Vermont Casting Stove 4322 User Manual

Regardless of its location, replacing a gasket involves  
these steps:  
1. Remove the existing gasket by scraping it out of its  
channel with an old screwdriver.  
2. Clean the gasketing channel with a wire brush. Be  
careful with adjacent surfaces, especially if they are  
enamelled. Remove any stubborn deposits with a  
small cold chisel. Clean both mating surfaces thor-  
oughly to bare metal.  
Gasket Kit #4322  
Installation Instructions  
for use on the  
3. Cut the appropriate size gasket to length, allowing  
an extra inch.  
Defiant Stove  
Vermont Castings’ stoves use a rope-type gasket to  
make a seal between some parts. With use, this gasket  
can become compressed and begin to lose its effective-  
ness. It should then be replaced.  
4. Knead the tube of cement before opening, to mix the  
contents thoroughly.  
5. Place an unbroken 1/8” bead of gasket cement in  
the channel. Do not use too much cement as it may  
saturate the gasket; the gasket must remain soft  
and resilient. One tube of cement will produce a 1/8”  
bead sufficient for all the gasket in this kit.  
This kit includes materials to re-gasket a Model #1910  
or #1945 Defiant stove. This stove model has glass  
panels in the front doors. This kit is not appropriate for  
the 1975-1988 model Defiant stoves which do not have  
glass panels in the front doors.  
6. Starting with one end, press the gasket into the  
cemented channel. If the gasket goes around and  
meets itself, ensure that you have a good joint be-  
fore trimming the excess gasket. Do not overlap or  
leave ragged edges.  
Contents  
7. Seat the gasket by placing it firmly against its normal  
mating surface. A slip of waxed paper between the  
gasket and its mating surface will help keep the ce-  
ment from traveling through the gasket and sticking  
to the mating surface. Clean away any excess ce-  
ment.  
3.5’ of 5/16” Glass Fiber Gasket for the damper  
7’ of 3/16” Glass Fiber Gasket (Glass)  
4¹⁄₂’ of 5/16” Wire Reinforced Glass Fiber “Armaseal”  
for the griddle  
10.9’ of 3/8” Glass Fiber Gasket for the ash door and  
main doors  
8. With enamel stoves, be careful to keep cement off  
the enamel finish. If cement does accidentally get on  
the enamel, wash it off immediately with warm water.  
3 oz. Tube of Gasket Cement  
Tools Required  
9. Allow to dry. Be sure to remove the waxed paper!  
Phillips screwdriver  
Utility knife or scissors  
Wire brush  
10. If you have questions, refer to the Defiant Owner’s  
Manual, or a Vermont Castings Dealer.  
Small cold chisel  
Rubber mallet, or hammer and wood block  
Griddle  
Remove the griddle. Pull off the old gasket and clean  
the channel with the wire brush. Set the steel reinforced  
5/16” gasket in the griddle channel and mark the cor-  
rect length. Place the gasket on a wood cutting surface  
and trim with a utility knife or scissors. Twist the ends  
slightly to prevent unraveling. Place a continuous 1/8”  
bead of gasket cement in the channel and press the  
gasket into place. Replace the griddle and compress  
against the gasket by striking around the edges with  
the rubber mallet or hammer and block of wood. Do not  
strike the stove top.  
Flashlight or droplight  
Installation Precautions  
Be sure the fire is out and the stove has cooled before  
replacing the gasket, and be sure to follow the standard  
safety procedure for working with dusty materials: Wear  
safety goggles and a dust mask.  
Installation Instructions  
Gaskets provide a tight seal between moving parts.  
Eventually these gaskets will become compressed and  
will no longer seal properly. Replacing the gaskets will  
improve performance. For a guide to each gasketed  
area, refer to the following sections and illustrations.  
2003144 8/08 Rev. 6  
 
