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DutchWest 2181 (Small) Service Manual

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SERVICE MANUAL
For the
Vermont Castings
Please place picture here.
1990 - 1993 D
UTCHWEST
CONVECTION
HEATERS
M
ODELS:
2181 (Sma
ll)
2183 (Large)
2184 (Extra L
arge)

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Summary of Contents for DutchWest 2181 (Small)

  • Page 1 SERVICE MANUAL For the Vermont Castings Please place picture here. 1990 - 1993 D UTCHWEST CONVECTION HEATERS ODELS: 2181 (Sma 2183 (Large) 2184 (Extra L arge)

  • Page 2: History Of Changes

    1990 – 1993 DUTCHWEST CONVECTION HEATERS Models 2181 (Small), 2183 (Large), and 2184 (Extra Large) In 1990, Vermont Castings changed the Dutchwest Convection Heaters to improve the appearance, performance and serviceability of the stoves. The changes include: • A horizontal brass bar in a convection outlet slot where the top and front meet. This replaces the earlier two separate screened openings.

  • Page 3: Repair Procedures

    REPAIR PROCEDURES 1990 – 1993 DUTCHWEST CONVECTION HEATERS Models 2181 (Small), 2183 (Large), and 2184 (Extra Large) INSTALLING THE TWO PIECE INNER TOP Tools Required: Phillips and flat screwdrivers, socket wrench with 7/16” socket/open-end wrench, rubber mallet, and 3 tubes of stove cement, caulking gun, putty knife, rags, hammer, cold chisel, and wooden block.
  • Page 4 11. Work in reverse order to re-assemble. Replacement inner tops include a separate ‘web’ piece between the catalyst chamber and the damper opening. This web can move separately in response to the high temperatures in that area. The web is loosely bolted into place at each end and has Interam gasket to seal its ends. On installation, the Interam gasket can look too small for the gap it seals.
  • Page 5 INSTALLING THE SHAKER CENTRE GRATE The shaker centre grate is easy to install in your stove. It should take about ten minutes to replace Start by removing the grate back and the side half-wall (called ‘air balance plate’ on some models). Each panel has two bolts holding it in place.
  • Page 6 ADJUSTING THE DAMPER Using a 7/16 socket wrench, preferably with a socket extension: 1. Remove the top. 2. Open the damper. 3. Carefully remove the refractory cover. 4. Loosen the adjusting bolt’s lock nut. 5. Loosen the anchor bolt’s lock nut, located on the underside of the damper and accessible inside the stove through the front door.

