Rebuilding a USSC 6041....

[cooljjay]

So I seen a stove at the local salvage yard the other day, and stopped in the next day. It was a pellet stove, with stove pipe and I asked about it. No one knew why it was there, if anything was wrong with it and the price was .25 cents a pound @ 250lbs! I was going to walk away but did a quick search and seen they retailed at 2k. So I said I would take it, expecting it just to be a bad part, cleaning needed etc...Something simple to fix...

Well I got it home, plugged it in while in the trunk of the car and no power! Read the manual and it said there were fuses, okay possible an easy fix...

I got it out, to discover.....Someone robbed all the fans, including the duct! Cut the fan wire too!

Yes there was three blown fuses....

I replaced the fuses, and the board powered up with the err8 code, telling me a bad blower....well duh, there is no blower lol

So I am thinking of rebuilding it....thoughts???

Also wondering if anyone has a stack of used parts for the missing items???

Another question is, is there any good way to test the circuit board, with out all the components of the stove? I know technically if I have to buy all the missing parts n circuit board I would still be below the cost of a new one...Issue is I just don't have that wad of money to toss at it but I really need a source of heat..

 

[Mt Bob]

My recommendation is take it back to scrapyard.

 

[bill3rail]

My recommendation is take it back to scrapyard.

^^This^^, unless you find a bunch of used parts too fill the gaps.

Although, $62.50 is a great price... If you have the time to search for cheap used parts.

Bill

 

[cooljjay]

I'm hard headed and will probably hang on to it. I may get lucky and find the MIA parts on ebay or there has to be at least 70$ worth of parts left that I could get the invest back in if I don't score the parts over the summer for next winter.

Been reading the forum, see all the issues with the stove ad understand the feeling on scrapping it "again"

 

[tlc1976]

I agree, you could rebuild it with new mechanicals for less than 2k, but sounds like you don't have the $$$ for that.

At least here I see plenty of used working stoves on craigslist for $400 and up, some even have the floor mat and the pipe. That's what I would do. Unless you've got a previous installation, the cost of those can be pretty significant.

And if you need the money now, I'd take the one you have and list it for enough to make it worth your while, and maybe someone else might want it to rebuild it as new, or strip it and then scrap it themselves. Otherwise if you've got the room, just keep it and see what you happen to find, the thrill of the hunt and the accomplishment is worth something too.

 

[cooljjay]

I agree, you could rebuild it with new mechanicals for less than 2k, but sounds like you don't have the $$$ for that.

At least here I see plenty of used working stoves on craigslist for $400 and up, some even have the floor mat and the pipe. That's what I would do. Unless you've got a previous installation, the cost of those can be pretty significant.

And if you need the money now, I'd take the one you have and list it for enough to make it worth your while, and maybe someone else might want it to rebuild it as new, or strip it and then scrap it themselves. Otherwise if you've got the room, just keep it and see what you happen to find, the thrill of the hunt and the accomplishment is worth something too.

Yeah my thought was to just toss money at a part, when I have it, kinda like a payment plan lol

Here they don't come up often, I seen one rusty as all heck for 600$! when I tell neighbors I want to get a pellet stove, they are all like whats that? Here it seems to be all about wood stoves, but I don't have a forest out my back yard to cut and for cut n season wood its expensive around here. I was also pondering if I bought a used one, that hasn't seen maintenance, and in one winter I may be tossing out just as much into it as it would cost to rebuild this one. At least with this one, I would know what is new and what isn't..

Oh I got the room! I bought a church n parsonage, so there is plenty of room, thought that project also needs about as much work as this lol

It really is a big conundrum and for person who likes to fix things, the hunt n challenge is accepted lol

 

[FirepotPete]

Been reading the forum, see all the issues with the stove ad understand the feeling on scrapping it "again"

From what I've seen over the years, most people that have trouble running this stove or the previous 6039 would have problems with just about any stove. I'm on my 11th year running a 6039, almost the same exact stove as the 6041. I think most people think you just plug in and you get instant, no work heat from a pellet burner, they are wrong, I don't care what brand you buy, they take some love and will in turn return it in nice constant heat for many years if taken care of.

I've had to make a fake fire board for it, the original cracked after two years. Had the control board go out, not under warranty at the time but USSC still replaced it after having the stove for 3 years.

I've had to replace the door gasket a couple of times, not unusual for any stove and last year I replaced the glass on the door as it had a hairline crack that started in the middle and probably would have been fine for a couple more years.

You can find most parts for this stove from third party sellers. Grainger would be a good start for the fans/motors. If the control board is good then I would try and fix it up. Is the fire board in it good? If not they are easy to make and much cheaper than buying one.

I also see that the pipe that runs from the fire box for the fresh air kit (FAK) is missing. You will want to replace that so you can hook up the FAK.

