Vermont Castings Defiant 1610 User manual

SERVICE MANUAL

SERVICE PROCEDURES
Defiant Non-Catalytic Model 1610 Woodstove
**Wear gloves, a dust mask and protective eyewear when servicing a stove. **
Replacing the Fountain Assembly
1. Remove the doors, andirons and the bottom grate. Carefully slide the refractory shoe out of the unit being
careful not to damage the gasket on the bottom (FIG. 1).
2. Take out the right side brick and insulating panel by removing the Phillips head screw holding the bracket
(FIG. 2) and carefully sliding the items out.
FIG. 1 Remove shoe
3. Remove the flue collar by backing out the two Phillips round head machine screws.
4. Remove the top. The top is held in place by two hex head bolts in the rear left and right corners of the top
(FIG.3) and by one socket flat head screw in the outside center of the top near the griddle opening (FIG. 4).
FIG. 2 Remove side brick and insulation panel
FIG. 3 Remove bolts in the top rear corners - shown
left rear FIG. 4 Remove flat head socket screw

4. Remove the rear shroud held by two Phillips round head machine screw in the center and four sheet metal
screws - two on each side. This allows access to the six hex head nuts and washers holding the damper housing
assembly and the fireback retainers.
FIG. 6 Left damper housing showing one bolt removed
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7. Slide the fireback brick forward and out of the unit.
8. Slide the fountain assembly out.
9. This completes the disassembly.
5. Remove the damper housing assembly. First remove the damper handle with the Allen key supplied with the
unit (FIG. 5). Locate and remove the four hex head through bolts, two per side on the outside of the inner back,
that hold the upper fireback in place (FIG. 6). The nuts and washers are on the outside of the back. This may
require the use of two 7/16" wrenches. Gently rotate the damper housing down right side first and maneuver out
of the firebox by sliding left to right to clear the damper rod from the left side. Please locate damper rod spacer
and remove from the hole in the side for reinstalling. Ensure damper rod washer is in place near the end (FIG.
8). This prevents the rod from sliding out of position when re-installed.
6. Remove the fireback. Locate the two hex
nuts on the outside of the inner back that hold
the lower refractory brackets in place (FIG. 7).
The nuts and washers are on the outside of
the back. This may require the use of two
7/16" wrenches. Remove the two hex nuts
with washers and pull out the hex head cap
screws holding the brackets. This may require
the use of two 7/16" wrenches. Remove the
brackets. Hold the top of the fireback while
removing the brackets as it will fall forward with
the brackets removed.
FIG.5 Remove damper handle

12. Install the fireback centered on the back and the fountain with the two fireback brackets removed
earlier and two hex head bolts and nuts with four washers and leave loose. Ensure it is against the
gaskets in the rear sides Replace the shoe before tightening the fireback brackets to ensure the fireback
and fountain line up properly to allow the shoe to enter. If not going in, line up the fireback and fountain a
s
close to center as possible. Once the shoe travels easily all the way to the back, tighten the brackets.
Verify the fireback seals against the rear gaskets.
17. Install the flue collar.
18. Install the grate with the shoe tab to the back. If not
fitting down, push hard on the shoe to allow grate to go all
the way down. This tab holds the shoe in place (FIG. 9).
19. Install the griddle, andirons and front doors.
FIG. 9 Install the
g
rate with tab holdin
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the shoe in
p
lace
10. Before reassembly, check the following and replace or repair where necessary:
• gaskets on the damper housing assembly
• gaskets on the back installed up either side for the fireback seal
• shoe gasket
• back to bottom and side seal (tighten if necessary)
• top gaskets including the flue collar and griddle seal
11. Slide the fountain assembly into place. Position it in the center of the back.
FIG. 8 Damper rod washer
13. Install the damper housing assembly. Insert the damper rod into the left
side of the unit, raise the right side up, slide over and attach using the four
hex head bolts, nuts and eight washers. Ensure the washer in in place near
the end of the rod (FIG. 8) to prevent the rod from sliding. Push tight against
the fireback and line up with holes in the back while tightening to make a
good seal against the fireback. This seal is critical to the proper operation of
the unit. Install the spacer around the damper rod on the outside.
14. Install the damper handle.
15. Install the right side brick and insulation panel with the notches to the
upper back with the bracket and hex head cap screw.
16. Position the top in place over the sides, back
and front and tighten down using the two hex head
bolts in the rear corners and one socket flat head
screw in the front center. Ensure there is a good
seal between the top edge of the damper housing
and the top by viewing through the flue collar
opening. Again, this seal is critical.

Inspecting the Primary Air Shutter
1. Remove the griddle plate. Locate the two hex head bolts holding the air wash manifold in place (FIG. 10) on
either side of the manifold. Remove the bolts and drop the manifold down and out. Hold the manifold while
removing the second bolt so it does not fall.
2. With the manifold removed you can see the air wash shutter underneath (FIG. 11).
FIG. 10 Remove Air Wash Manifold FIG. 11 Shutter under the air wash manifold
3. Remove the side brick and insualtion panel by extracting the hex head bolt holding the bracket (FIG. 12).
4. Remove the right air wash manifold by extracting the upper and lower hex head bolts (FIG. 13).
FIG. 12 Remove side brick and insulation panel FIG. 13 Right Air Wash Manifold with bolts removed.

120-3588 5/16” Medium Density 6ND Gasket 3.5' Damper Housing for Damper Opening
4' Left Door
3' Right Door
120-3589 ⅜" Fiberglass Gasket Low D 6ND 4.5' Ashdoor
30002422 ⅜" Adhesive Fiberglass Gasket 16' Bottom
6' Around Stove to Seal Top
6' Back Fireback Seal
2.5' Left Side
2.5' Right Side
2.5' Front Air Manifold
6' Front
5' Left Side Air Plate
5' Right Side Air Plate
6' Damper Housing Main Seal
120-3668 5/16” Gasket Wire Fiberglass with Core 4.25’ Top for Griddle
30001910 7/16" Adhesive Fiberglass Gasket 4.25’ Flue Collar
30002864* Insul. Gasket, Shoe Defiant 1 Bottom of Shoe
120-3556*
*
3/16" 4ND Black Fiberglass Gasket 3.5' Each Glass Panel
* 000-3446 Evereburn Gasket Kits contains the shoe gasket and the moustache gasket for fountain
** 000-3427 Glass Gasket Kit contains enough gasket and cement to gasket all glass with rope gasket
Gaskets
5. This reveals the complete air shutter assembly for inspection and repair if necessary (FIG. 14)
FIG. 14 Primary air system showing levers

FIG. 15 Damper housing assembly shown
rear vie
w