Repair KIt Instructions Bixby Energy Systems

Adding the Air Diverter Plates MaxFire 5000 to 9800

Tools needed to add the air diverter plates

• 5/64” hex wrench (Allen wrench) Adding the air diverter plates:

• Remove the five screws holding the upper louver (left, right and center). See Figure 1.

• Pull the louver forward and out. See Figure 2.

• Slide the air diverter plates into the louver slots. The plates need to be close to the center tab. See Figure 3.

• Slide the plates all the way back, placing the base of the back tab above the heat

exchange tubes. The plates will snap into place and rest on the lip of the top of the stove. The plates may have to be moved left or right to lock into place. If needed, slide the plates forward once to rest on the base of the top. See Figure 4.

• Install the louver and the five screws.

Slide louver out

DWG. NO. 4000254 Rev B 11/2007 Kit 4000262

Figure 1 Figure 2

Plates rest on base of top

Plate tight above tubes

Plates slide in

Figure 3 Figure 4

DWG. NO. 4000270 Rev B 10/2007 Kit: 4000171, 4000204 4000189, 4000212 4000197, 4000551

Replacing the MaxFire Hood Tools needed to replace the hood

• Drill with 1/8” drill bit • Rivet tool • Flat head screw driver • 5/8” socket or nut driver

Replacing the hood

• Remove the screws on the back panel holding the control panel in place. See Figure 1.

• Remove the control panel by sliding it forward (towards the front of the stove). This will be tight and a rubber mallet might be needed.

• Mark and disconnect the ribbon cable from the panel and set the panel to the side. • Remove the side panels by removing the screw at the top. • Remove the wrap from the front of the stove (two screws on each side,

inside the side panels). See Figure 1. • Drill out the rivets holding the hood to the stove frame.

Three rivets near the back of the stove frame (under side profile). See Figure 1.

Three rivets on the back panel. See Figure 1 Three rivets inside the hopper. See Figures 3 & 4. One rivet under the hood (if applicable). See Figure 2.

• Remove the hood. • Install new hood. If needed remove the louvers from the old hood and attach them to

the new hood. • Using the rivets included in the kit, install the hood. • Install the control panel, connecting the ribbon cable to the panel first. Be sure to

connect the ribbon cable in the same orientation as it can off. • Install the screws on the back of the stove to anchor the control panel.

Figure 1 Figure 3

Figure 4 Figure 2

Rem

ove 5 rivets

Rem

ove rivet under hood

Rem

ove these 3 rivets

Wrap screw

s – right side

Control panel screw

s

DWG. NO. 4000270 Rev B 10/2007 Kit: 4000171, 4000204 4000189, 4000212 4000197, 4000551

14000288 REV A

Directions

Step 1:Remove screws holding upper louvers (left and right side, plus center).

Step 2:Pull louvers forward.

Louver Replacement Kit

Slide louver out

Remove screws(both sides, plus center)

Step 3:Slide replacement louvers in and replace screws.

Tools needed

5/64 hex tool

DWG. NO. 4000296 Rev B 11/2007 Kits 4000733, 4000741 4000759, 4000767 4000775, 4000783

Replacing the MaxFire Control Panel MaxFire (S/N > 5,000)

Reasons for changing the control panel:

• Control panel has been damaged Tools needed to change the touchpad:

• Short Philips screwdriver

Replacing the control panel:

□ Unplug the stove.

□ Remove the top screw on each side of the back panel of the stove. See Figure 1.

□ Slide the control panel forward and lift up to remove. See Figure 2.

□ Mark the two cables as per their orientation. See Figure 3.

□ Carefully unplug the touch pad from the ribbon cable (the plug is just under the

touch pad).

□ Plug the touch pad into the ribbon cable in the same orientation as the old touch

pad.

□ Install the control panel onto the stove.

□ Install the two screws on the back panel of the stove.

□ Plug the stove in.

□ Test for proper operation. .

Figure 3

Figure 2

Figure 1

Control Panel

Figure 3

Figure 2

Figure 1

Control Panel

Remove

DWG. NO. 4000296 Rev B 11/2007 Kits 4000733, 4000741 4000759, 4000767 4000775, 4000783

Replacing the Feeder Wheel MaxFire (S/N > 5,000) and UBB

Reasons for feeder wheel motor replacement:

• Feeder wheel is warped. • Any problem associated with only the wheel.

Tools and equipment needed to replace the feeder wheel:

• 5/16" nut driver or socket and ratchet • Phillips Screw Driver • Vacuum

Replacing the feeder wheel

□ Unplug the stove. □ Open the hopper lid. □ Remove all of the corn in the hopper. □ Remove the four 5/16" screws holding the feeder wheel cover.

See Figure 1. □ Remove the feeder wheel cover □ Remove four shoulder bolts and springs from the Feeder Wheel. See Figure 2. □ Remove the feeder wheel. □ Vacuum the area under the feeder wheel. □ Put the feeder wheel back on the hub, installing the four shoulder bolts and

springs. □ Replace the feeder wheel cover. □ Secure it with the four 5/16" screws. □ Plug the stove in. □ Check for proper operation.

Definition of terms: Hub - The round metal piece that connects the feeder wheel motor shaft to the feeder wheel. Self-tapping screw - A screw with a small drill bit built into the end of it. It will screw into metal without a pilot hole.

DWG. NO. 4000353 Rev B 10/2007 Kit 4000006

Figure 2

Figure 1

5/16" Feeder Wheel

rews Cover Sc

Shoulder Bolt & Springs

DWG. NO. 4000353 Rev B 10/2007 Kit 4000006

Replacing the Heat Exchanger Cover PlatesMaxFire (S/N > 5,000) and UBB

Tools needed to replace the heat exchanger cover plates: Vacuum

Replacing the Heat Exchanger Cover Plates Unplug the stove.

Make sure the stove is cool - open the fire box door.

To remove the heat exchanger cover plates: Insert your hand into the slot at the top of

the plate lifting in an upward direction allowing the bottom to swing out.

Holding the scraper handle with one hand, remove the heat exchanger cover plate from

the burn chamber.

Move the scrapers up and down to clean off the heat exchanger tubes.

Vacuum the area around the heat exchanger and the burn chamber.

To replace the heat exchanger covers: Insert the cover plates into the burn chamber

bottom end first. Lift the scraper all the way up swinging the top of the cover plate up and

into the slot of the scraper. Swing the bottom of the cover plate towards the rear of the

stove contacting the heat exchanger. Lower the scraper and the cover plate down unto

the lower retaining channel.

Make sure the scrapers are sitting on the top of the plates.

Close the firebox door.

Heat exchanger

Channel in scraper

Heat exchanger cover plates

Scraper

Slot in cover plate

Plug the stove in.

The stove is ready for use.

.

DWG. NO. 4000387 Rev B 10/2007 Kit 4000022

Replacing the Exhaust Clean Out Cover GasketMaxfire (S/N > 5,000) and UBB

Tools needed to replace the exhaust clean out cover gasket:

• Philips screw driver • 5/32" hex head wrench • Scraper • Vacuum

Replacing the exhaust clean out cover gasket


□ Remove the right side screw and panel.

□ Remove the ten (10) 5/16” bolts from the exhaust box cover. See Figure 1.

□ Carefully remove the cover and the gasket.

□ With a brush, gently clean the fan blades.

□ Use a vacuum to remove any ash from the box. See Figure 2.

□ Replace the gasket and install the cover.

□ Replace the ten (10) 5/16” bolts and tighten.

□ Replace the right side panel and screw.


□ The stove is ready to use.

DRW. NO. 4000402 Rev B 10/2007 Kit 4000056

Figure 1

Figure 2

DRW. NO. 4000402 Rev B 10/2007 Kit 4000056

Replacing the MaxFire Touch Pad Reasons for changing the touch pad:

• LED’s are burned out on the touch pad • Buttons have stopped working on the touch pad

Tools needed to change the touchpad:

• Short Philips screwdriver • Scraper or putty knife

Replacing the touchpad:


□ Remove the top screw on each side of the back panel of the stove. See Figure 1.

□ Slide the control panel forward and lift up to remove. See Figure 2.

□ Mark the two cables as per their orientation. See Figure 3.

□ Carefully unplug the touch pad from the ribbon cable (the plug is just under the

touch pad).

□ Remove the old touch pad.

□ Carefully remove the backing on the new touch pad.

□ Feed the connector through the cutout in the control panel.

