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See diagram 5. 5 4.3 Undo the thermocouple connection from the back of the gas valve and carefully pull the thermocouple clear of the pipework and valve. See diagram 6, arrow A. 6 AR1114 A 4.4Undo the pilot pipe connection from the pilot unit, remove the 2 screws securing the pilot and remove the pilot assembly. See diagram 7. 7 4.5 Replace with a new pilot unit of the correct type (refer to short spares list) and re-assemble. Set the spark gap as shown in diagram 5, replace the appliance and check the pipework for gas soundness, especially the inlet connection and pilot pipe connection. 4.6 Carry out flame failure functional check as detailed in the flow chart paying particular attention to the mag drop out time. 27 SERVICING INSTRUCTIONS REPLACING PARTS 5. MAGNETIC UNIT 7. PRIMARY AERATION PLATE 5.1 Remove the thermocouple from the back of the control valve. See diagram 8 arrow B. 8 B C 5.2 Undo the mag unit retaining nut. See diagram 8, arrow C 5.3 After removing the retaining nut, the mag unit can be tapped out and a replacement fitted. 5.4 Replace the mag unit retaining nut and tighten. Note - this is a gas tight seal. 5.5 Replace thermocouple and check for gas leaks. 5.6 After reassembly, carry out the flame failure functional check, detailed in the flow chart following, particularly the mag unit drop out time. 6. MAIN INJECTOR 6.1 Remove the fire. See section 1. 6.2 With the fire removed, where appropriate undo the injector compression nut. 6.3 Rotate the injector until it is fully removed. 6.4 Replace with the correct replacement injector. When ordering always state the model, gas type and serial number. 6.5 After re-assembly, check for gas leaks. 7.1 Locate the aeration plate on the underside of the airbox and remove the Nyloc nut, see diagram 9. 7.2 When replacing the aeration plate, ensure that the hole in the aeration plate is correctly aligned to one of the holes in the underside of the airbox, replace the Nyloc nut. NOTE: ENSURE THE CORRECT SIZE AERATION HOLE IS ALIGNED WITH ONE OF THE HOLES IN THE AERATION BOX - SEE TECHNICAL SPECIFICATION. LPG APPLIANCES DO NOT REQUIRE A PRIMARY AERATION PLATE 9 AR0564 28 SERVICING INSTRUCTIONS REPLACING PARTS 8. GAS VALVE 8.1 Remove the fire, refer to section 1. 8.2 Disconnect the 2x8mm and 1x4mm gas pipe fittings at the back of the gas valve, arrow A and disconnect the thermocouple. See diagram 10 arrow B. 10 A B 8.3 Undo the single screw that secures the left-hand side of the control cover. See diagram 11. 11 8.4 To release the right hand side of the control cover, insert a narrow blade screwdriver into the slot shown in diagram 12, lever it gently and pull from the right hand side at the same time. The cover will now come off. There is a small cylindrical metal spacer inside the cover, this must be kept and replaced on the fixing screw during re-assembly. 12 8.5 Disconnect the ignition lead from the gas valve, see section 2. 8.6 Undo the two screws securing the gas valve to the control bracket and remove the valve. 8.7 Replace in reverse order. 8.8 Check all joints for gas leaks; check operation of the thermocouple and ignition lead. 9. CHANGING BETWEEN GAS TYPES 9.1 The following parts must be changed when converting from one gas type to another: • Engine Assembly • Air Box Gasket • Pilot Assembly • Databadge Please note: The control valve will be preset for the correct gas type and model number. 29 SERVICING INSTRUCTIONS REPLACING PARTS 9. SHORT SPARES LIST COMMON COMPONENTS Control Valve GC0096 Ignition lead GC0090 Magnetic Unit GC0092 Control Cover GC0087 Upgrade Kit 8455 Pilot Shield (Standard) GZ1368 Pilot Shield (Glass Granules) GZ4424 Small Clay Beads (0.5 ltr) CE0239 Small Clay Beads (1.0 ltr) CE0240 Large Clay Beads (1.0 ltr) CE0241 Large Clay Beads (2.0 ltr) CE0242 Glass Granules CE0489 Small Moulded Coals (9) CE0216 Small Moulded Coals (14) CE0235 Large Moulded Coals (6) CE0217 Large Moulded Coals (9) CE0236 Sqaure Coals (Black) CE0007 Square Coals (White) CE0460 Small Pebbles (9) CE0456 Small Pebbles (14) CE0457 Large Pebbles (6) CE0458 Large Pebbles (9) CE0459 A1 Burnt Log CE0220 B1 Burnt Log CE0222 No. 1 Log CE0224* No. 6 Log CE0227* No. 7 Log CE0228* No. 8 Log CE0229* No. 9 Log CE0230* No.11 Log CE0231* No.12 Log CE0232* No.13 Log CE0233* No.14 Pine Cone CE0234* Natural Gas Components 1100 Injector IN0013 1600 Injector IN0010 Pilot Unit PI0047 Aeration Plate ME0833 LPG Gas Components 400 Injector IN0007 600 Injector IN0026 Pilot Unit PI0048 *DW Suffix indicates driftwood effect. 30 SERVICE RECORDS 1ST SERVICE Date of Service:........................................................................... Next Service Due:....................................................................... Signed:........................................................................................ Dealer's Stamp/CORGI Registration Number 3RD SERVICE Date of Service:........................................................................... Next ServiceDue...

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