPT
pipe tappings in front and rear section top.
4. Insure wrapper fits snugly around rear section
tankless heater collar/ mounting flange (if boiler
is equipped with tankless heater) and trim the
insulation at tankless heater cutout.
5. Tack Insulation Wrapper bottom ends under
section assembly, between front and rear
section legs.
6. Locate and remove Burner Power Outlet
Receptacle with factory attached Burner
Harness from Control Carton.
7. Feed Molex end of Burner Harness thru front
jacket panel right side outlet receptacle cutout.
Insure that the receptacle middle prong
opening is facing down. Snap the receptacle
into front jacket panel. Temporarily, stuff Molex
end of Burner Harness between front panel
insulation and insulation wrapper near boiler
top.
J. SIDE AND TOP JACKET PANEL INSTALLATION.
1. Pick up Left Side Jacket Panel from Jacket
Carton. See also “Service Parts” Section,
“Jacket Assembly” illustration for part
identification.
2. Place Left Side Jacket Panel over four #8 x
½ in. shoulder sheet metal screws, earlier
installed at Front and Rear Jacket Panel
side flanges, so teardrop cutouts in the side
panel inside flanges engage all four screws
simultaneously.
3. Slide the panel downwards to lock all screws
securely.
4. Pick up Right Side Jacket Panel from Jacket
Carton. See also “Service Parts” Section,
“Jacket Assembly” illustration for part
identification.
5. Pick up Molex end of Burner Harness
stuffed between front panel insulation and
insulation wrapper and feed it thru Right Side
Jacket Panel front cutout, letting the harness
connector to hang over the cutout edge
temporarily.
2
Unit-Pak Boiler Assembly
(continued)