□ Carefully line up the touch pad in the recess.

□ Gently make sure the cable for the touch pad is pulled all the way out from behind

the touch pad.

□ Press the touch pad down firmly all the way around.

□ DO NOT BEND. The touch pad is extremely fragile.

□ Plug the touch pad into the ribbon cable in the same orientation as the old touch

pad.

□ Install the control panel onto the stove.

□ Install the two screws on the back panel of the stove.


□ Test for proper operation.

DWG. NO. 4000428 Rev B 10/2007 Kit 4000072

Figure 3

Figure 2

Figure 1

DWG. NO. 4000428 Rev B 10/2007 Kit 4000072 DWG. NO. 4000428 Rev B 10/2007 Kit 4000072

Figure 3

Figure 2

Figure 1

Verify Proper Igniter Board Operation On the MaxFire (S/N 3000 – 9800)

NOTE: An igniter board may get damaged when an igniter burns out leaving the igniter circuit in the "ON" condition. When this happens, the fuse may likely be damaged as well.

When an igniter is burned out, do the following test to assure proper solution to the problem:1) Unplug the stove.2) Replace the medium blow 6.3A fuse with a fast blow fuse between 5 to 6 amps.

DO NOT use the 6.3A fuse.3) Unplug the damaged igniter.4) Unplug the exhaust fan, (J13 on the main control board),

plugging it into an igniter port (J5 or J7) on the igniter board.5) Plug in the stove. If the exhaust fan runs, STOP - the igniter board is bad - Replace the igniter board.

Test the other igniter port in the same manner.If the exhaust fan runs while plugged into either igniter port, replace the igniter board.

NOTE: If an igniter is burned out on the stove, the stove may not perform the ash dump.

J7

J5

J13

J7

J5

J13

DWG. NO. 4000436 Rev C 10/2007 Kit 4000080

Replacing the MaxFire Igniter(s)MaxFire (S/N 3000 – 9800)

Tools needed to replace the igniter(s)

5/64” hex head wrench Needle nose pliers Philips head screw driver

Side cutters Cable ties Wire markers

Replacing the MaxFire igniter(s):

Unplug the stove. Remove the left and / or right side screws and panel(s). Using a 5/64" hex head wrench or a Philips screw driver, remove the screws holding the lower

louver in place. Remove the louver. See Figure 1. Clip the cable ties holding the Igniter wires. Mark the igniter wires “upper” for (J5) and “lower” for (J7) so you don’t mix them up. Unplug the igniters from the main control board. See Figure 2.

NOTE: READ BEFORE CONTINUING

If an error code of (#7 & #1), (#7 & #2) or (#7 & #1-2) has occurred, follow the next instructions BEFORE REMOVING either of the igniters! DO NOT ASSUME!

Using an ohmmeter (use the lowest scale), measure the resistance of each Igniter todetermine which Igniter is BAD. A good Igniter will read +/- 28 ohms.

Once it is determined which Igniter is bad, continue with the following instructions.

Remove the grommet. See Figure 3. With one finger, move the securing clip out of the way. Using needle nose pliers (any othertool or a wire with a hook on it) to pull the igniter out about 2" past the front of the stove. See Figure 4. Remove the air hose from the igniter. See Figure 5.Remove the igniter ground wire from the igniter. Pull the igniter the rest of the way out.Feed the new igniter plug & wires through the grommet hole. Insert the new igniter into the hole in the side of the firebox. Attach the ground wire and air hose to the igniter. Push the igniter back into the lower burn pot into the igniter tip guide. Make sure the securingclip has moved over to hold the igniter in place. Plug both igniters back into the main control board.Replace the rubber grommet.Secure wires with cable ties.Put the lower louver back on.Install the screws.Plug the stove in. Check for proper operation.Install the left and / or the right side panel(s) and screw(s).

DWG. NO. 4000436 Rev C 10/2007 Kit 4000080

` Figure 1

Figure 2

Figure 3

DWG. NO. 4000436 Rev C 10/2007 Kit 4000080

Figure 4

Figure 5

Ground Wire

DWG. NO. 4000436 Rev C 10/2007 Kit 4000080

Replacing the Feeder Wheel Motor MaxFire (S/N > 5000) and UBB

Reasons for feeder wheel motor replacement:

• Motor jams often or may not turn at all even though it is not jammed. • #8 LED indicator light blinking and the feeder wheel does not turn.

Tools and equipment needed to change a feeder wheel motor:

• 5/16" nut driver or socket and ratchet • 1/4" nut driver or 1/4" socket • 3/4" wrench or socket and ratchet • Phillips Screw Driver • Vacuum

Changing the feeder wheel motor :

□ Unplug the stove. □ Remove the left side panel. □ Open the hopper lid. □ Remove all of the corn in the hopper. □ Remove four 5/16" screws holding the feeder wheel cover. See Figure 1. □ Remove the feeder wheel cover. □ Remove the 3/4" jam nut and turn the wheel counter clockwise to remove. See

Figure 4. □ Vacuum the area under the feeder wheel. □ Undo the two spade terminals going to the motor (about 6" from the motor). □ Remove the four 1/4" screws that hold the feeder wheel motor from inside the

hopper. See Figure 2. □ Remove the motor. See Figure 3. □ Install the new motor. □ Replace the four 1/4" screws from within the hopper that secure the motor. See

Figure 2. □ Put the feeder wheel back on by turning the wheel clockwise until it touches the

feeder wheel plate, tighten 1-1/2 turns more, then put the 3/4" jam nut back on and tighten while holding the Feeder wheel.

□ Replace the feeder wheel cover. □ Secure it with the four 5/16" screws. □ Attach the two wires going to the motor. □ Install cable ties to the wires. □ Plug the stove in. □ Check for proper operation. □ Install the left side panel.

Definition of terms: Hub - The round metal piece that connects the feeder wheel motor shaft to the feeder wheel. Self-tapping screw - A screw with a small drill bit built into the end of it. It will screw into metal

without a pilot hole.

DWG NO. 4000444 Rev B 11/2007 Kit 4000099

Figure 1

Figure 2

Figure 4

Figure 3

DWG NO. 4000444 Rev B 11/2007 Kit 4000099

Replacing the MaxFire Exhaust Fan

MaxFire (S/N 5000 – 9800)

Tools needed to change the exhaust fan:

• Philips screw driver • 5/16" wrench or ratchet and socket • 5/32" Allen wrench

• Side cutters to remove cable ties • Vacuum • .5 oz. of 600 degree silicone

Replacing the exhaust fan

□ Unplug the stove. □ Remove the right side panel. □ Unplug the exhaust fan tach and exhaust fan from the main control board. See Figures

1 & 2. □ Cut the cable ties that secure both of the above wires. □ Separate the vent pipe from the converter box. □ Loosen the hose clamp on the black intake hose on the converter box and remove the

hose. □ Remove the top two 5/32" Allen bolts that hold the exhaust tube on the exhaust

manifold. See Figure 3. □ Remove the exhaust fan / converter box assembly as one unit. □ Remove the four 5/16" screws holding the black exhaust fan housing on to the

converter box. See Figure 5. Separate the exhaust fan housing and the converter box. □ Loosen the five 5/16" screws that join the exhaust fan and the exhaust fan cleanout

box and separate the two. □ Remove the two 11/32" nuts that hold sensor and bracket - carefully set the sensor

aside. □ On the replacement fan, remove the two corresponding 11/32" nuts. See Figure 4.

Install the sensor on the replacement fan - tighten the two nuts. □ Remove as much of the old silicone as possible from the converter box. □ Put new silicone on the converter box. □ Slide the converter box and the new exhaust fan together. See Figure 4. □ Install the four screws holding the joint together. See Figure 5. □ Add more silicone over the joint. □ Connect the exhaust fan / converter box and the exhaust fan cleanout box with the five

5/16" screws removed earlier. See Figure 4. □ Clean the area on the exhaust manifold and the exhaust tube that mate together. □ Put the assembly back into the stove. □ Run the wires over to the main control board. □ Install the exhaust tube onto the exhaust manifold (using a new exhaust tube flange

gasket) with the two 5/32" Allen bolts removed earlier. □ Plug the exhaust fan into the main control board. See Figures 2. □ Plug the exhaust fan tach into the main control board. See Figure 1. □ Add cable ties to bundle and secure the wires. □ Plug the stove in. □ Test for proper operation. □ Install the right side panel.

