2
6. Remove the left and right inner walls (Fig. 6, Items
5, 13) of the stove. Hex bolts at the top and bottom hold
them in place. These walls have rope gaskets, forming
seals between the inner walls and the outer walls of the
stove. With the bolts removed, pry the forward edges
of the inner walls toward the center of the firebox; it will
also help to slide the bottom edges of the inner walls to-
ward the center of the firebox. The panels will come out
through the front opening or through the griddle opening.
7. Use the Allen wrench to loosen the Allen bolt (Fig.
6, Item 14) in the base of the damper handle (Item 15).
Leave the loosened bolt in the handle to keep from mis-
placing it. Pull the handle base off the damper rod. (Fig.
6, Item 7)
8. If the stove has a steel rear outer heat shield, remove
it. Four bolts hold it to spacers threaded into the back of
the stove. Leave the spacers in place.
9. A hex bolt (Fig. 6, Item 1) on each side of the stove
back holds the upper fireback assembly (Item 6) in
place. Remove and discard these bolts. Keep the wash-
ers. From inside the firebox, pull the right-hand end of
the upper fireback forward; you may need to use a flat
screwdriver to pry the fireback loose from the panel be-
hind it. With the upper fireback assembly removed from
the stove, save the #22 spacer and the #23 washer (Fig.
6) for reuse.
10. Remove the catalyst access panel (Item 16), part of
the refractory package (Item 3) that houses the catalytic
combustor (Item 17). It is friction-fit into place. Wiggle
it slightly to loosen it. Notice its positioning; this will be
important when you install the catalyst in the new refrac-
tory package.
11. Remove the catalytic burner carefully, inspect and
clean it, and set aside. To clean it, take outdoors and
blow gently through it. Do not use compressed air; do
not run anything through the honeycomb. The catalyst is
a thin coat of platinum on the ceramic honeycomb, and
friction can remove the coating, shortening the unit’s life.
Check your Encore owner’s manual for details on evalu-
ating the catalyst.
12. Remove the refractory package. (Fig. 6, Item 3) Pull
it straight toward yourself, and slide it out through the
front door opening. Put it in a closed bag to contain any
airborne dust.
13. On the outer back side of the stove, there is a steel
plate (Fig. 6, Item 21) held in place with two Phillips
bolts. Remove the bolts and the steel plate.
14. Behind the steel plate, there is a secondary probe
assembly (Item 20). This consists of a probe and a bi-
metal coil secured by a phillips screw. (Fig. 5) There is a
slender steel rod between the end of the coil and a pivot-
ing valve plate (Item 19). Remove the phillips screw and
pull the coil and probe partway out of the stove back.
When the probe is halfway out of the stove back (about
1” showing), remove the slender rod from the tab at the
end of the coil. Leave the rod hanging from its tab on the
secondary valve. Leave the secondary valve, Item 19, in
place.
15. Remove the two steel heat deflectors (Items 4, 18)
from the back of the firebox; these were originally on
each side of the refractory package.
Re-Assembly
Use a hammer and a cold chisel or old screwdriver to re-
move any remaining cement from the upper rear area of
the firebox, where the upper fireback attaches. Remove
any debris from the stove’s back chamber.
1. Remove the catalyst access panel (Fig. 6, Item 16)
from the new refractory chamber. Install the chamber in
the back of the stove, with the opening facing forward.
2. Reinstall the two steel heat deflectors, (Fig. 6, Items
4, 18) one on each side of the refractory package. The
shorter arm of each goes at the bottom of the deflector,
with the longer arm against the cast iron back sides of
the rear chamber. These deflectors provide important
protection from the very hot gases leaving the refractory
chamber.
3. Slide the catalytic combustor (Fig. 6, Item 17) into
place within the refractory chamber. Notice that the
openings of the honeycomb must be on the top and bot-
tom horizontal surfaces of the combustor, as shown in
Figure 6.
4. Install the refractory access panel in front of the cata-
lyst. It friction-fits into place.
5. Install the new upper fireback assembly. Place the
#22 spacer and the #23 washer on the protruding end of
the damper rod. (Fig. 6) Swing the assembly’s left end
into the firebox, with the end of the damper rod passing
through the hole in the left outer stove side. Swing the
right end into position, and secure the assembly with
two new 1/4”-20 x 1¹⁄₂” bolts. Be sure to use the origi-
nal washers. These bolts should be snug but not tight,
especially if the stove back is enamelled. Overtightening
these bolts can cause excess tension on them and/or
the upper fireback assembly.
ST645
Encore
remove fireback
3/01
Fireback
ST645
Fig. 3 Lift out the lower fireback.
