background image

Shell Parts - Defiant Encore Model #0028 / 2140

Part Name

Classic

Red

Sand

Blue

Midn't

Ant Grn

Ant Brn

Gray

(130)

(131)

(132)

(133)

(134)

(138)

(139)

(136)

Flue Collar

1304280

2324280*

1324280

1334280

1344280

N/A

N/A

N/A

Ash Lip

1307406

2327406*

1327406

1337406

1347406

N/A

N/A

N/A

Leg

1307427

1317427

1327427

1337427

1347427

N/A

N/A

N/A

Front

1308612*

1318612*

1328612*

1338612*

1348612*

N/A

N/A

N/A

Left Door

1308613*

N/A

1328613*

1338613*

1348613*

N/A

N/A

N/A

Right Door

1308614*

N/A

1328614*

1338614*

1348614*

N/A

N/A

N/A

Left End

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Right End

1308619*

1318619*

1328619*

1338619*

1348619*

N/A

N/A

N/A

Top

1307405

1317405

1327405

1337405

1347405

N/A

N/A

N/A

Back

1307439

1317439

1307439*

1337439

1307439*

N/A

N/A

N/A

*Substitute for original number

PACKED INSIDE THE STOVE 

500-7300

Parts Bag

500-4022 Griddle Handle Complete

160-0658  Griddle Handle Stub Only
160-0661  Griddle Handle Wooden Knob Only
120-1900  Griddle Bushing (2 Used)
120-1308  8-32 x 1" Phillips Pan Head Screw
120-3210  1/4-so Plain Hex Nut

160-0600 Holder, Door Fallaway Handle
120-5116 Allen Wrench, 1/8” Short Arm
120-5147 Allen Wrench, 5/32” Short Arm
120-2061 #10 x ¾” Black Phillips Pan Head Sheet Metal Screw

000-4342

Complete Handle Package

160-0660

Thermostat Wooden Knob

120-1243

Thermostat Screw 8-32 x 2"

2000913

Encore 0028/2140 Manual

GASKETS

120-3588

5/16” Medium Density 6ND Gasket

4’

Left Door

3'

Right Door

3.5’

Damper Housing for Damper

3'

Upper Fireback

1.4'

Lower Fireback

4’

Ashdrop

3.5'

Catalytic Access Panel

5'

Back

120-3668

5/16”  Gasket Wire Fiberglass with Core

4’

Top for Griddle

120-3537

Interam Gasket 9" Long

1

Bottom of Each Glass

120-6115

Kaowool 3/4" x 7"

6

Lwr Fireback, Ref Package

120-3591

5/16” Adhesive Backed Gasket

3.25’

Flue Collar

120-3589

3/8" Low Density 6ND Fiberglass

3.5'

Ashdoor

120-3518

Pre-formed Gasket

1

Primary Air Frame

120-3556*

3/16" 4ND Black Fiberglass Gasket   

3'

Each Glass Panel

*000-3427 kit contains enough gasket and cement to gasket all glass with rope gasket

ACCESSORIES

Heat Shields

160-1755 1 ¼” Spacer Used On Bottom & Rear 

140-2252 Ashdoor Heatshield

000-5834 Spacer Hardware Kit – Set of 4-160-1755

120-1780 Ashdoor Heatshield Spacer

000-5925  Internal Rebuild Kit 

             Complete interior rebuild comes with lower fireback, upper fireback assembly, kawool,
             refractory assembly,heat exchanger, cement, hardware, gaskets & instructions.

Warming Shelf

130-2221 Left Bracket

130-2222 Right Bracket

160-1705 Mittenrack

500-7234 Hardware Package

Part Name

Classic

Old Red

Sand

Blue

Midnt

Ant Grn

Ant Brn

Gray

Shelf

1302208

1312208

1322208

1332208

1342208

N/A

N/A

N/A

Dagon Bracket

1302220

1312220

1322220

1332220

1342220

N/A

N/A

N/A

Summary of Contents for Deviant Encore 0028

Page 1: ...F o r t h e V e r m o n t C a s t i n g s Defiant Encore Models 0028 2140 F o r t h e V e r m o n t C a s t i n g s Defiant Encore Models 0028 2140...

Page 2: ...dary air valve flap was modified in December of 1986 to accept a pop rivet which acts as a valve stop or limiter to prevent the valve from hanging below its intended position and eliminate vibration o...

Page 3: ...ts Illustrations 2 Parts List 3 Drill and Tap Illustrations 4 Drill and Tap Guide 5 Individual Part Replacement Repair Procedures 6 Complete Disassembly Procedure 7 Complete Gasketing Procedure 8 Comp...

Page 4: ......