Definition of Terms: Converter box - This is where the venting enters the stove. It is a galvanized box that separates the intake and exhaust air.

P/N 4000452 Rev B 10/2007 Kit P/N 4000105

Exhaust Fan Tach

Sensor J10 Figure 1 Exhaust Fan J13 Figure 2 Figure 3 5/32" Allen screw

P/N 4000452 Rev B 10/2007 Kit P/N 4000105

Figure 4 11/32" Nuts

5/16"

4 5/16" screws holding the converter box & fan together

Figure 5

P/N 4000452 Rev B 10/2007 Kit P/N 4000105

Replacing the MaxFire Burn Drive Motor

MaxFire (S/N 3000 – 9800)

Reasons for replacing the burn drive motor:

• The brake is malfunctioning and causing the motor to stop past the limit switch. • The motor will not cut through the clinker during normal operation. • The motor runs but the gear box does not turn.

Tools needed to change the burn drive motor:

• #2 Phillips head screw diver • 7/16” wrench or ratchet with socket • 5/16” wrench or ratchet with socket

Changing the burn drive motor:

□ Unplug the stove. □ Remove the left side panel. □ For burn drive motor location, See Figure 1. □ Loosen pinch bolt on the cam. See Figure 2. □ Remove the cam. □ Remove the key if it did not come out in the cam. See Figure 3. □ Unplug the two orange wires going to the burn drive motor. See Figure 4. □ Remove the four screws holding the motor. See Figure 4. □ Remove the motor. □ Install the new motor. □ Install and tighten the four screws that hold the motor. See Figure 4. □ Carefully install the cam and key so as not to bend the arm on the switch. □ Tighten the pinch bolt. □ Plug the two orange wires in going to the motor. See Figure 4. □ Plug the stove in. □ Check for proper operation. □ Install the left side panel.

Definition of Terms: Key – Fits into the keyway in the motor shaft and cam. It keeps the shaft from spinning inside the cam. Cam – Moves the tie rod, which in turn moves the paddles inside the firebox.

DWG. NO. 4000460 Rev B 10/2007 Kit 4000113

Figure 1

Figure 2Figure 4

Figure 3

Mother B

oard

Burn D

rive M

otor

Pinch B

olt

Cam

Shaft

Key

Figure 1

Figure 2Figure 4

Figure 3

Mother B

oard

Burn D

rive M

otor

Pinch B

olt

Cam

Shaft

Key

DWG. NO. 4000460 Rev B 10/2007 Kit 4000113

Replacing the Air Pump MaxFire S/N 5000 - 9800

Reasons for Replacing the air pump:

• Air pump has stopped working. • Air pump has a low output

Tools needed to change the air pump:

• 5/16" socket, ratchet and short extension or a 5/16" nut driver • Phillips screw driver

Changing the air pump:

• Unplug the stove. • Remove the left side panel. • Unplug the pump from the mother board (J14). See Figure 2. • Remove the Igniter hoses from air pump. • Remove the three wing nuts holding to pump to the stove. See Figure 1-A. • Remove the air pump assembly from the stove. • Remove the ground wire of the old pump from the frame of the stove. • Attach the ground wire of the new pump to the frame of the stove. • Install the air pump assembly into the stove. • Install and tighten the three wing nuts. See Figure 1. • Plug the pump into the mother board (J14). See Figure 2. • Attach the two output hoses to the pump. • Plug in the stove. • Test for proper operation. • Install the left side panel.

Figure 1

A

DWG. NO. 4000478 Rev B 10/2007 Kit 4000121

Figure 2

Air pump J14

DWG. NO. 4000478 Rev B 10/2007 Kit 4000121

Replacing the Convection Fan MaxFire (S/N 5,000 – 9800)

Tools needed to replace the convection fan motor:

• Philips screw driver • 5/16” wrench or 5/16” ratchet with 5/16” socket • 6mm wrench or 1/4”ratchet with 6mm socket • Side cutters • Cable ties

Replacing the convection fan:

□ Unplug the stove. □ Remove the left and right side panels. □ Unplug the convection fan connector J12on the main control board. See Figure 1. □ Cut the cable tie that holds the wires. □ Remove the three thumb screws holding the main control board bracket and lean the

bracket / main control board towards the rear of the stove. □ Remove the wing nut and convection fan ground wire connected to the stove frame. See

Figure 2. □ Remove the four 5/16” screws that hold the convection fan housing on to the bottom of the

hopper. See Figure 4. □ Remove the housing from the stove. □ Remove the six 5/16" screws that hold the convection fan cover on. See Figure 3. □ Remove the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the

convection fan housing. See Figure 4. □ Lift the fan out. □ Place the new fan in the housing. □ Install the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the

housing. See Figure 4. □ Install the six 5/16" screws that hold the convection fan cover on (Figure 3). □ Place the housing back into stove. □ Install the four 5/16” screws that hold the convection fan to the bottom of the hopper. □ Install and tighten the three thumb screws that hold the main control board bracket. □ Plug the fan back into J12 on the main control board. See Figure 1. □ Connect the ground wire and replace the wing nut. □ Bundle wires with cable ties. □ Plug in the stove. □ Check for proper operation. □ Install the left and the right side panels.

Definition of Terms:

Convection fan cover – Silver ring that is used to channel air into the convection fan.

P/N 4000486 Rev B 10/2007 Kit P/N 4000139

Figure 1

J12

Figure 2

Ground Wire

P/N 4000486 Rev B 10/2007 Kit P/N 4000139

Figure 3

Six 5/16" screw

s

Figure 4

4- 5/16" screw

s

M4-0.7x6m

m

screws

P/N 4000486 Rev B 10/2007 Kit P/N 4000139

DWG. NO. 4000501-B 11/2007 Kit 4000361

Replacing the Feeder Wheel Sensor Tools needed to replace the feeder wheel sensor:

• 9/16” wrench • Side cutters to remove cable ties • cable ties • 3/4” socket and torque wrench • 5/16” socket wrench • straight edge • Philips head screw driver • Vacuum

o Unplug the stove. o Remove the left side screw and panel. o The feeder wheel sensor is located underneath the hopper (red, blue and black

wires). o Clip the cable ties that are holding the feeder wheel sensor wires. o Unplug the sensor connector from the main control board (J9). o Loosen the 1/2" jam nuts and remove the sensor. (See figure 1). o Remove the hopper lid. o Vacuum out the hopper. o Remove the four 5/16” bolts from the feeder wheel cover, lift out the cover. (See

figure 2). o Remove four shoulder bolts and springs from the feeder wheel, lift out the feeder

wheel. (See figure3). o Vacuum the area behind the feeder wheel. o Carefully screw new sensor into hole. Be careful not to cross thread it. o Set the height sensor flush with the feeder wheel plate - back the sensor out 1/2 to 1

turn out. (See figure 4). o Tighten the top nut on the sensor. o Tighten the lower jam nut. o Plug the sensor back into the mother board. o Replace all of the cable ties. o Put the feeder wheel back on. o Reinstall the shoulder bolts. o Replace the feeder wheel cover and reinstall the four 5/16" screws. o Put the hopper lid back on. o Replace the left side panel and screw. o Plug the stove back in. o Check for proper operation.

Figure 1

Figure 2Figure 3

Figure 4

DWG. NO. 4000501-B 11/2007 Kit 4000361

Replacing the Thermocouple MaxFire (S/N 5000 – 9800)

Reason for replacing the thermocouple:

#2 light comes on even though the thermocouple is plugged in and the stove lights correctly

Tools needed to change the thermocouple:

• Side cutters to remove cable ties • .5 oz 600 degree high temp silicone

Replacing the thermocouple:

• Unplug the stove. • Remove the right side panel. • Remove the left side panel. • Unplug the thermocouple from the mother board (J18) (upper right of the mother

board, 2 prong plug with a yellow and red wire) (Figure 2). • Clip the cable ties holding the wire in place. • Pull the thermocouple out of the exhaust manifold (Figure 3) (the single wire going

into the exhaust manifold with silicone around it). • Remove the old silicone from the exhaust manifold. • Run the wire to the mother board, securing it with cable ties. • Plug the 2 prong plug into the upper right of the mother board. • Install the new thermocouple with 1" inside the exhaust manifold (Figure 1). • Seal the outside with silicone. • Replace both side panels. • Plug the stove. • Test for proper operation.

