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Palladian/ Keystone Models 202/204 Maintenance Kit
Please read all of the instructions before you begin. Confirm that you
have all the necessary tools and parts required. Allow about one hour to
complete the procedure. If you have any questions, technical support is
available toll free at 1-800-866-4344, Monday- Saturday 9:00-5:00 E.T.
Tools Needed:
- ½" wrench or socket
- Putty knife
- Wire brush
- Vacuum
- WD-40 or similar penetrating liquid
- Standard size caulk gun
- Sharp scissors
- 7/16" wrench and socket
- 1/8" allen wrench
- 5/32" allen wrench
Materials included in maintenance kit:
- 3' .375 gasket- Loading door (Keystone)
- 3' .312 gasket- Loading door (Palladian)
- 3' .500 gasket- Bypass frame
- 3' .500 gasket- Ash door
- 3' .250 gasket- Under combustor
- 11' adhesive window gasket- surrounding glass
- 6' .250 gasket- Flue collar and cover plate
- 1 tube stove cement
- gasket glue
- #00 steel wool
The gasket in your kit has been roughly cut to size and marked with its
diameter and length. To determine its exact length, dry fit the gasket in its
appropriate location and then re-cut. Gasket glue or stove cement will then
be applied to secure each length in its proper place. The steel wool provided
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Summary of Contents for Woodstock Soapstone Palladian 202
- Page 1 Palladian/ Keystone Models 202/204 Maintenance Kit Please read all of the instructions before you begin. Confirm that you have all the necessary tools and parts required. Allow about one hour to complete the procedure. If you have any questions, technical support is available toll free at 1-800-866-4344, Monday- Saturday 9:00-5:00 E.T.
- Page 2 Use a vacuum to help contain the dust. High temperature touch up paint is available to match the cast iron frame of your stove, and can be ordered through Woodstock Soapstone Co. Please note that the photos displayed here are a mixture of Keystone and Palladian.
- Page 3 3. Lay the door face down on a suitable work surface. Use a putty knife to remove the old gasket. A wire brush may be used to clean out any cement residue from the gasket channel. Vacuum any leftover debris from the door and gasket channel.
- Page 4 4. Dry fit the gasket to the door. Start with one end of the gasket at the center bottom of the door. Press it firmly into the gasket channel all the way around the door. Do not stretch or compress the gasket as you work it around the door.
- Page 5 6. Return the door to the stove. Align the hinge pins with the hinges on the door frame. As you press down on the pins it may be helpful to swing the door back and forth until it is all the way down on the hinges. 7.
- Page 6 8. Allow the stove cement to cure for 24 hours before using the stove. Replacing Bypass frame gasket 1. Make sure the stove is cool. You will need 3’ of .500 gasket and gasket glue. 2. Remove the cover plate with the allen wrench provided (or go through the flue collar) to access the catalytic combustor area of the stove.
- Page 7 3. Use a ½” wrench or socket to remove the bolts that secure the bypass loop to the top of the bypass door. Spray with penetrating liquid if necessary. Move the bypass lift guide to the side and open the bypass door as wide as possible to access the gasket beneath it.
- Page 8 5. Dry fit the replacement gasket by starting one end in any corner of the gasket channel and working it all the way around the perimeter. Cut to proper length with sharp scissors. Remove the gasket. 6. Apply a small bead of gasket glue into the gasket channel. Firmly press the new gasket into the glue.
- Page 9 8. Return combustor to the stove and replace the heat shield. You may also choose to replace the gasket below the combustor before returning it to the stove. Replacing combustor gasket 1. Make sure the stove is cool. You will need 3’ of .250 gasket and gasket glue.
- Page 10 3. Use a putty knife to remove the old gasket from the area directly under the combustor. Remove any residual gasket and glue with a wire brush and vacuum. 4. Dry fit the new gasket. Start one end of the gasket in any corner and press it into the gasket channel, work it all the way around to the starting point.
- Page 11 4. each part. Remove any residual gasket and glue with a wire brush and vacuum. 5. Dry fit the new gasket. Start one end of the gasket in any corner and press it into the gasket channel. Do not stretch or compress the gasket as you work it around the channel.
- Page 12 7. Turn the parts over and allow the glue to set up for 15 minutes before installing on the stove. Replacing window gasket 1. Make sure the stove is cool. You will need approximately 11’ of adhesive window gasket. Spray all hardware to be removed with penetrating liquid, several applications may be necessary.
- Page 13 3. Use a 1/2” socket or wrench to remove the andirons and glass retainer from inside the firebox. 4. Remove the two window clips, located halfway up the glass sides, using a 7/16” socket or wrench. 5. Remove the glass panels from the front frame. Start with the bottom edge and carefully pull them into the firebox and out through the loading door.
- Page 14 6. Remove the old gasket from the glass panels and clean the glass using household window cleaner and a soft cloth. (If a more aggressive cleaning is needed you may use a cleaner made for ceramic cook tops, or very fine steel wool). Rinse and dry thoroughly. 7.
- Page 15 9. Place the panels together. The fully gasketed glass is the exterior panel. The non gasketed face of the interior panel is the firebox side. 10. Slide the two panels up into the window frame together ensuring that they are aligned with each other. 11.
- Page 16 12. Install the glass retainer and andirons. 13. Confirm there is a 1/4” space between the interior glass panel and the air guide. (A ¼” drill bit is helpful to check the gap). The air guide is at the top front of the firebox. Loosen the two bolts with a 7/16” socket if adjustment is necessary.
- Page 17 3. Use a putty knife to remove the old gasket. A wire brush may be used to clean out any cement residue from the gasket channel. Vacuum any leftover debris from the door and gasket channel. 4. Dry fit the gasket to the door. Start with one end of the gasket at the center of the hinge side of the door.
- Page 18 6. Install ash door onto stove base. Keep the door closed to seat the gasket. Sealing the firebox seams 1. Make sure the fire is completely extinguished and no hot coals or embers are hidden in the ashes in the firebox. 2.
- Page 19 We need your help! Woodstock Soapstone Co. takes great pride in providing the highest quality products as well as the best customer service in our industry. We welcome your suggestions and input to help us achieve these goals. If you have any comments to improve our products, service, and information provided in these instructions please contact us at (800) 866- 4344 or info@woodstove.com.
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