Vermont Casting 1990CE Replace Refractory Package, Replace the Stove Gaskets as Needed

Refractory Chamber

	Catalytic Block
	Upper
	Fireback
	with Throat
	Hood
Exhaust
Pockets
Refractory Access Panel	Clamps
	ST533

Fig. 32 Removing the catalytic element.

9.Use a flashlight and a mirror, inserted into one of the exhaust pockets of the refractory chamber, to in- spect the probe. The end of the probe should extend about 1” into the combustion chamber, and should not show any signs of deterioration.

Use the stove in your usual manner for two weeks, inspecting the chimney and the chimney connector frequently.

If creosote does not build up as quickly as before, it is likely that the performance change was caused by fly ash deposits on the catalytic element. However, moni- tor the chimney system for a few weeks to ensure that proper performance continues.

If you continue to find a significant creosote buildup or if you continue to see excessive smoke from the chimney, the catalytic element will need to be replaced. Call your dealer for information about a replacement.

NOTE: Use only replacement catalyst, part no. 160- 2521.

Replace Refractory Package

Refer to Figure 32.

1.Remove andirons.

2.Reach inside the stove with a pair of pliers and turn the two clamps that hold the fireback 90°. Turn the left clamp clockwise and the right clamp counter- clockwise. The bolts that hold these clamps are tapped into the back as well as capped by chrome acorn nuts in the back.

3.Grasp the upper fireback by its vertical ribs and re- move it, together with the attached throat hood. Pull the left side out first.

4.Carefully remove the refractory access panel in front of the catalytic block.

5.Gently slide the catalytic block out of the refractory chamber.

30003840

Intrepid II Woodburning Stove

6.Remove the damper housing. It is held in place by two weld screws and two chrome acorn nuts in the back of the stove. Loosen the chrome acorn nuts and rotate the tabs to release the damper housing. You may find it necessary to remove or loosen the thermostat cover to access the one of acorn nuts installed behind the cover.

7.Remove the rear airtube in the back of the stove which is held in place with two phillips screws.

8.Take out the secondary probe by removing the upper phillips screw and sliding the probe out of the hole.

9.Lift the damaged refractory chamber up and out of the firebox.

10.Reverse the procedure for installing the new refrac- tory chamber.

Replace the Stove Gaskets as Needed

The Intrepid uses fiberglass rope gaskets to make a tight seal between some parts. With use, particularly on those parts that move, gaskets can become brittle and compressed, and can begin to lose their effectiveness. These will need periodic replacement.

The sizes of replaceable gasket are listed below, along with their applications.

Gasket Diameter... And the Parts it Seals 5/16” wire gasket The griddle to the stove top

5/16”The damper to the upper fire back; the front doors to the stove front; and the door halves to each other

There is a flat, die-cut gasket between each glass panel and its door. See page 25 for information on replacing the glass panel or its gasket.

If you need to change a gasket, first obtain an appropri- ate replacement from your Vermont Castings, Dealer.

Wait until the fire is out and the stove has cooled. Be sure to follow the standard safety procedure for working with dusty materials: Wear safety goggles and a dust mask.

The procedure for replacing the gaskets is the same, regardless of the gasket location.

1. Remove the existing gasket by grasping an end and pulling firmly.

2. Use a wire brush or a screwdriver to clean the chan- nel of any remaining cement or bits of gasket. Re- move stubborn deposits of cement with a cold chisel if necessary.

3. Determine the correct length of the appropriate-sized gasket by laying it out in the channel. Allow an extra 25-50 mm (1-2”) and mark the spot to be cut.

4. Remove the gasket from the channel, place it on a wood cutting surface, and cut it at the marked spot with a utility knife. Twist the ends slightly to keep the

gasket from unraveling.

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