DWG. NO. 4000527-B 11/2006 Kit 4000329

Figure 2 Figure 1

Figure 3

DWG. NO. 4000527-B 11/2006 Kit 4000329

Replacing the Firebox Door Latch Tools needed to replace the firebox door latch

• 9/16” wrench

• 3/4” deep socket

• Open the fire box door.

• Loosen the 9/16” (C) nut and remove the latch hardware (B & A).

• Loosen the 3/4" nut (D) and remove the old handle.

• Put the new handle back in the door and install the mounting nut.

• Put the latch jam nut (A) on about half way.

• Install the latch pawl (B) and snug the nut.

• Adjust the door for a tight fit and tighten the jam nut (C) when a tight fit is achieved.

• Close the fire box door.

• The stove is ready to use.

B

C A

D

DWG. NO. 4000543-B 10/2006 Kit 4000345

DRW. NO. 4000593-B 11/2006 Kit 4000014 & 4000015

Replacing the MaxFire Convection Fan Capacitor

MaxFire (3000 – 9800)

Tools needed to replace the convection fan capacitor:

Philips head screw driver 9/16” socket wrench Side cutters Cable ties

• Unplug the stove.

• Remove the left side panel.

• Clip the cable tie holding the wires of the capacitor.

• Unplug the two spade terminals from the capacitor. (See Figure 1).

• Loosen the 9/16” nut on the capacitor. (See Figure 2).

• Remove the capacitor from the bracket.

• Install the new capacitor and tighten the nut.

• Reconnect the spade terminals.

• Replace the cable tie.

• Plug in the stove.

• Check for proper operation.

• Put the left side panel back on.

Figure 1

Figure 2

DRW. NO. 4000593-B 11/2006 Kit 4000014 & 4000015

Replacing the Hopper Snap Disc

Reasons for replacing the hopper snap disc:

#3 LED indicator light blinks and stove shuts down

Tools needed to change the hopper snap disc: Phillips screw driver

5/16" hex (Allen) wrench

Checking the Hopper Snap disc:


• Remove the two brown wires from the feeder wheel snap disc. (As you are

facing the left side of the stove, the wires are located in the upper right above

the exhaust manifold. (See Figure 1).

• Unplug the two spade terminals and install a jumper wire between the two

wires (an alligator clip or a small piece of wire with ¼" spade terminal ends).

This will bypass the hopper snap disc.

• Start the stove again and check for normal operation (no #3 light blinking).

• If this fixes the problem, continue with replacing the hopper snap disc.

Replacing the Hopper snap disc:



• Undo the two spade terminals on the snap disc. (See Figure 1).

• Remove the screw holding the snap disc. (See Figure 2).

• Install the new snap disc.

• Connect the wires

• Plug the stove back in.


• Put the side panel back on.

DWG. NO. 4000957-B 10/2006 Kit 4000600

Snap Disc -Brown wires

Snap Disc

Figure 2

Screw

Figure 1

DWG. NO. 4000957-B 10/2006 Kit 4000600

Replacing the Exhaust Fan Sensor

Tools needed to replace the exhaust fan sensor:

• Philips screw driver • 9/16" wrench • 5/32" hex head wrench • 5/16" nut driver or wrench • Side cutters and cable ties

• Unplug the stove. • Remove the right and left side panel screws and panels. • Remove the sheet metal screws from the stove vent pipe. • Carefully separate the pipe from the stove. • Cut the cable ties holding exhaust fan wires. • On the mother board, unplug the exhaust fan motor connector (J13) and the exhaust fan sensor connector (J10). See Figs 1 & 2. • Loosen the hose clamp on the 3" black hose connected to the converter box. • Remove the hose from the converter box. See Fig 6. • Remove the two 5/32” hex head screws that hold the exhaust tube to the exhaust manifold, pull whole assembly out of stove. See Fig 3. • Remove the ten 5/16" screws from the exhaust clean out cover. (This step will ease in the adjustment of the sensor to the fan blades). • Remove the two 11/32” nuts that hold the sensor on and then the sensor. Note the position of the sensor to the cooling fan on the motor shaft. See Fig 5. • Install the new sensor on the fan centering the sensor on the fan blades. • Adjust the sensor until it touches the blades - back it out one turn. • Spin the fan, see Fig 4, checking the clearance between the sensor and the motor cooling fan blades. See Fig 5. • Check that the sensor is still centered on the cooling fan blades. • Tighten the jam nuts. • Again spin the fan and check the clearance between the sensor and the blades. • Install ten 5/16" screws, NEW gasket and the exhaust clean out cover. • Position the exhaust fan assembly in the stove • Connect the intake hose. • Tighten the hose clamp. • Install the exhaust tube to the manifold using the new gasket. • Plug the exhaust fan and sensor back onto the mother board. • Install the cable ties. • Put silicone on the vent pipe and reconnect it to the stove. • Replace the screws onto the vent pipe. • Plug in the stove. • Check for proper operation. • Install the left and right side panels.

DWG NO. 4000965 Rev B 11/2006 Kit 4000618

DWG NO. 4000965 Rev B 11/2006 Kit 4000618

Figure 1

Exhaust Fan Tach Sensor J10

Figure 2

Exhaust Fan connector J13

Figure 5

9/16" Adjusting

Nuts

5/32" Allen screw Figure 3 Figure 4

3" Black Hose Hose Clamp Converter Box

Figure 6

5/16"

Cooling Fan Blade

Replacing the Exhaust Clean Out Cover Screws Tools needed to replace the exhaust clean out cover screws:

• Philips screw driver

• 5/32" hex head wrench


• Remove the right side screw and panel.

• Remove the five 5/16” bolts from the exhaust box cover. (See figure 1).

• Install five of the 1/4” long bolts.

• Remove the other five long bolts.

• Install the last five 1/4” long bolts.

• Replace the right side panel and screw.


• Stove is ready to use.

Dwg No 4001062-B 11/2007 Kit 4001054

Replacing the igniter board MaxFire (S/N 3000 – 9800)

Tools needed to replace the igniter board:

• Needle nose pliers.

• Phillips screwdriver.

o Unplug the stove. o Remove left side screw and panel. o The igniter board is located vertically to the right of the main control

board. o Pay close attention to where the wires are on the igniter board. o It may be helpful to mark the wires as you take them off. o NOTE: Only remove wires from the igniter board o Disconnect all of the wires going into the daughter board. o There are four clips at the corners that need to be removed. (See figure

A) o Remove the old igniter board from the stove. o Install the new igniter board. o Reconnect all the wires. o NOTE: Be careful when connecting the black ribbon cable to the

"J3" terminal making sure that the connector sits on ALL of the pins.

o Replace the left side screw and panel. o Plug the stove back in. o Check for proper operation.

DWG. NO. 4001179-B 11/2007 Kit 4000626

A

A

J3

Igniter Board

Left Igniter

Right Igniter

120v Power in/out

Black Communication Cable Connector

DRW. NO. 4001187-B 11/2007 Kit 4000676

Replacing the Converter Box Reasons for changing the converter box:

• The exhaust fan is running at too low of speed (#6 diagnostic light will come on)

Tools needed to change the converter box:

• Philips screw driver • 5/16” wrench or ratchet and socket • 3/8” wrench or ratchet and socket • 500 degree silicone • Side cutters to remove cable ties • Cable ties (6)

Changing the Converter Box:

o Unplug the stove. o Remove the right and left side panels. o Unplug the exhaust fan tach from the main control board (J10). o Unplug the exhaust fan from the main control board (J13). o Cut the cable ties that secure both of the above wires. o Carefully remove the vent pipe from the converter box. o Loosen the hose clamp on the black combustion air hose and remove the hose. o Remove the two 5/32” bolts (See Figure 1) that hold the exhaust fan assembly onto the

exhaust manifold. o Remove the exhaust fan assembly and exhaust tube as one unit. o Remove the four 5/16” screws holding the black exhaust fan housing to the converter

box. o Separate the exhaust fan housing and the converter box. (See Figure 2). o Remove as much of the old silicone as possible. o Put a 1/4" silicone bead around the converter box where the old silicon was. (See

Figure 3). o Slide the converter box and exhaust fan together. o Install the four screws holding the joint together. o Add more silicone over the joint and the four screws holding the joint together. o Put the assembly back into the stove. o Run the wires over to the main control board. o Replace the exhaust tube gaskets as necessary. o Install the two bolts that hold the exhaust fan assembly to the exhaust manifold and

tighten. o Plug the exhaust fan into the main control board. (J13). o Plug the exhaust fan tach into the main control board. (J10). o Add cable ties to secure the wires. o Plug the stove in. o Test for proper operation. o Reinstall the side panels.