Is the auger in it? Is the firepot in it? Is the agitator in it? Glass in it OK? If so I'd go for it. Let us know what you decide, there are a few of us 6039/6041 owners here and willing to help, just ask.

 

[cooljjay]

From what I've seen over the years, most people that have trouble running this stove or the previous 6039 would have problems with just about any stove. I'm on my 11th year running a 6039, almost the same exact stove as the 6041. I think most people think you just plug in and you get instant, no work heat from a pellet burner, they are wrong, I don't care what brand you buy, they take some love and will in turn return it in nice constant heat for many years if taken care of.

I've had to make a fake fire board for it, the original cracked after two years. Had the control board go out, not under warranty at the time but USSC still replaced it after having the stove for 3 years.

I've had to replace the door gasket a couple of times, not unusual for any stove and last year I replaced the glass on the door as it had a hairline crack that started in the middle and probably would have been fine for a couple more years.

You can find most parts for this stove from third party sellers. Grainger would be a good start for the fans/motors. If the control board is good then I would try and fix it up. Is the fire board in it good? If not they are easy to make and much cheaper than buying one.

I also see that the pipe that runs from the fire box for the fresh air kit (FAK) is missing. You will want to replace that so you can hook up the FAK.

Is the auger in it? Is the firepot in it? Is the agitator in it? Glass in it OK? If so I'd go for it. Let us know what you decide, there are a few of us 6039/6041 owners here and willing to help, just ask.

I am right there with you! Everything needs maintenance, and just watching the youtube video, it isn't all that complicated to maintain one but if you have no idea about what they are talking about in that video, then you won't be able to use a pellet stove. I believe that is what happen with this stove, they just plugged it in and hoped to forget about it. Fuses started blowing and they had no idea what was the issue and out the door it went. Sad really.

I have noticed that, that there are a lot of aftermarket parts that will work fine in this stove at a third the cost of ussc, its just that exhaust manifold that the exhaust fan hooks to that I may have to order from them. I read there is a 68$ fan that is identical to the one they charge near 300$ for.

Looking at the schematics/diagrams, I don't think there was ever a fresh air pipe on this model. I'll have to look again and see, but even in the video, I didn't see one.

Here's a few more pics, all looks to be there but dirty. It looks like the stove wasn't burning correctly and there is a bunch of ash in it, again looks like the last owner never got a copy of the manual.

 

[Lake Girl]

You'll have to get the caps for the holes in the firebox (each side of the pellet chute)...a small but important detail. Might want to check FirepotPete's cleaning routine noted in his sig lines.

Grainger's has been noted as a good source for replacement fans.

Keep us posted on progress...

 

[cooljjay]

You'll have to get the caps for the holes in the firebox (each side of the pellet chute)...a small but important detail. Might want to check FirepotPete's cleaning routine noted in his sig lines.

Grainger's has been noted as a good source for replacement fans.

Keep us posted on progress...

I just read that "mod" and about using a gasket on the burn pot too. I was also reading how to add an auto on n auto off and a few other cool details.....Horrible though, because now more then ever I want to get it all back together!

I'll keep you all posted! Think in a few weeks, I might be able to get one part ordered or maybe I'll get lucky and get a contact with someone with a parts stove..

 

[Mt Bob]

And you might get it all together and find other problems,like a cracked heat exchanger allowing fumes into the house.

 

[Lake Girl]

Should be able to rule that out by sealing off exhaust/cold air vent (other access points like around ignitor and airwash if it has seperate entry) and putting burning incense in the fire box.

 

[FirepotPete]

And you might get it all together and find other problems,like a cracked heat exchanger allowing fumes into the house.

Good point. I use a small inspection camera that my step-son has for inspecting auto motor blocks. I go all over in the stove in the spring and then fall. The heat exchanger on top, behind the firebox wall and the side heat exchangers. He should be able to get one at an auto parts store to rent pretty cheap. Or if he has a friend that has one, borrow it for a day. Time well spent before rebuilding the stove and easy enough.

And you might get it all together and find other problems,like a cracked heat exchanger allowing fumes into the house.

 

[Mt Bob]

Good point. I use a small inspection camera that my step-son has for inspecting auto motor blocks. I go all over in the stove in the spring and then fall. The heat exchanger on top, behind the firebox wall and the side heat exchangers. He should be able to get one at an auto parts store to rent pretty cheap. Or if he has a friend that has one, borrow it for a day. Time well spent before rebuilding the stove and easy enough.

I have this one,except it says ac/delco,costs twice as much,is same camera. http://www.harborfreight.com/digital-inspection-camera-61839.html

 

[cooljjay]

Should be able to rule that out by sealing off exhaust/cold air vent (other access points like around ignitor and airwash if it has seperate entry) and putting burning incense in the fire box.

I'll have to try that! I did notice a crack, on the upper right corner of the opening of the stove, you can kinda see my figure wipe mark in the photo and I couldn't figure out that one. Figure the door when closed would seal over it.

It seems odd though, if there was an internal crack, that the last owner would only salvage the blowers from the stove and not more parts...

 

[FirepotPete]

I have this one,except it says ac/delco,costs twice as much,is same camera. http://www.harborfreight.com/digital-inspection-camera-61839.html

Yup, very handy to have. I even used it two years ago. We had a leak on our roof coming down into the living room, two story, drove us and two roofing contractors nuts for a couple of years. Finally crawled up on the roof by the dormer where I thought the leak was and stuck that camera in a crack I made. Found where the water was getting in and fix it and haven't had any problems since.

 

[FirepotPete]

I'll have to try that! I did notice a crack, on the upper right corner of the opening of the stove, you can kinda see my figure wipe mark in the photo and I couldn't figure out that one. Figure the door when closed would seal over it.

It seems odd though, if there was an internal crack, that the last owner would only salvage the blowers from the stove and not more parts...

I see that. Run your finger up under that area, you will find a lip there. I bet the previous owner didn't clean that area good and ash built up, insulated that little area and when the rest of that area of the stove heated up it cracked. You should be able to weld that crack as the really isn't anything related to the heat exchanger there. You will want to put a good straight edge on the face of the stove to make sure it didn't warp it, also check the door for warp.

 

[cooljjay]

Well that was kinda upsetting, though expected. I stop by the salvage place, and asked who brought this in? His words were I don't know, it probably came from the rail yard but I just don't know. I followed with, its missing like 400$ worth of parts, he was oh well! Really? I then said I wasn't expecting it to be missing the parts, and I was hoping to find them again. He repeat with I don't know who brought it in and you can ask the guys outside but quickly noticed what he said and went back to I don't know where it came from. I then asked do you have any other pellet stoves that were brought in, he said no that is all we have gotten like that. I then walked out the door, my buddy turns to me and says...he knows where the parts went! I was like yeah I know he does...

Well I will stay on the hunt for parts, and maybe they'll show in one of the dozen places I am following/posting...

 

[cooljjay]

I see that. Run your finger up under that area, you will find a lip there. I bet the previous owner didn't clean that area good and ash built up, insulated that little area and when the rest of that area of the stove heated up it cracked. You should be able to weld that crack as the really isn't anything related to the heat exchanger there. You will want to put a good straight edge on the face of the stove to make sure it didn't warp it, also check the door for warp.

I'll have to do that, when ever I get to the point, I am glad it can be easily welded. I will have to check that ledge! I know I pulled the two sliders up in the fire box area and there was tons of ash in there, imagine the ride here, loosened up a bunch of stuff that was never cleaned out...

Its sad really, that these stoves just need to be kept cleaning to keep working and they honestly don't seem that hard to clean but yet no one seems to be able to keep them clean. Shesh that is how I always got my vacuum cleaner lol they were always plugged the heck up with crap..

 

[Lake Girl]

I then walked out the door, my buddy turns to me and says...he knows where the parts went! I was like yeah I know he does...

He's likely got the parts as spares for the pellet stove at his house He beat you to the good stuff!

 

[cooljjay]

He's likely got the parts as spares for the pellet stove at his house He beat you to the good stuff!

Ha read my mind! At least he could have done was left me the exhaust duct lol

I wish I had the cash, just found a 6039 with a bad auger for 300$ though its almost three hours away...I'll keep an eye on it, maybe they'll opt to let it go for cheaper...

 

[Lake Girl]

Might be worth the $300 ... exhaust duct on the 6041 goes for around $170. Then add the missing fans and whatever else... Are parts compatible between the 6039 and 6041?

 

[alternativeheat]

You remind me of my stepson, but I'm glad at least he has his own yard now for all the crap he brings home for next to nothing. Good luck with your "project stove", if you're anything like Scott that stove will run LOL!

 

[FirepotPete]

Are parts compatible between the 6039 and 6041?

Yes. No. Maybe. Sometimes.

The auger twist ratio is different and I believe the 6041 is shorter as they have a different angle from the fuel hopper.

The fuel pot for a 6039 won't work without drilling out a hole for the ignitor that the 6039 didn't have. But, having said that I once saw a USSC stove that was identified as a 6041, name plate and all documentation that came with it. It had the square fuel chute like all other 6041's but no ignitor, and the firepot was the same as a 6039.

In some cases you might find a different make of low/high limit switch, no problem they will work, also the vacuum switch might be a different make, again not a problem. I think they just went with whatever could be sourced and met specs.

The fake firebrick will fit from one to another but you need to mod it for either a square auger hole or a round one.

Edited to add. The gear box for the auger motors are a different ratio also. I don't consider that a problem though because you can adjust the fuel feed by pounds per hour in each heat range.

 

[Lake Girl]

Yes. No. Maybe. Sometimes.

Well that's decisive Thanks for the explanation...