3. Open the front doors of the stove and remove the  
ashes. If necessary, empty the ashpan, and rake the  
ashes left and right in the firebox till they fall through  
the slots in the grate, and into the ashpan.  
Rope Gasket  
Glass Panel  
4. Lift the baffle off its support brackets. Remove it from  
the stove and set it down on a protected surface.  
(Fig. 6)  
Baffle Support Brackets  
Catalytic  
Element  
ST555  
KT317  
Replacement Glass Gasket  
Fig. 6 Remove the baffle.  
Fig. 4 Glass gasket.  
Alignment Notches  
paper all around the perimeter of the damper opening.  
With the damper closed and locked, it should not be  
possible to pull the papers out without resistance. The  
more easily the paper pulls out, the less secure the seal  
is at that spot.  
Right Wedge  
Left Wedge  
1. To adjust the damper seal, loosen the locking hex nut  
on the adjusting allen screw. (Fig. 5) Turn the screw  
clockwise with a hex wrench, in half-turn increments,  
until the damper grips the paper slips securely when  
you test the damper’s operation. When you have  
achieved a snug seal, fasten the locking nut against  
the face of the damper. The seal should not be tight  
since the metal parts will expand slightly under heat.  
Brick Guide  
Brick Clip  
Pressure Ad-  
justing Screw  
Bricks  
ST556  
Lock Nut  
Allen  
Wrench  
Damper  
Fig. 7 Remove the bricks and brick retainer.  
5. Remove the firebricks. Lift off the steel clip and re-  
move the firebricks individually. (Fig. 7)  
6. Tap the left and right wedges upward with a rubber  
mallet or a hammer and block of wood to protect the  
cast iron. (Fig. 7) Remove the wedges and remove  
the lower fireback by pulling its top edge toward  
yourself. (Fig. 8) Lift the lower fireback out of the fire-  
box and set it on a shielded surface.  
ST554  
Fig. 5 Damper adjustment.  
2. It is possible, but awkward, to replace the damper  
gasket without removing the upper fireback panel  
which locates and supports the damper. To remove  
the upper fireback assembly, open the damper. Use  
an allen wrench to remove the damper handle from  
the damper rod on the left side of the stove.  
7. Four hex head bolts pass through the stove’s outer  
back to fasten the upper fireback in place. Remove  
these bolts. If the stove has a rear heat shield in  
place, you may find it easier to remove the shield  
first, and then the upper fireback bolts. You can  
leave the heat shield spacers in place.  
3
2003144  
 
on access, inspection, evaluation and replacement if  
needed.  
11. Work in reverse order to replace parts once the gas-  
ket cement has dried on the upper fireback assem-  
bly. Be sure to install the spacer on the left end of  
the damper rod before installing the upper fireback  
assembly.  
12. Install the upper fireback assembly, left end first;  
pass the damper rod through he hole in the left side  
of the stove, then lift the right end of the assembly  
into place. Loosely install all four bolts before you  
tighten any of them. These bolts should be snug but  
not tight, to allow some expansion and movement  
under heat.  
Lower Fire-  
back  
ST557  
Fig. 8 Remove the lower fireback.  
8. From inside the firebox, pull the right-hand end of the  
upper fireback toward yourself. Carefully maneu-  
ver the left end of the fireback assembly to let the  
damper rod clear its hole in the left side of the stove.  
Be sure to capture the spacer on the left end of the  
damper rod. Remove the assembly from the stove  
and set it on a shielded working surface.  
13. Test the damper operation and the gasket’s snug-  
ness, as described at the start of this section.  
Continue after you are sure the damper operates  
properly.  
14. Install the lower fireback. Note that there are two  
notches in the bottom edge; these must align behind  
two mating nubs on the firebox floor.  
15. Stand the five firebricks on end in front of the lower  
fireback. Note that these stand behind a raised rib  
on the firebox floor. (Fig. 7) Join the firebricks by  
slipping the steel clip onto their top ends. The clip’s  
longer edge should go behind the firebricks, for  
easier installation.  
Gasket  
16. Replace the left and right wedges. Note that their  
rear vertical edges bear against the outermost left  
and right edges of the lower fireback. Gently tap the  
wedges downward with a rubber mallet or a ham-  
mer and a block of wood to cushion the impact. The  
wedges should be snug but not overly tight.  
KT318  
Fig. 9 Back view of upper fireback (damper and rod re-  
moved).  
17. Replace the baffle by placing its ends on the sup-  
port brackets which are part of the lower fireback.  
The baffle shields the catalytic combustor from direct  
flame impingement and must be in place during  
operation.  
9. Pull the damper rod out of the upper fireback.  
Release the bolts holding the steel tabs in place,  
and remove the damper. Pull off the old gasket  
and clean off the old cement. Thoroughly clean the  
damper plate and around the damper opening in  
the upper fireback. Cut a piece of the 5/16” gas-  
ket material to length, allowing a one inch excess.  
Place a continuous 1/8” bead of gasket cement in  
the damper gasket channel. Press the new gasket  
in place, trimming off the excess length. (Fig. 9)  
Remove any excess cement. Replace the damper,  
the steel tabs and bolts, and the damper rod. Close  
and lock the damper to seat the gasket. Use waxed  
paper between the damper and the upper fireback to  
keep the cement from traveling through the gasket  
and sticking to the fireback.  
Testing the Gasket Seals  
After the cement has had several hours to dry, test the  
new door seal by closing and latching the door on slips  
of paper placed at approximately 6” intervals along the  
top and bottom of the door opening. Be sure to include  
the area where the right front door overlaps the left  
door. It should not be possible to slide the papers, and  
they should be pulled straight out only with consider-  
able resistance. If the paper pulls out easily, readjust  
the doors as needed till the doors hold the paper tightly.  
Do not apply this test to the glass gasketing - it is not  
accessible and does not get the repeated impacts that  
other seals receive.  
10. This is a fine opportunity to inspect the catalyst.  
Follow the directions in the Defiant Owner’s Manual  
MHSC  
149 Cleveland Drive • Paris, Kentucky 40361  
2003144  
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