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AK and 3K Series Installation and Service Instructions
4211-171 06-25-10
C. WATER SOLENOID REPLACEMENT:
Disconnect power from the unit. Turn the water
supply OFF. Disconnect the water supply from the
water solenoid valve. Remove the front cover. Re-
move the two blue wires from the water solenoid
valve. Rotate the self-tightening hose clamp so it can
be loosened with a pair of pliers. Squeeze the clamp
and move it down towards the shelf and off the valve
outlet tube. Remove the two 1/4" - 20 hex head bolts
and lock washers that attach the valve to the chassis.
Pull the valve off the rubber fill hose. To install the
valve, reverse these instructions. Test the unit per
SECTION 7: OPERATIONAL TEST.
D. LEVEL PROBE REPLACEMENT:
Disconnect power from the unit. Remove the front
cover. Note where the blue wire is connected to the
triple pronged water level probe. Disconnect all three
wires from the water level probe. Using a 1-1/4" box
wrench, remove the level probe. Install a new level
probe. Use Teflon Tape on threads of probe if re-
quired. Tighten until the bottom of the plastic nut is
1/8" to 3/8" inch above the top of the port. See
diagram 17. Reattach the three wires. Test the unit
per SECTION 7: OPERATIONAL TEST.
IMPORTANT
The blue wire connected to “L” on the
PCA must be connected to the shortest of the
three level probes.
IMPORTANT
The level probe may be extremely tight. Damage
to the insulation or chassis may result unless the
tank is properly blocked or supported during
probe removal or installation. It may be neces-
sary to completely disconnect and disassemble
the generator.
SEE DIAGRAMS
SECTION 8: SERVICE (continued)
- FLUSH TANK - Flush monthly, or more often,
depending on local water conditions.
- FLUSHING PROCEDURE:
1. The generator should be cool.
2. Press the ON/OFF. The control should light.
3. Open the manual drain valve.
4. The unit will drain without heating the water.
5. Allow the water to run for a full 10 minutes, then
press the ON/OFF. The control light should turn off.
6. Allow the unit to drain completely. When the water
stops, close the manual drain valve.
3. REPAIR OF AK SERIES GENERATORS
A. ELEMENT REPLACEMENT:
Disconnect power from the unit. Drain the tank. Open
the front and HEATING ELEMENT ACCESS covers.
Note the wire connections. See diagram 15. Remove
the element wires. Using a hot water element socket,
remove the element. To install a new element, mount
a new element gasket on the element. Clean the
element port and add a light coat of Rectorseal No. 5
pipe thread compound to the threads. Insert and
hand tighten the element-gasket combination. Notice
the element end orientation as shown in diagram 16.
Tighten the element until the orientation is the same
as diagram 16, ± 15°. The gasket should be set and
tight but not deformed to a rounded or bulbous
appearance. If the drain valve was removed reinstall
it. Reconnect the wiring. Test the unit per SECTION 7:
OPERATIONAL TEST. Check for leaks at the element.
Replace the front cover and the HEATING ELEMENT
ACCESS cover.
B. PRINTED CIRCUIT REPLACEMENT:
Printed circuit assembly (PCA) removal and replace-
ment must be performed in the sequence described
below. Any other method can damage the PCA.
IMPORTANT
The PCA’s contain static sensitive devices.
Static electricity may damage PCA’s. Handle
accordingly.
Disconnect power from the unit. Note and tag the
positions of all wires that plug into the printed circuit
assembly mounted relays. Remove all the wires from
the relays. When removing these wires, pull on the
connector, not the wire. Note the blue wire connected
to the shortest of the triple pronged water level probe.
Disconnect all three wires from the water level probe.
Remove PCA from all seven standoffs by pinching the
tops. When it is completely disconnected, it may be
lifted out of the enclosure. See diagram 20. To install
the board, reverse this procedure. Test the unit per
SECTION 7: OPERATIONAL TEST.
IMPORTANT
The blue wire connected to “L” on the
PCA must be connected to the shortest of the
three level probes.
All electrical supplies should be
disconnected when servicing
generator.
Electrical Shock Hazard. PCA’s have
exposed 208 / 240 VAC on them.
Disconnect 208 / 240 VAC power to
the generator before servicing.
The relays may be damaged if the
correct orientation of the connectors
is not observed. See diagram 19.
WARNING
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