Page 5: ...5471 Primary Air Cable c w 2 Sleeves 64 160 1490 Secondary Air Flap 18 130 8609 Primary Air Cover Plate rep 130 7418 65 120 1986 Secondary Air Shim Ring 19 See Chart Front 66 160 1486 Secondary Air Li...

Page 6: ......

Page 7: ...ps Pan Head Screw 20 120 2560 Washer Narrow 21 120 0334 7 16 20 x 1 Socket Set Screw 22 120 1392 20 x 2 Zinc Hex Head Cap Screw Gr 2 23 120 1376 20 x 1 Hex Head Cap Screw 24 120 1326 20 x 1 Black Hex...

Page 8: ...660 Thermostat Wooden Knob 120 1243 Thermostat Screw 8 32 x 2 2000913 Encore 0028 2140 Manual GASKETS 120 3588 5 16 Medium Density 6ND Gasket 4 Left Door 3 Right Door 3 5 Damper Housing for Damper 3 U...

Page 9: ...G 13 64 5 8 1 4 20 Bottoming H 13 64 3 8 1 4 20 Bottoming I 13 64 7 16 1 4 20 Bottoming J 13 64 11 16 1 4 20 Bottoming K 13 64 27 32 1 4 20 Bottoming L 13 64 3 4 1 4 20 Bottoming M 3 16 Thru N 5 16 Th...

Page 10: ......

Page 11: ......

Page 12: ......

Page 13: ......

Page 14: ......

Page 15: ......

Page 16: ......

Page 17: ......

Page 18: ...before re cementing or re gasketing If the cleaning process is not thorough proper alignment and a complete seal will be impossible to achieve Replacing the Primary Air Valve to Thermostat Cable Tool...

Page 19: ...to the griddle opening and watch fir the end of the fishing tool to pass the thermostat pocket When the end of the cable fishing tool becomes visible stop moving the tool and reach through the thermos...

Page 20: ...ull the damper handle rod from its drilling in the left stove end and the forward drilling in the actuator link with the other hand Do not drop the 3 8 flat washer between the stove end and the air we...

Page 21: ...wear plate Tap the chisel end of the pry bar with the ball peen hammer until fireback starts to separate from the lower fireback Pull down on the pry bar until the cement holding the upper fireback to...

Page 22: ...ractory Assembly Tools Required 7 16 Combination Wrench box open Cold Chisel Hammer Ball Peen 12 oz Caulking Gun Frame Thermocement 11 oz tube Masking Tape Tape Measure 6 Shears 10 12 Safety Goggles S...

Page 23: ...uctions Fill the stove back cement channel in the stove bottom with thermocement STEP 9 Place the refractory package into the stove back Place the right and left heat deflectors into their proper posi...

Page 24: ...not remove the left door Strip the old gasket from its groove and clean the groove thoroughly with the wire brush Apply an unbroken bead of gasket cement in the bottom of the groove Cut a 4 length of...

Page 25: ...x key Allen wrench 1 8 1 Hex key Allen wrench 5 32 1 Hex key Allen wrench 3 16 1 Hex key Allen wrench 7 32 1 Drop light A C 40 60 watt 15 25 cord 1 Pail electricians side cutting pliers 6 1 Putty knif...

Page 26: ...ews and 4 each flat washers right and left inside rear and 1 each 20 x 3 4 Phillips flat head machine screw centre front under the griddle handle indent Strike the top upward with the rubber mallet to...

Page 27: ...a safe area until you are ready to examine and clean it STEP 14 Disconnect the thermostat cable at the primary air valve outer rear of the stove bottom Loosen the Allen set screw and snip off the cabl...

Page 28: ...and left joints and remove the front with the air manifold and andirons attached STEP 18 Remove the right end 1 each 20 x hex head cap screw and 1 each flat washer located at the centre of the inside...

Page 29: ...the andirons 1 each 20 x hex head cap screw and 1 each flat washer per andiron STEP 25 Remove the two piece half hinge from the ash drop 3 each 20 x hex head cap screws and 3 each flat washers Take th...

Page 30: ...lap 1 each 10 24 x Phillips pan head machine screw and 1 each shim ring Remove the secondary air link from the air flap Remove the secondary air probe 1 each 10 24 x Phillips pan head machine screw Se...

Page 31: ...en crushed or badly deformed Remove the hinge boss from the door frame 3 each 20 x hex head leveler bolts and 3 each flat washers Inspect the hinge pins If the pins are broken or severely bent drive t...

Page 32: ...ement part 120 6122 place an unbroken 1 8 bead of gasket cement in the channel or groove to be gasketed STEP 6 Starting with one end press the gasket into the cemented channel or groove If the gasket...

Page 33: ...opening one place 4 Armaseal 5 16 diameter cored part 120 3668 Ash Drop Fig 2 Ash drop to bottom seal one piece both sides and back 4 Thermocord 5 16 diameter 6 needle part 120 3588 Lower Fireback Fi...