  • Page 7: Disassembly And Assembly

    DISASSEMBLY and ASSEMBLY 1990 – 1993 DUTCHWEST CONVECTION HEATERS Models 2181 (Small), 2183 (Large), and 2184 (Extra Large) DISASSEMBLY Clear a space for storing parts as you take the stove apart. You will need pliers, a 7/16” socket wrench or open end wrench, a 5/32” Allen wrench and a Phillips head screwdriver to remove nuts and bolts and screws.
  • Page 8 **NOTE: To protect the refractory package and the catalytic combustor from damage as you work on the stove, remove these parts from the inner top. It may be necessary to rock the catalyst gently to free it from the top. 5.
  • Page 9 **NOTE: Stoves are constantly being improved. You may notice some small differences between the stove you are working on and these instructions. These instructions will serve as a guide for disassembling and assembling your stove. 9. Remove the Balance Air Plate. Remove the two hex head cap screws that hold the balance air plate to the inside of the right side plate, and remove the air plate.
  • Page 10 **NOTE: The next step is to remove the back. Before removing the back, brace the two sides to prevent them from falling over when the back is removed. A pipe clamp adjusted to hold the two sides together works well.* 11.
  • Page 11 14. Remove the Rocker Grates and the Fixed Grate. Lift the two rocker grates and the fixed grate from the inner bottom. 15. Remove the Inner Top. The inner top is supported by the left side and inner back. Slide the inner top a short distance to the right, and lift it from the inner back.
  • Page 12 Underside of the inner top. Use this illustration for steps 20, 21 and 22 20. Remove the hex nut from the Anchor Bolt. 21. Remove the Channel Cap. Remove the hex head cap screw holding the channel cap to the inner top, and remove the cap. 22.
  • Page 13 24. Remove the Damper Tabs. Remove the hex head cap screws holding the damper tabs to the inner top, and remove the tabs. 25. Remove the Adjuster Bolt. Remove the hex head cap screw holding the adjuster to the damper. 26.
  • Page 14 ASSEMBLY All nuts and bolts are ¼ - 20 thread size unless otherwise noted. Lengths of bolts are given with the assembly instructions. Use automotive “never-seize” on screw threads to make future repairs easier. Gasketing If new parts need to be gasketed, or old parts re-gasketed, do all of the gasketing before starting to assemble the stove Instructions and illustrations are given at the end of this section of the manual.
  • Page 15 Work in an area where there is plenty of light, and a level work surface. Wear gloves and protective eyewear. If the parts to be cemented are new, start with step 2. If old parts are to be re- cemented, they will need to be cleaned. Start with step 1. 1.
  • Page 16 2. Install the Damper Operating Rod. Screw the damper operating rod into the side of the collar until the square end of the operating rod meets the end of the crank. Put the square opening in the end of the crank over the square end of the rod.
  • Page 17 7. Attach the Channel Cap. Cement the channel for the channel cap on the underside of the inner top as shown in figure #C-1 below. Fig. C-1 Underside of the inner top. Attach the channel cap with a 2” hex head cap screw, being sure the air distributor is lined up properly as you secure the cap.
  • Page 18 10. Place the Left Side in position. Cement the channels in the left side as shown in figure #C-3. Fig.C-3 Left Side Fig.C-4 Inner Bottom Stand the left side in position, and brace it so it will stay upright as you install the next parts. 11.
  • Page 19 13. Install the Right Side. Cement the channels in the right side as shown in figure #C-5. Fig. C-5 Right Side Place the bottom of the right side plate in position and move the top of the plate forward. With the top of the side leaning slightly outward, place the right side in position on the bottom. Push the top inward making sure the right edge of the inner top id in the groove in the right side.
  • Page 20 With the back leaning slightly outward, put the back in position on the bottom. Push the top of the back inward so the studs at the top of the back will pass through slotted tabs on the sides. Place washers on the studs. Screw hex head nuts onto the studs to secure the back to the sides.
  • Page 21 18. Install the Balance Air Plate. Attach the Balance Air Plate to the Right Side with two ¾” cap screws. 19. Install the Front. Cement the channel in the front as shown in figure #C-7. Fig. C-7 Front Place the front on the bottom with the top leaning slightly outward. Move the top of the plate into position so the studs in the front pass through the slotted tabs in the sides.
  • Page 22 20. Install the Catalytic Combustor and the Refractory Package. Be sure the interam gasket is in place around the bottom of the combustor. Replace the gasket if necessary. Install the catalytic combustor and refractory package. 21. Insert the Brass Trim in the top of the Front. 22.
  • Page 23 If you are replacing all gaskets while re-building a firebox, follow the instructions given below. Prepare parts carefully so that new gaskets will stay firmly in place. Channels must be free of old gasketing, cement and paint, and free of dust. Work in an area where there is plenty of light and a level work surface.
  • Page 24 Fig. G-1 Underside of Top Fig. G-2 Top Side of Inner Top 50” - ⅜” fiberglass 25” - ⅜” fiberglass Seals underside of top to inner top. Seals damper to inner top Fig. G-3 Side Door 46” (Extra Large), 40” (Small & Large) – 7/16” fiberglass Seals side door to left side.
  • Page 25 Fig. G-5 Ash Door 43” (Extra Large), 36” (Large), 29” (Small) – 7/16 fiberglass Seals ash door to front. Fig. G-6 Grate Seal Gasket 6” - 5/16” griddle gasket Seals grate seal to side Fig. G-7 Balance Air Plate 30” – 3/16” fiberglass Seals balance air plate to right side.
  • Page 26 I N N E R T O P R E P L A C E M E N T , 1 9 9 0 D U T C H W E S T C O N V E C T I O N S T O V E S These instructions cover 1990 versions of the small, large, and extra-large Dutchwest Convection stoves.
  • Page 27 align the inner top with the bypass operating rod’s hole in the left side so that the bypass gate operates freely without causing the operating rod to be forced to one side of the hole in the stove’s left side. Adjust the bypass gate so it closes with only a little pressure. 12.

This manual is also suitable for:

2184 (extra large)2183 (large)