Blaze King

• King 40

• Install Instructions PDF for Blaze King S.CAT40

If the combustor needs replacing, discontinue use of the appliance until the new combustor has been installed!

1.) First, remove the flame shield by simply lifting the shield off of the two tabs (Pay particular attention to orientation as there is a top and bottom edge to the flame shield) Note: The stove's fire must be out for at least 12 hours prior to the removal process. A combustor can reach 1400°F and hold high temperatures for several hours even after the fire is out.

2.) Once you remove the flame shield, you’ll find the combustor.

3.) The combustor has a metal tab across the bottom and on each side. Using a flat blade screwdriver or pocketknife blade, slide the blade behind the metal tab and the heavy steel dome of the stove (The dome is the housing that surrounds the combustor).

4.) Apply slight pressure until the combustor begins to move forward, about 1/4”. Repeat the process on the opposite tab (Continue working back and forth until the combustor is worked free of the dome housing). It is normal for the gasket surrounding the metal band to fall apart during this process. It will need to be replaced).

5.) Now that the combustor has been removed, you’ll be able to see one stainless bypass retainer on each side (These can remain in place and do not need to be removed. The clips are not fixed in position and can fall into the firebox. Make sure they are in position before replacing the combustor).

6.) Using the same screwdriver or pocketknife, scrape any old gasket from the surface areas of the dome (It is a good idea to have a spare combustor gasket on hand prior to performing any maintenance).

7.) Some combustors will ship with the gasket preinstalled. On others, the gasket will need to be attached (Note: If you’re installing a gasket it must wrap around the combustor as shown in the picture. Also, use 1” masking tape around the perimeter front and rear. During the first fire the masking tape will burn off and the combustor gasket will swell providing a tight seal).

8.) Slowly push the combustor into place. Apply even pressure to the left and right corners (Rember to position the tab across the bottom edge of the combustor. Do not force the combustor into the dome. Take your time and work it into place slowly).

9.) Once the combustor is installed completely so that all three tabs at touching the face of the dome reinstall the flame shield (Note: The brackets welded to the back flame shield are shaped like a triangle. The point of the triangle should face down when installed correctly. Never operate your stove without the flame shield in place).

10.) The flame shield will rest on the two tabs located on the dome guard and lean slightly forward.

11.) Now that your combustor has been installed you can relight your stove!

Click here to view: Blaze King's Catalytic Combustor Replacement Guide

Catalytic Combustor Troubleshooting-

PROBLEM - CREOSOTE PLUGGING:

Possible Cause: Burning materials that produce a lot of char and fly ash. Solution: Do not burn materials such as garbage, gift wrap, or cardboard. Possible Cause: Burning wet, pitchy woods or burning large loads of small-diameter wood with the combustor in the operating position without the thermostat needle in the active zone. Solution: Burn dry, seasoned wood, don’t engage the bypass until the temperatures are high enough to initiate light-off (indicated by the thermostat needle in the active zone). Possible Cause: Combustor not functioning. If proper burning procedures have been followed to no avail, the combustor is not functioning. Solution: Replace the combustor.

PROBLEM - CATALYST PEELING:

Possible Cause: Extreme temperatures (above 1800°F, or 1000°C.) at the combustor surface can cause the catalysts to peel. Overfiring and flame impingement on the combustor are primary causes. Minor peeling is normal and does not affect function. Severe peeling shows that are closed or plugged. Solution: Avoid extreme temperatures and flame impingement. If peeling is severe, remove and replace the combustor.

PROBLEM - CATALYST DEACTIVATION:

Possible Cause: Burning large quantities of trash, pressure-treated lumber, or painted wood. Solution: Burn quality woods available in your area. If you decide the catalyst has been deactivated, replace the combustor.

PROBLEM - CATALYST MASKING:

(The catalyst is coated with a layer of fly-ash or soot which prevents catalytic activity) Possible Cause: Accumulation of fly-ash Solution: Brush the cooled combustor with a soft-bristled brush or vacuum lightly at least once per burning season.

PROBLEM - THERMAL CRACKING:

Possible Cause: Normal operation, as long as the combustor remains intact. Solution: If cracking causes large pieces to fall out, replace the combustor.

PROBLEM - MECHANICAL CRACKING:

Possible Cause: Mishandling, abuse, or operating without a properly gasket-sealed combustor. Solution: Handle with care Possible Cause: Distortion of the holding collar. Solution: Combustor should be held firmly in its can. It should slide easily into and out of the holding collar of the stove. If severe cracking has resulted in the loss of large chunks of the combustor, replace the combustor. Also, replace any warped stove parts.

PROBLEM - CRUMBLING:

Possible Cause: Air leaks Solution: Inspect door gasket, see “MAINTENANCE” in the stove's manual. Possible Cause: High draft Solution: Maintain draft to manufactured specifications. 

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