Glossary: Converter box – This is where the piping enters the stove. It is a galvanized box that separates the intake and exhaust air.

Figure 1

Figure 2

Figure 3

DRW. NO. 4001187-B 11/2007 Kit 4000676

DWG. NO. 4001195-B 11/2007 Kit 4000692

Replacing the Feeder Wheel Silicone Seal Tools needed to replace the Feeder Wheel Silicone Seal:

• 5/16” socket / wrench • 1/8" hex driver (allen head) • 1/8" drill bit • Pop rivet gun

o Unplug the stove. o Remove the hopper lid.

o Remove all the corn from the hopper.

o Remove the two 5/16” bolts from the feeder wheel inspection cover. (See

figure 1).

o Remove the inspection cover assembly.

o Remove the two shoulder screws and springs from the inspection cover

plate/seal assembly removing the old seal assembly. (See figure 2).

o Install the new seal assembly using the two shoulder screws and springs onto

the inspection cover plate. (See figure 3 & 4).

o Install the new assembly unto the feeder wheel cover plate.

o Reinstall the two 5/16” bolts.

o Put the hopper lid back on

o Plug stove back in.

o Check for proper operation.

Figure 1

Figure 2

Figure 3

Figure 4

DWG. NO. 4001195-B 11/2007 Kit 4000692

Replacing the Ash Drawer Switch

Tools needed to replace the ash drawer switch:

• Phillips screw driver

• Flat tip screw driver

• 3/4” deep socket wrench


• Remove the left side screw and panel.

• Remove the ash drawer. See Figure 1.

• The switch is located on the back left side of the ash drawer

compartment.

• Loosen and remove the nut (from within the ash drawer compartment).

See Figure 2.

• Pull the switch out from the back side. See Figure 3.

• Remove both of the wires from the switch.

• Install the wires onto the new switch.

• Run one nut on all the way unto the shaft of the new switch.

• Put the switch back into the hole.

• Run the second nut unto the switch shaft and tighten the nut.

• Put the ash drawer back in.


• Test the switch for proper operation.

• Install the left side screw and panel.

DWG. NO. 4001210 Rev B 11/2007 Kit 4000569

Figure 1

Figure 2

Figure 3

DWG. NO. 4001210 Rev B 11/2007 Kit 4000569

DWG. NO. 4001228-B 11/2007 Kit 4000585

Replacing the Burn Drive Motor Switch Tools needed to replace the burn drive motor switch:

• Philips head screw driver

• 7/16” wrench or socket wrench

o Unplug the stove.

o Remove the left side screw and panel.

o The burn drive motor switch is located behind the burn drive cam on top of the

burn drive motor assembly. (See figure 1).

o Push in the brake on the burn drive motor. (See figure 2 & 3).

o Rotate the linkage to give you room to remove the switch. (See figure 4).

o Unplug the wires from the switch. (See figure 5).

o Remove two screws that hold the switch onto the bracket. (See figure 4).

o Replace the switch.

o Reinstall the screws and mounting hardware.

o Holding in the brake, rotate the motor shaft so the arm on the shaft is lines up

with the switch. (See figure 3 & 1).

o Before tightening screws, rotate the front of the switch toward the burn drive

motor shaft so the switch clicks.

o If necessary, realign the arm and the switch and if necessary, adjust the switch

so it clicks at this point. The arm of the switch should be about 1/16" from the

body of the switch.

o Plug the wires back into the switch. (See figure 5).

o Plug the stove back in.

o Check for proper operation.

o Replace the left side panel.

Figure 2

Figure 3

Figure 5

Figure 1

Figure 4

DWG. NO. 4001228-B 11/2007 Kit 4000585

Replacing the MaxFire Exhaust Fan Gasket

MaxFire (S/N 5000 – 9800)



• Side cutters to remove cable ties • Vacuum • .5 oz. of 600 degree silicone

Replacing the exhaust fan:

• Unplug the stove. • Remove the left and right side panels. • Unplug the exhaust fan tach and exhaust fan from the main control board. See Figures

1 & 2. • Cut the cable ties that secure both of the above wires. • Separate the vent pipe from the converter box. • Loosen the hose clamp on the black intake hose on the converter box and remove the

hose. • Remove the top two 5/32" Allen bolts that hold the exhaust tube on the exhaust

manifold. See Figure 3. • Remove the exhaust fan / converter box assembly as one unit. • Loosen the five 5/16" screws that join the exhaust fan and the exhaust fan cleanout

box and separate the two. • If necessary, scrape off the old gasket from the exhaust fan and / or the exhaust fan

clean out box. • Position the new exhaust fan. • Connect the exhaust fan / converter box and the exhaust fan cleanout box with the five

5/16" screws removed earlier. See Figure 4. • Clean the area on the exhaust manifold and the exhaust tube that mate together. • Put the assembly back into the stove. • Run the wires over to the main control board. • Install the exhaust tube onto the exhaust manifold (using a new exhaust tube flange

gasket) with the two 5/32" Allen bolts removed earlier. • Plug the exhaust fan into the main control board. See Figures 2. • Plug the exhaust fan tach into the main control board. See Figure 1. • Add cable ties to bundle and secure the wires. • Plug the stove in. • Test for proper operation. • Install the left and right side panels.

Definition of Terms: Converter box - This is where the venting enters the stove. It is a galvanized box that separates the intake and exhaust air.

DWG NO.4000452 Rev B 11/2007 Kit 4000668

Figure 1

Exhaust Fan Tach Sensor J10

Figure 2

Exhaust Fan J13

DWG NO.4000452 Rev B 11/2007 Kit 4000668

5/32" Allen screw Figure 3

Figure 4

5/16"

DWG NO.4000452 Rev B 11/2007 Kit 4000668

Replacing the Exhaust Tube Gaskets MaxFire (S/N > 5000)

Tools needed to replace the exhaust tube gaskets:

• Philips screw driver • 5/32" hex head wrench • Scraper

Replacing the exhaust tube gaskets:


• Remove the right side panel.

• Remove four hex head screws from the exhaust tube flanges.

See Figure 1 & 2.

• Remove the tube from the stove.

• Use a scraper to remove the old gaskets.

• Put the new gaskets and tube in place.

• Replace the four hex head screws.



• Replace the right side panel.


DWG NO. 4001252 Rev B 11/2006 Kit 4000650

Figure 2

Figure 1

DWG NO. 4001252 Rev B 11/2006 Kit 4000650

Replacing the Firebox Door Switch MaxFire (S/N > 5000)

Tools needed to replace the firebox door switch:

• Philips screw driver

• Flat tip screw driver

• 5/16” socket wrench

Replacing the fire box door switch • Unplug the stove.

• Remove left side screw and panel.

• Open the fire box door to relieve pressure on the switch from the

actuating rod. See Figure 1.

• The door switch is located in left side of the stove above the burn drive

motor. See Figure 2.

• Disconnect the wires from the switch.

• Remove the two mounting screws and pull out the switch. See Figure 3.

• Remove the switch from the bracket.

• Screw the new switch to the bracket.

• Attach the wires you removed from the old switch to the new switch.

• Put the switch back in the stove.

• Snug the bolts and reconnect the wires.

• Push the rod in to hear the switch click. Adjust if necessary. See Figure 3.

• Tighten the mounting screws on the switch if it operates correctly.

• Close the fire box door.

• Test the switch by opening the door. The switch should click just as the

handle reaches the first detent. ADJUST IF NECESSARY. See Figure 3.


• Put the left side panel and screw back on.

DWG NO. 4001286 Rev B 11/2006 Kit 4000577

Figure 1

Figure 3

Figure 2

DWG NO. 4001286 Rev B 11/2006 Kit 4000577

DWG NO. 4001294 Rev B 11/2007 Kit 4000064 4000065

Replacing the Main Control Board

MaxFire (S/N > 3000) Tools needed to replace the main control board:

• Side cutters

• Needle nose pliers

• Cable Ties

Replacing the main control board



• Unplug all the wire connectors paying close attention to where the wires

are plugged in on the main control board. See Figure 1.

• All connectors use one way plugs so they can not be installed upside

down. NOTE: Unplug ONLY the connecters on the main control board

leaving all other plugs intact.

• Remove the main control board from the six plastic clips. See Figure 2.

• Remove the old main control board.

• Touch the frame of the stove to discharge any static electricity.

• Install the new main control board.

• NOTE: Several connecters can be put on so one or more pins may not go into the plug. Carefully inspect all plugs for this condition and correct if necessary.

• Replace all wire connections to the main control board.



• Replace the left side panel and screw.

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Rectangle

DWG NO. 4001294 Rev B 11/2007 Kit 4000064 4000065

Igniters J5 & J7

Laptop Terminal

Feeder Wheel

Input Power J4 & Trim Pots J8

Communications

Current Coil T1

Touch Pad J7 Thermocouple Low Voltage Molex

Main Fuse F3

Thermostat J6

Exhaust Fan Sensor

Air Pump J14

Convection Fan

High Voltage Molex

Exhaust Fan J13

Igniter Fuses F1 &

Air Pump J14

Input Power J4

Communications Cable J3

J12

Figure 1

Figure 2

Replacing the Ash Drawer Gasket Tools needed to replace the ash drawer gasket:

• Alcohol or suitable surface cleaner

• Putty Knife or similar tool

Replacing the ash drawer gasket


• Remove the ash drawer.

• Remove the old gasket.

• Clean the surface where the gasket sits with alcohol or a suitable surface

cleaner.

• Remove the backing from the new gasket

• Stick the gasket around the opening leaving about 1/8” space all the way around

on the inside.

• Reinstall the ash drawer.

• Plug stove back in.

1/8" Space on inner edge

Gasket

DWG NO. 4001327 Rev B 11/2007 Kit 4000717

Replacing the Fuel Deflector

Tools needed to replace the fuel deflector:

• Vacuum • 5/16” wrench or socket


• Open the firebox door.

• Use a vacuum to remove any ash from the top of the firebox area.

• Remove the two 5/16” screws and lift out the fuel deflector.

• Put new fuel deflector back in.

• Replace the bolts.

• Set bottom edge of fuel deflector centered approximately on the burn pot.

• Let stove feed for about 1 to 2 minutes. Check for even fuel distribution in the

bottom of the burn pot.

• Tighten the two 5/16" screws on the fuel deflector



DWG. NO. 4001390 Rev B 11/2007 Kit 4000379

Adding the UBB hopper extension

Tools needed to add the hopper extension: Philips screw driver 1/8” hex wrench


• Remove hopper lid.

• Disconnect the wires from lid switch inside hopper.

• Remove 4 button head screws from hopper sides.

• Remove the hopper top.

• Install new hopper extension.

• Install original hopper top.

• Install hopper mounting screws and hopper extension screws.

• Pull additional hopper lid switch wire (approx. 6”) thru grommet.

• Attach hopper lid switch wire to lid switch connectors.

• Close the hopper lid.

• Plug in stove. Turn on power.

• And check for proper operation.

4001426 Rev. A.

DWG. NO. 4001442 11/2007 Kit 4001434

Replacing the Top Burn Plate Gasket MaxFire < 5000

Tools needed to replace the upper burn plate gasket:

• Drill with a 1/8” bit • Awl • Utility scissors • Scraper • Vacuum cleaner • Rivet gun

Removing the upper burn plate gasket:

• Unplug the stove. • Open the fire box door. • Remove the fuel deflector and vacuum any ash from the firebox. • Lift out the upper burn plate. • Vacuum any ash from the bottom of the fire box area. • Remove the old gasket by drilling out the existing rivets. Note where the seam of the

gasket is located. • Using the scrapper, remove any remaining gasket from the upper burn plate and steel

gasket retainer. • Vacuum up the debris.

Replacing the upper burn plate gasket:

• Starting at the front edge of the upper burn plate, install the new gasket by removing the adhesive liner from the new gasket (a little at a time) as you apply the gasket to the bottom perimeter edge. The seam of the gasket should be as it was on the old gasket.

• The bulb of the gasket should fit closely to the outer edge of the plate. • Trim any excess length after applying the gasket to the entire perimeter of the upper

burn plate. • Punch mounting holes in the gasket with the awl over the existing thirteen rivet

locations. • Assemble the steel gasket retainer to the bottom of the upper burn plate with rivets

included in the kit using the rivet gun. • Install the upper burn plate in the stove. • Install the fuel deflector. • Close the firebox door. • Plug the stove in. • Check for proper operation.

Replacing the Convection Fan Motor MaxFire < 5000


• Philips screw driver • 5/16” wrench or 1/4” ratchet with 5/16” socket • 6mm wrench or 1/4” ratchet with 6mm socket • 1/4” nut driver or 1/4" ratchet with a 1/4" socket • 1/8” Allen wrench • Side cutters • Cable ties • Wire stripper • Vacuum • Small Wire Nut

Preparing to replace the convection fan motor:

• Unplug the stove. • Remove the left and right side panels. • Unplug the convection fan connector J12 on the mother board. See Figure 1. • Cut the cable tie that holds the wires. • Cut the yellow/green wire in the cord of the convection fan leaving it as long as possible to the

stove frame. The yellow/green wire from the stove frame will be used later. • From the right side of the stove, remove and disconnect the axial fan. See Figures 2a & 2b. • Disconnect the two wires from the capacitor to the convection fan cable. • Remove the 5/16” screw holding the air pump and pull the air pump to the outside of the stove. • Disconnect the upper red air hose from the side of the converter box and move it out of the way.

Removing the feeder wheel motor:

• The feeder wheel motor must be removed to allow room to remove the convection fan. • Remove all of the fuel in the hopper. • Vacuum the Hopper out. • Remove the four 5/16" screws holding the feeder wheel cover. • Remove the feeder wheel cover. • Using a 1/8" hex wrench (Allen wrench) remove the four screws, springs and spacers from the

Feeder Wheel. • Remove the feeder wheel and set aside. • Loosen the two set screws on the feeder wheel hub using a 1/8" hex wrench (Allen wrench). • Remove the hub. • Remove the four 1/4" screws from inside the hopper that secure the motor. • Remove the feeder wheel motor and gently set down next to the stove. If necessary, the feeder

wheel motor may be disconnected from the wiring harness.

P/N 4001476 Rev B 11/2007 Kit P/N 4000140

Replacing the convection fan motor:

• Remove the six 1/4" screws that hold the convection fan cover on. See Figure 3. • Remove the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the

convection fan housing. See Figure 4a & 4b. • Lift out the fan. • Place the new fan in the housing. • Install the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the housing.

See Figure 4a & 4b. • Install the six 1/4" screws that hold the convection fan cover on. See Figure 3. • Plug the fan back into J12 on the mother board. See Figure 1. • Cut and strip the two yellow/green wires. • Connect the ground wire to the ground wire tail left from the old motor using a wire nut. • Connect the two wires from the capacitor to the convection fan cable. • Bundle wires with cable ties. • Connect the upper red air hose from the side of the converter box and tighten the hose clamp. • Connect and install the axial fan on the right side of the stove. Be sure to ”seat” the fan on the

stoves frame.

Replacing the feeder wheel motor: • Connect the feeder wheel motor to the wiring harness if it had been disconnected earlier. • Hold the feeder wheel motor in place and install the four 1/4” screws from inside the hopper. • Install the feeder wheel hub tightening the two screws using the 1/8” Allen wrench. • Install the feeder wheel using the four screws, spacers and springs • Tighten the four screws using the 1/8” Allen wrench. • Install the feeder wheel cover using four 5/16” screws and tighten. • Add fuel to the hopper • Plug in the stove. • Check for proper operation. • Install the left and the right side panels.



P/N 4001476 Rev B 11/2007 Kit P/N 4000140

P/N 4001476 Rev B 11/2007 Kit P/N 4000140

FiFigure 2b

gure 2a

Figure 3Figure 1

Convection Fan

J12

Convection Fan

Capacitor

Axial Fan

Exhaust Fan C

lean out C

over

Converter B

ox

Axial Fan

Axial Fan

Mounting Tabs

FiFigure 2b

gure 2a

Figure 3Figure 1

Convection Fan

J12 Exhaust Fan C

lean out C

over

Convection Fan

Capacitor

Axial Fan

Converter B

ox

Axial Fan

Axial Fan

Mounting Tabs

Figure 4a

Figure 4b

P/N 4001476 Rev B 11/2007 Kit P/N 4000140

P/N 4001509 10/2006

Replacing the Convection Fan Capacitor

Tools needed to replace the Convection Fan Capacitor: Philips head screw driver 9/16” socket wrench

• Unplug the Stove.

• Remove the left side panel and the Air Filter from the back of the Stove.

• Unplug the Capacitor from J20 on the Mother Board (See Figure 1).

• Using an Ohm Meter, confirm that the Capacitor is BAD.

• Set the Ohm Meter on a HIGH scale and connect to the capacitor.

• A Bad capacitor will read either zero or infinity.

• A Good capacitor will read infinity to zero (or close to zero) then rise to infinity again.

• Reverse the leads and recheck

• Loosen the 9/16” nut on the capacitor (See Figure 2).

• Remove it from the bracket.

• Put the new Capacitor on and tighten the nut.

• Plug the Capacitor into J20 on the Mother Board (See Figure 1)

• Put the left side panel back on.

• Reinstall the Air Filter on the back of the stove.



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Figure 1

Figure 2

J20

P/N 4001509 10/2006

Replacing the Feeder Wheel Motor Assembly

• Unplug the stove. • Remove the left side panel. • Undo the two spade terminals going to the Feed Wheel Motor. • Locate the Feeder Wheel Sensor on the under side of the hopper (black, red and

green wires) and unplug them from the Mother Board (J9). Cut any wire ties securing the wires to any other wires.

• Open the hopper lid. • Remove all of the corn in the hopper. • Vacuum the Hopper out. • Remove the four 5/16" screws holding the feeder wheel cover (Figure 2). • Remove the feeder wheel cover. • Remove the two (2) outer 5/16" screws from the silicone flap. The silicone seal and

screws will be reused. • Using a 1/8" hex wrench (Allen wrench) remove the four (4) screws, springs and

spacers from the Feeder Wheel and set aside for reuse. • Set the Feeder Wheel aside for reuse. • Remove the two (2) remaining 5/16" screws from the Feeder Wheel Plate.

• STOP - READ • On the back of the Feeder Wheel Plate is a very small Safety Switch which must be

removed. • The feeder tube may be siliconed to the Feeder Wheel Assembly. Carefully and

slowly pry the assembly away from the back of the Hopper. • Using a 5/64" hex wrench (Allen wrench), remove the Safety Switch from the rear of

the Feeder Wheel Plate. (Fig. 1). There is no need to disconnect the wires to this Safety Switch.

• Loosen the 2 (two) 1/2" nuts with a 9/16" open end wrench and carefully unscrew the Feeder Wheel Sensor from the Feeder Wheel Assembly.

• Remove the Feeder Wheel Assembly from the hopper. Put the NEW Feeder Wheel Assembly back in the hopper.

• Screw the Feeder Wheel Sensor into the Feeder Wheel Assembly. • Set the height of the Sensor FLUSH with the Feeder Wheel Plate - back the Sensor

out 1/2 to 1 turn out. • Tighten top jam nut. • Tighten the lower jam nut. • Re-install the Safety Switch onto the rear of the new assembly with the supplied 6-32

Phillips head screw. • Make sure the Feeder Tube Seal and Washer is carefully aligned and correctly

installed (see Fig. 1). • Secure the assembly to the hopper with two (2) 5/16" screws (Fig. 4). • Attach the old Feeder Wheel to the new hub using the four (4) screws, springs and

spacers you removed earlier (Fig. 4). • Re-install the silicone flap using the two (2) 5/16" screws removed earlier (Fig. 3). • Replace the Feeder Wheel cover and spacers with the four (4) 5/16" screws (Fig. 2). • Re-attach the two wires going to the motor.

P/N 4001525_I-A 06/2007

• Plug the Feeder Wheel Sensor into J9 on the Mother Board. • Install cable ties to bundle wires in a neat manner. • Install the left side panel. • Plug the stove back in. • Check for proper operation.

Tools and equipment needed to change a feeder wheel motor: 5/16" nut driver or socket and ratchet 9/16" open end wrench 5/64" hex wrench (Allen wrench) #2 Phillips screwdriver Definition of terms: Hub - The round metal piece that connects the feeder wheel motor shaft to the feeder wheel.

Fig. 1

Make sure the Feeder Tube

Seal Washer is installed properly

Spring

Washer

Safety Switch

Feeder Wheel Sensor

Return Instructions: This part is NOT to be returned

P/N 4001525_I-A 06/2007

Caution: The feeder Wheel Assembly with its "seal" must be installed properly to insure safe operation of the stove. Bixby Energy Systems assumes no responsibility

for improper installation of this kit.

Fig. 2

Fig. 3

Fig. 4

Feeder wheel Cover

Nylon Spacer

Silicone Seal

Feeder Wheel Hub

Mounting Holes for Silicone Seal

P/N 4001525_I-A 06/2007

P/N 4001541_I-A 08/2007

Replacing the Printed Circuit Board UBB

Tools needed to replace the Mother Board: Side cutters

Needle nose pliers

Cable Ties



• Mark ALL the Plugs on the PCB with their "Jxx" location.

• Unplug all the wire connectors paying close attention to where the wires

are plugged in on the circuit board. (See Figure 1).

• DO NOT PULL ON THE WIRES OF THE PLUGS TO REMOVE THEM

• All connectors use one way plugs so they can not be installed incorrectly.

NOTE: Unplug ONLY the connecters on the Printed Circuit Board (PCB)

leaving all other plugs intact.

• Remove all six knobs and the three wing nuts at the base of the

PCB bracket and remove from the stove.

• Remove the Printed Circuit Board from the six (6) plastic clips (Figure 1).

• Install the new Printed Circuit Board.

• Install the PCB back into the stove; reinstall the wing nuts and the knobs.

• Set the Fuel to type A or B and all other knobs to the detent.

• Replace all wire connections on the board.

• NOTE: Several connecters can be put on so one or more pins may not go onto the plug. Carefully inspect all plugs for this condition and correct if necessary.

• Replace all wire ties that were removed with new wire ties.



• Replace the left side panel and screw.

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P/N 4001541_I-A 08/2007

Figure 1

Fire Door Switch Ash Drawer Switch Hopper Door Switch (UBB) Burn Drive Motor Limit Switch

Touch PadExhaust

Thermocouple

Plastic Clips Plastic Clips

J7

J14

J16

J17

J18

J19

J2

J1

J11

J12

J4

J8

J20

TC1

J3

Exhaust Fan

Future

e

Ash Content

Convection Fan

ype

Feed Wheel Motor

Right Igniter

Burn Drive Motor

Air Pump

Exhaust Fan

Convection Fan

Fan Capacitor

120v Power

Feed Rat

Left Igniter Fuel T

Feed Wheel Sensor

Exh Fan Tachometer

Thermostat

Replacing the Exhaust Fan UBB



• .5 oz. of 600 degree silicone • Side cutters to remove cable ties • Vacuum

Replacing the exhaust fan:

□ Unplug the stove. □ Remove the right side panel. □ Unplug the exhaust fan tach and the exhaust fan from the main control board. See Figures 1. □ Cut the cable ties that secure both of the above wires. □ Carefully remove the thermocouple from the exhaust fan clean out box. See Figure 2. □ Separate the vent pipe from the converter box. □ Loosen the hose clamp on the black intake hose on the converter box and remove the hose. □ Remove the top two 5/32" Allen bolts that hold the exhaust tube on the exhaust manifold. See

Figure 3. □ Remove the exhaust fan / converter box assembly as one unit. □ Remove the four 5/16" screws holding the black exhaust fan housing on to the converter box.

See Figure 5. Separate the exhaust fan housing and the converter box. □ Loosen the five 5/16" screws that join the exhaust fan and the exhaust fan cleanout box and

separate the two. □ Remove the two 11/32" nuts that hold sensor and bracket - carefully set the sensor aside. □ On the replacement fan, remove the two corresponding 11/32" nuts. See Figure 4. Install the

sensor on the replacement fan - tighten the two nuts. □ Remove as much of the old silicone as possible from the converter box. □ Put new silicone on the converter box. □ Slide the converter box and the new exhaust fan together. See Figure 4. □ Install the four screws holding the joint together. See Figure 5. □ Add more silicone over the joint. □ Connect the exhaust fan / converter box and the exhaust fan cleanout box with the five 5/16"

screws removed earlier. See Figure 4. □ Clean the area on the exhaust manifold and the exhaust tube that mate together. □ Put the assembly back into the stove. □ Run the wires over to the main control board. □ Install the exhaust tube onto the exhaust manifold (using a new exhaust tube flange gasket)

with the two 5/32" Allen bolts removed earlier. □ Plug the exhaust fan into the main control board. See Figures 1. □ Plug the exhaust fan tach into the main control board. See Figure 1. □ Replace the thermocouple in the exhaust fan clean out box. □ AFTER the thermocouple is inserted, put a dab of silicone around it as shown in Figure 2. □ Insert and tighten the screw holding the thermocouple. □ Add cable ties to bundle and secure the wires. □ Plug the stove in. □ Test for proper operation. □ Install the right side panel.

Definition of Terms: Converter box - This is where the piping enters the stove. It is a galvanized box that separates the intake and exhaust air.

DWG NO. 4001616 Rev A 11/2007 Kit 4001608

Exhaust Fan Sensor J12

Exhaust Fan J18

Figure 1

DWG NO. 4001616 Rev A 11/2007 Kit 4001608

Figure 2

Thermocouple

Silicone

5/32" Allen screw Figure 3

DWG NO. 4001616 Rev A 11/2007 Kit 4001608

Figure 4

5/16"

11/32" Nuts

Figure 5

4 5/16" screws holding the converter box & fan together

DWG NO. 4001616 Rev A 11/2007 Kit 4001608

Replacing the Air Pump UBB

Reasons for replacing the air pump:

• Air pump has stopped working. • Air pump has a low output

Tools needed to change the air pump:

• 5/16" socket, ratchet and short extension or a 5/16" nut driver • Phillips screw driver

Changing the air pump: o Unplug the stove. o Remove the left side panel. o Unplug the pump from the main control board. See Figures 3. o Remove the Igniter hoses from air pump. o Remove the 3 wing nuts holding the pump to the bottom plate. See Figure 2. o Remove the old pump. o Remove the ground wire from the pump. o Attach the ground wire to the new pump. o Install the filter on the pump. See Figure 1. o Install the new pump unto the bottom plate. o Install and tighten the 3 wing nuts. See Figure 2 o Plug the pump into the main control board. o Attach the two output hoses to the pump. o Plug in the stove. o Test for proper operation. o Install the left side panel.

Figure 1

Figure 2

P/N 4001658 Rev A 10/2007 Kit P/N 4001640

J17

Figure 3

P/N 4001658 Rev A 10/2007 Kit P/N 4001640

Replacing the Convection Fan UBB


• Philips screw driver • 5/16” wrench or 5/16” ratchet with 5/16” socket • 6mm wrench or 1/4”ratchet with 6mm socket • Side cutters • Cable ties

Replacing the convection fan:

□ Unplug the stove. □ Remove the left and right side panels. □ Unplug the convection fan connector J19 on the main control board. See Figure 1. □ Cut the cable tie that holds the wires. □ Remove the three thumb screws holding the main control board bracket and lean the

bracket / main control board towards the rear of the stove. □ Remove the wing nut and convection fan ground wire connected to the stove frame. See

Figure 2. □ Remove the four 5/16” screws that hold the convection fan housing on to the bottom of the

hopper. See Figure 4. □ Remove the convection fan housing from the stove. □ Remove the six 5/16" screws that hold the convection fan cover on. See Figure 3. □ Remove the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the

convection fan housing. See Figure 4. □ Lift the fan out. □ Place the new fan in the housing. □ Install the four (M4-0.7 x 6mm HH metric) screws that hold the convection fan to the

housing. See Figure 4. □ Install the six 5/16" screws that hold the convection fan cover on (Figure 3). □ Place the convection fan housing back into stove. □ Install the four 5/16” screws that hold the convection fan to the bottom of the hopper. □ Install and tighten the three thumb screws that hold the main control board bracket. □ Plug the fan back into J19 on the main control board. See Figure 1. □ Connect the ground wire and replace the wing nut. □ Bundle wires with cable ties. □ Plug in the stove. □ Check for proper operation. □ Install the left and the right side panels.



DWG. NO. 4001674 Rev B 11/2007 Kit 4001666

Figure 1

J19

Figure 2

Ground W

ire

DWG. NO. 4001674 Rev B 11/2007 Kit 4001666

Figure 3

Six 5/16" screw

s

Figure 4

4- 5/16" screw

s

M4-0.7x6m

m

screws

DWG. NO. 4001674 Rev B 11/2007 Kit 4001666

Adding the 110 Corn/Pellet Conversion Switch Adding the Switch and Wires to the Stove

• From Fig. 1, loosen the two (2) screws as shown in fig.2 – DO NOT REMOVE. • Slide the new Switch Assembly between the Terminal Block and the back plate. • Tighten the two (2) screws as shown in Fig.2. The Switch Assembly in now

mounted. • You will be installing the two (2) wires into the plug as shown in Fig 1 (J11). • Carefully insert the wires as shown in fig. 4 into the slots as shown in Fig. 3. • Push the wires into the slots ALL the way in until you feel a small click. • The two (2) wires should now look like those in fig.5 • You are now done with the conversion. • Turn the switch to either Corn or Pellets for the fuel you are using. • Plug the stove in. • Test for proper operation

Tools needed to add the switch: Phillips screwdriver Straight blade screwdriver

P/N 4001814_I-A 9/2007

Figure 1

Figure 2

Figure 3

Figure 4

J11

Figure 5

P/N 4001814_I-A 9/2007

Replacing the Converter Box

Tools needed to replace the Converter Box Side cutter 5/16" wrench Ratchet and 3/8" socket Utility Knife


• Remove the right side panel.


• Unplug the Exhaust Fan from J13 on the Mother Board (Figure 2).

• Unplug the Exhaust Fan Tachometer from J10 on the Mother Board (Figure 2).

• Cut all cable ties holding Exhaust Fan wires.

• Loosen the upper intake hose clamp on the Converter Box and remove the

hose (Figure 2-A).

• Remove the four 5/16" bolts that hold the Exhaust Fan onto the Exhaust

Manifold (Figure 2-B).

• Remove the four bolts that hold the Converter Box to the stove frame. You will

need a 5/16" wrench and a 3/8" socket. (Figure 1-C)

• Loosen the hose clamp and remove the top hose on the far side of the

Converter Box (Figure 1-E).

• Remove the gasket between the Exhaust Manifold and Exhaust Fan (Fig 1-G).

• Move the back of the assembly out a few inches and remove the last intake

hose on the far side of the Converter Box.

• Remove the whole assembly.

• Remove the four 5/16" screws that join the Converter Box and the black

Exhaust Fan (Figure 1-D).

• Separate the Converter Box from the Exhaust Fan assembly.

P/N 4001856 Rev A 10/2007 Kit_4001848

• Remove as much of the old silicone as possible.

• Put a 1/4" bead of 600° silicone just inside the front of the Converter Box where

it mates to the Exhaust Fan housing (Figure 3).

• Slide the Exhaust Fan housing and the Converter Box together.

• Install the four screws that hold them together (Figure 1-D).

• Add more silicone to the joint (smoothing it with a wet finger) to ensure a good

seal.

• Route wires over near the mother board.

• Put the assembly back into stove.

• Connect the lower intake hose and tighten the hose clamp (Figure 1-E).

• Connect the upper intake hose and tighten the hose clamp (Figure 1-E).

• Install a new Exhaust Manifold gasket (included in the kit) (Figure 1-G).

• Install the four bolts between the Exhaust Manifold and the Exhaust Fan

housing (Figure 1-B).

• Tighten all four bolts

• Install the four screws that hold the Converter Box to the stove frame (Fig 1-C).

• Tighten the bolts on the back of the Converter Box.

• Attach the upper intake hose and tighten the hose clamp (Figure 1-A).

• Plug the Exhaust Fan into J13 and Exhaust Fan tachometer into J10 on the

mother board (Figure 2).

• Secure wires with the supplied cable ties.

• Allow 24 hours for the silicone to set.

• Plug the stove in and test for proper operation.

• Replace left and right side panels.

P/N 4001856 Rev A 10/2007 Kit_4001848

Figure 1

A

D

C

B

G

E

P/N 4001856 Rev A 10/2007 Kit_4001848

600º Silicone

Figure 3

Figure 2

J10

J13

P/N 4001856 Rev A 10/2007 Kit_4001848

Repair KIt Instructions Bixby Energy Systems

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