Page 34: ...seal 1 piece 4 thermocord 3 8 diameter 4 needle part 120 3589 Damper Fig 6 Complete damper to upper fireback seal 1 piece 3 5 thermocord 5 16 diameter 6 needle part 120 3588 Back Fig 7 Stove back to e...

Page 35: ...6 thermocord 5 16 diameter 6 needle part 120 3588 Right Door Fig 10 Right door to stove front seal 1 piece 3 thermocord 5 16 diameter 6 needle part 120 3588 Left Door Fig 11 Left door to stove front...

Page 36: ...cushioning between the outer glass pane and the castings in addition to a seal 1 piece 3 2 thermocord 3 16 diameter part 120 3556 part of Gasket Kit 000 3427 G a s k e t 3 p r o v i d e s Gasket 3 pro...

Page 37: ...ottom upside down on a flat surface Install 4 each hex head leveler bolts 20x1 in the 4 stove legs finger tight Install the 4 legs on the stove bottom using 4 each hex head bolts 3 8 16x1 and 4 each s...

Page 38: ...rn the assembly over and install the socket head cap adjusting screw 20 x 3 8 in the centre of the air valve finger tight Fig A 1 Primary Air Regulatory System Assembled STEP 6 Install the primary air...

Page 39: ...ith 1 each hex head cap screw 20 x 1 and 1 each hex lock nut 20 centre bottom of the stove front Fig C 3 Bottom with Air Tube Cover Fig C 4 Front Plate in Place STEP 10 Cement all mating surfaces on t...

Page 40: ...e bottom push the back against its mating surfaces on the right and left stove ends aligning drillings in the stove back with their corresponding tapped holes in the stove ends If alignment cannot be...

Page 41: ...ove in an upright position Thread the primary air system cable through the hole in the centre of the thermostat pocket of the wear plate see Figure A 3 Insert the front mating surface of the right air...

Page 42: ...n the vertical ribs on the inside of the stove back Make sure that the kaowool in the bottom of the stove back provides a good seal between the bottom of the stove back and the combustion package asse...

Page 43: ...ange of movement insuring that all the slack is out of the cable and that the cable is responding to the movement of the thermostat handle without catching or binding With the thermostat handle in the...

Page 44: ...new damper tab and 1 each hex head cap screw 20x Secure the torsion bar to the upper fireback with 1 each torsion bar clip and 1 each hex head cap screw 20x and 1 each standard flat washer Operate the...

Page 45: ...is deficiency by first insuring tight and proper assembly If the deficiency persists consider replacement of the tabs clip torsion bar actuator link and or the damper handle rod STEP 28 Install the da...

Page 46: ...ap moves up and down freely and that the flap rests at or near the closed position See figure A 8 Fig A 8 Positioning of Secondary Air Probe Flap STEP 32 Install the secondary air cover plate Secure w...

Page 47: ...ck the gasket area of the door to insure that the gasket mates evenly all the way around the door with the front edge of the ash drop and front lip of the stove bottom Adjust the door by tapping side...

Page 48: ...s Secure with 2 each hex head cap screws 20x stainless steel and 2 each stainless steel flat washers STEP 38 Assemble the doors At this point in time the doors should have been completely disassembled...

Page 49: ...sh the stove down especially the outside seams and joints Remove all visible dirt and thermocement Mask the damper handle stub and thermostat handle with masking tape Cover the secondary air system co...

Page 50: ...oor and either file or grind the handle face of the tab at an angle see Fig A 11 a little at a time until a tight latch is obtained If when latched the door handle is not in the vertical position remo...

Page 51: ...underside of the griddle and secure with 2 each hex head cap screws 20x Install the griddle handle assembly and secure with 1 each hex nut 10 24 and 1 each 10 washer Install the griddle on the stove...

Page 52: ...SUGGESTED FIX FOR BENT DAMPER CLIPS ENCORE 0028 2140 DIAGRAM PART QUANTITY DESCRIPTION KEY NUMBER A 160 1036 1 Torsion Bar Clip B 120 2474 2 Flat Washer C 120 1310 2 20 Plain Nut D 120 0446 1 20 x 1...

Page 53: ...e rust and repaint any heat shields or chimney connectors INSPECT THE CATALYTIC COMBUSTOR Fly ash can accumulate on top of the combustor If sufficient quantity accumulates it can block the flow of gas...

Page 54: ...condary air flap up to the open position with your finger and place a vacuum nozzle at the opening Replace the cover CHECK THE GASKET SEALS ON THE DAMPER AND ASH PAN DOOR In addition to the gaskets on...

Page 55: ...old gasket and clean the channel Place a thin bead of gasket cement in the channel Cut a length of gasket to size and press it into the channel Allow the cement to harden for 24 hours before firing t...

Reviews: