SERVICE MANUAL
Contents
1. Hex Head Cap Screw Washer Zinc 14 Flat Ya 20 x Ya Knl Cup Point Socket Set Screw Ya 20 Hex Nut 16 Toplock Z Hex Head Jam Nut Ya 20 x 7 Hex Head Cap Screw Ya 20 x Socket Flat Head Screw Washer Zinc 34 Flat 36 16 x 1 4 Zinc Hex Head Bolt Ya 20 x 1 Zinc Hex Head Leveler Bolt Handle Holder 36 16 x 174 Socket Head Allen Bolt Ya 20 x 2 Black Phillips Flat Head Screw Ya 20 x 7 Hex Head Leveler Bolt Pin Cotter 080 x 1 9 16 10 24 x Zinc Phillips Pan Head Screw Washer 34 Narrow 7 16 20 x 1 Socket Set Screw Ya 20 x 2 Zinc Hex Head Cap Screw Gr 2 Ya 20 x 1 Hex Head Cap Screw Ya 20 x 1 Black Hex Head Cap Screw Gr 2 or sub 120 1376 Ya 20 x 24 Phillips Flat Head Screw Washer Black Narrow Flat Ya 20 x 1 Black Phillips Round Head Screw Nut 20 Plain Square Washer 14 Flat 294 id x 620 od Stainless Steel 5 16 16 x 5 16 Socket Set Screw 8 32 x 2 Z Slot Round Head Rivet Pop dia x Grip or use 6 x 74 Round Head Screw Shim Ring 18 Ga Nickel 10 24 x 74 Phillips Pan Head Screw Ya 20 x Phillips Pan Head Screw Ya 20 x 2 Stainless Steel Hex Head Cap Screw replaced 120 1373 5 8 May 03 Ya 20 x 3 Zinc Slotted Pan Head Screw Ya 20 x 3 Zinc Slotted Pan Head Screw Glass Clip Long 75 Glass Clip Short 62 Ya 20 x 174 Hex Head Cap Screw Kawool x 7 Friction Spring Washer 14 Plain Flat Ya 20 x e2. Bottoming Bottoming Bottoming Taper DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Catalyst Access Plate outside view DEFIANT ENCORE DRILL amp TAP ILLUSTRATION Om Stove Front outside view DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Right Door inside view Left Door inside view Ash Lip bottom view eem Hinge Boss inside view Door Manifold inside view DRILL amp TAP ILLUSTRATIONS Z X e H e 4 i Griddle bottom view fs a lt ES Da mper KG gt s DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Ash Drop left inside view Ash Door inside view DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Tk CO N w o o Flue Collar top view Stove Bottom bottom view DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Primary Air Tube Cover Plate Primary Air Frame Primary Air Valve lt f il Lower Fireback Upper Fireback DEFIANT ENCORE DRILL amp TAP ILLUSTRATIONS Split Half Hinge Clevis Half Left End inside view Right End inside view Defiant Encore Individual Repair Section GENERAL The manner in which to proceed with the most repairs to this stove will be obvious to the competent mechanic Individual parts replacement and adjustment procedures are covered in the Disassembly and Assembly sections of this manual Cleanings re gasketing and or cementing pr
3. Fig 1 Fig 2 Fig 1 Ash Drop Top Griddle 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 Both sides to wear plates seal two pieces 8 each Lower Fireback Fig 3 thermocord 5 16 diameter 6 needle part 120 3588 Jilin P E Fig 4 Upper Fireback Lower Fireback Upper Fireback Fig 4 Both sides to wear plates and lower fireback seal 2 pieces 18 each thermocord 5 16 diameter 6 needle part 120 3588 Ash Door Fig 5 Complete door to ash drop seal 1 piece 4 thermocord 3 8 diameter 4 needle part 120 3589 C d m mn TI a Fig 5 Fig 6 Ash Door Damper 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 ends and top seal piece 5 thermocord 5 16 diameter 6 needle part 120 3588 Fig 7 Back Inside Fig 8 Back Outside Flue Collar Back Fig 8 Stove back flue collar seal 1 piece 3 25 5 16 diameter adhesive backed gasket part 120 3591 Catalyst Access Panel Fig 9 Catalyst access panel to stove back seal 1 piece 3 6 thermocord 5 16 diameter 6 needle part 120 3588 Fig 9 Catalyst Access Panel Fig 10 Right Door Right Door Fig 10 Right door to stove front seal 1 piece 3 thermocord 5 16 diameter 6 needle part 1
4. 1 each hex nut 10 24 and 1 each 10 washer Install the griddle on the stove and tap gently around its perimeter with a rubber mallet to seat the gasket APPENDIX 1 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 14 Plat Washer C 120 1310 2 14 20 Plain Nut D 120 0446 1 14 20 x 114 Socket SS D Upper Fireback ae Allen Key Wrench End APPENDIX 2 YEARLY MAINTENANCE SUGGESTIONS The 0028 and 2140 Defiant Encore is a sophisticated combustion machine and regular fine tuning will give you the full benefits of its operating potential GENERAL CHECKLIST Inspect the chimney for blockage such as squirrels nests branches etc Have a chimney sweep inspect and clean the chimney if necessary Inspect the connector pipe for wear and replace if necessary Make sure each length of connector pipe if single wall is joined by three screws Inspect the stove gaskets for wear using the Dollar Bill Test and replace as necessary Remove any surface 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 gases through it and cause restriction and back puffing e Remove the four Philips head fasteners which secure the cast iron panel to the rear of the stove Remove the
5. air wear plate against the right stove A 4 end at a 30 degree angle Holding the wear plate A i as close to the stove top as possible swing the A back of the wear plate against its mating surface BL back of the right stove end Tap into proper position with the rubber mallet so that the top and bottom drillings in the wear plate align with Fig C 10 Right Air Wear Plate the tapped holes in the right stove end Secure with 2 each hex head cap screws M4 20x 11 Ready to be Installed STEP 17 Insert the right and left heat deflectors in the right and left bottom corners of the stove back Cut 4 each 5 strips of 34 square kaowool Place 2 each kaowool strips side by side between the left and right pair of ribs in the bottom of the stove back see Fig A 4 Fig A 4 Kaowool amp Heat Deflector Placement STEP 18 Assemble the combustion package assembly If the refractory package and or the catalyst access panel refractory are being replaced it may be necessary to cut and fit the access panel Use the serrated edge kitchen knife and achieve a good tight all around fit Place the heat exchanger into the front opening of the refractory assembly tape in place with masking tape Insert the canned catalyst block into its opening in the rear of the refractory package honeycombs vertical Insure that the catalyst block slides over the lip of the heat exchanger and seats properly in its recess Place the catalyst acc
6. and the catalyst block access panel for breaks chips separations etc If the catalyst block refractory chamber and refractory access panel are in good condition clean them with low pressure air from your vacuum cleaner Remove the catalyst access plate from the stove back 4 each 14 20 x 5 8 Phillips round head machine screws Remove the secondary air cover plate from the stove back 2 each 14 20 x 3 8 Phillips pan head machine screws Remove the secondary air flap 1 each 10 24 x 14 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 14 Phillips pan head machine screw Separate the air link from the secondary air probe Check the air flap and air link for distortion Check the air flap and air link for distortion Check the air probe coil for breaks and or heat damage Replace any suspect parts Examine all castings for cracks chips distortions etc Remove all old gasket material from the gasket channels and mating surfaces Remove all gasket and furnace cement from channels and mating surfaces using the appropriate size punch drive pin in the channels and cold chisels on the flanges and flat mating surfaces Clean all channels and mating surfaces with a wire brush hand or power Examine all mechanical linkage parts for distortion worn or egg shaped drillings unusual wear burrs etc Repair or replace as necessary Replac
7. cement seal Lift the stove back up out of its cement groove in the stove bottom and pull the back from the stove bottom first Replace and or replace service the refractory package catalyst block heat exchanger heat deflectors and refractory cover Clean the catalyst block and refractory package with low pressure air Reassemble the refractory assembly Tape the heat exchanger catalyst block access panel and refractory cover in place with masking tape STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 Inspect the kaowool strips in the lower fireback and the bottom of the stove back If the kaowool strips are compressed below the top edge of the inside ribs of either the lower fireback or the stove back replace them The kaowool strips when in place must provide a complete seal as well as a cushion for the refractory package Clean all old furnace cement from the bottom flange of the stove back and the stove back and the stove back cement channel in the stove bottom Re gasket the stove back Refer to the gasketing section of this manual for instructions Fill the stove back cement channel in the stove bottom with thermocement Place the refractory package into the stove back Place the right and left heat deflectors into their proper positions in the stove back Install the stove back Replacing the Secondary Air Thermostat Flap and Linkage Tools Required Screwdriver Phillips 2 tip Refer to step 30 of the disassembl
8. each standard flat washers 14 An STEP 12 Cement channels and mating surfaces as indicated in Figure zz C 6 Place the right stove end firmly into its mating channel ax in the stove front swing the back of the end onto the stove bottom so that the drilling in the inside bottom flange of the i end aligns with the tapped hole in the stove bottom Secure the end to the bottom and the end to the front with 2 each hex head cap screws 14 20 x 34 and 2 standard flat CEE washers 14 Fig C 6 Right End STEP 13 Place the stove back onto its cemented channel in the stove 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 achieved loosen the cap screws securing the stove ends to the bottom and the ends to the front and tap the entire assembly into proper alignment with the rubber mallet When alignment is achieved secure the back to the stove ends with 6 each hex head cap screws 14 20 x 34 and 6 each standard flat washers 4 Retighten the cap screws securing the ends to the bottom and the ends to the stove front STEP 14 Cement channels and mating surfaces on the underside of the stove top as indicated in Figure C 8 Place the top in position on the stove front ends and back insuring that a good all around seal is achieved Use the
9. into position against the combustion package assembly aligning the drillings in the lower fireback with the tapped holes in the right and left air wear plates Secure with 2 each hex head cap screw l4 20x1 and 2 each standard flat washers 44 a ld EN 5 me m 2 5 Fig A 7 Kaowool Placement Lower Fireback STEP 24 STEP 25 STEP 26 Assemble the damper and the upper fireback Place the re gasketed damper into its mating recess in the upper fireback Insure that the damper seats properly Secure the damper shafts with 2 each new damper tabs and 2 each hex head cap screw 4 20x 2 Insert the torsion bar through its drilling in the upper fireback and swing the opposite end of the torsion bar into its recess in the centre of the damper Secure the torsion bar to the damper centre with 1 each new damper tab and 1 each hex head cap screw M4 20x 32 Secure the torsion bar to the upper fireback with 1 each torsion bar clip and 1 each hex head cap screw 14 20x 1 2 and 1 each standard flat washer 14 Operate the damper through its full range of movement using the end of the torsion bar If binding occurs correct by filing or grinding Do not bend the torsion bar tabs or clips Install the upper fireback and damper assembly Start the left end into position first insuring that the torsion bar end is above the opening in the left air wear plate Push the entire assembly upward i
10. onto the socket set screw protruding from the top centre of the right door With the door handle flush against the door face the handle tab should enter its slot in the top centre of the stove front STEP 41 Cont and when turned counter clockwise against its stop should pull both doors snugly against the stove front and each other If the doors are loose when the handle tab is fully engaged open the right door and turn the door handle 360 degrees one full turn counterclockwise Close the door and attempt to latch If the tab will not enter its opening in the stove front remove the handle from the door 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 Fig A 11 Door Handle Fig A 11 Door Handle W Tab Before Grinding W Tab After Grinding If when latched the door handle is not in the vertical position remove and replace the split roll pin 3 16 x1 in the handle tab opening of the stove front After leveling and plumbing the doors and adjusting the latching mechanism check the seal of both doors by applying the notepaper test see Fig A 12 If the doors fail the test re adjust the hinge bosses latch the doors and re test STEP 42 Assemble and install the griddle Place the griddle quadrants on the underside of the griddle and secure with 2 each hex head cap screws J4 20x12 Install the griddle handle assembly and secure with
11. panel e Gently pry off the refractory catalyst cover with a flat blade screwdriver e Visually inspect the catalyst for fly ash using a small mirror It is not necessary to remove the catalyst for this purpose e If the catalyst appears coated with fly ash carefully remove the catalytic combustor The catalyst element is contained within a stainless steel jacket can You may have to grasp the element with two flat bladed screwdrivers at the element ends to draw the element from the stove If the honeycomb is clogged take the element outside for cleaning Blow gently through the honeycomb Inspect the element Although small hairline cracks will not affect performance the element should essentially be intact If elements are broken or missing the catalyst should be replaced If the catalyst is in good shape and all the fly ash has been removed re install the combustor in the stove by sliding it into the the opening making sure that it is resting on the stainless steel support ledge which is visible before installation of the catalyst Gently reinstall the catalyst cover The U shaped ridge should be toward the stove with the open end down The refractory cover should be flush with the other refractory surfaces Replace the access panel and securely tighten the fasteners CLEAN THE SECONDARY AIR PASSAGE Fly ash can also accumulate in the secondary air passageway Once a year it is a good idea to vacuum out this opening The secondary
12. surface on the left air wear plate and upper fireback of all old furnace cement Proceed to step 26 thru 28 of the assembly section of this manual Replacing or Servicing the Upper Fireback and Damper Assembly e Ratchet Handle 3 8 drive e 7 16 Deepwell socket 3 8 drive e Rolling head pry bar 6 10 Also see note in Appendix Tools Required Caulking Gun Frame Thermocement 11 oz tube Cold Chisel 1 2 Hammer Ball Peen 12 oz e Allen Wrench 5 32 e Safety Goggles Perform steps 1 thru 5 of the damper linkage repair section STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 Remove the 4 cap screws that secure the upper fireback to the right and left air wear plates Place the chisel end of the rolling head pry bar in the seam between the upper and lower fireback about 2 in from the right or left air 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 the stoves top loosens Remove the upper fireback and damper assembly Service and or replace the upper fireback damper torsion bar damper tabs and torsion bar clips Re gasket the damper and the upper fireback Refer to the gasketing section of this manual Clean the upper fireback of all old furnace cement Clean the cement channel for the upper fireback in the underside of the stove
13. the cement seams and a ball peen hammer to loosen Remove the damper handle rod from its drilling in the left stove end and the forward drilling in the damper actuator link to fall between the left stove end and the left air wear plate Remove the upper fireback and damper assembly 4 each 14 20 x 1 hex head cap screws and 4 each 14 flat washers Do not allow the damper actuator link to fall into the opening between the wear plate and the stove end STEP 11 STEP 12 STEP 13 STEP 14 STEP 15 Remove the lower fireback 2 each 14 20 x 1 hex head cap screws and 2 each 14 flat washers Pry the fireback loose with a pinch bar from its bottom cement channel Remove the stove back 6 each 14 20 x 3 4 hex head cap screws and 6 each 14 flat washers Strike the stove back joint areas with a rubber mallet to loosen the cement Remove the combustion package assembly and the right and left heat deflectors from the stove back Handle the combustion package assembly gently and place it in a safe area until you are ready to examine and clean it Disconnect the thermostat cable at the primary air valve outer rear of the stove bottom Loosen the Allen set screw and snip off the cable loop Gently pull the thermostat from its recess in the right air wear plate Do not lose the washer spring jump ring and cable in the process Remove the right air wear plate 2 each 4 20 x 1 hex head cap screws Chip away the ce
14. the damper does not move freely correct by filling or grinding the suspect parts Do not bend or force any damper linkage parts If the damper does not lock correct this 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 damper link access panel Cement the mating surface on the access panel as indicated in Fig C 12 Place the access panel against its mating 9 surface on the left air wear plate and upper fireback rear portion first Secure with 2 each socket flat head machine screws l4 20x 42 Check the damper operation if binding or stoppage occurs correct the problem Do not force the linkage Fig C 12 Damper Link Access Panel STEP 29 Install the catalyst access panel Secure with 4 each Phillips round head machine screws l4 20x5 8 STEP 30 Install the flue collar Position the flue collar for either top or rear exit secure with 2 each Phillips round head machine screws 4 20x1 STEP 31 Assemble and install the secondary inlet assembly Holding the secondary air probe and thermostat assembly with the probe facing away from you and the mounting tab at 12 o clock the tab on the end of the thermostat coil should be at 4 o clock position loosen the lock nuts on the probe shaft and adjust the coil tab and the mounting tab to the 4 o clock and 12 STEP 31 Cont o
15. 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 114 Spacer Used On Bottom 8 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 amp instructions Warming Shelf 130 2221 Left Bracket 130 2222 Right Bracket 160 1705 Mittenrack 500 7234 Hardware a Old Red Sand Blue Gray Shelf 1302208 1312208 1322208 1332208 Se NACH Dagon Bracket lt CHM AAHATOAZAZMATTTATAOADS IE Note Defiant Encore Drill and Tap Guide Drill 13 64 22 22 22 25 64 13 64 13 64 13 64 13 64 13 64 13 64 13 64 3 16 5 16 3 16 1 8 5 16 1 8 W G 3 8 1 4 When threading to the bottom of a blind hole always finish with a bottoming tap after cleaning the hole of all chips Depth Thru 1 2 3 8 Thru Thru 1 2 5 8 3 8 7116 11 16 27 32 3 4 Thru Thru 11 16 1 2 Thru Thru Thru Thru Thru Thru Tap Size 1 4 20 10 24 10 24 10 24 7 16 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 3 8 16 Tap Type Taper Bottoming Bottoming Taper Taper Bottoming Bottoming Bottoming Bottoming
16. 20 3588 Left Door Fig 11 Left door to stove front and right door seal 1 piece 4 thermocord 5 16 diameter 6 needle part 120 3588 Fig 11 Left Door Inner Fig 11 Left Door Outer Door Glass Fig 12 Gasket 1 provides cushioning between the casting and the bottom of the glass panes 1 piece 9 Interam 3M flat part 120 3537 This gasket is applied with Tite Bond Glue or gasket adhesive Gasket 2 provides 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 Gasket 3 provides cushioning and separates the inner and outer glass panes This gasket is pre formed and comes ready made part 500 2798 This gasket does not require glue or cement NOTE Both doors require the same door glass gasketing Defiant Encore 0028 2140 Assembly Service Manual General NOTE Caution STEP 1 STEP 2 STEP 3 All parts were carefully inspected and cleaned to bare metal or replaced during the disassembly process Assembly may now begin To achieve a properly functioning air tight stove 6 each 11 oz tubes of thermocement part number 120 6125 are required Cut the thermocement tube tips so that a 14 3 8 unbroken bead of thermocement may be applied to the cement channels flanges and or flat mating surfaces Cement is indicated by the shaded area in the C series
17. 846 57 130 7415 58 500 4265 59 130 7423 60 130 7434 61 500 4224 160 0660 500 4264 120 1243 62 130 7442 63 160 1489 64 160 1490 65 120 1986 66 160 1486 67 160 1492 68 140 1115 69 500 2789 120 3537 70 130 7419 71 130 0797 72 130 0809 000 4444 73 160 1025 74 160 1027 500 5746 75 500 4022 160 0658 160 0661 120 1900 120 1308 120 3210 76 000 4342 77 160 0620 78 160 0650 79 120 1294 80 160 0664 81 120 2471 82 120 2560 83 120 6115 84 120 1310 DESCRIPTION Upper Fireback Only Upper Fireback Ass y 47 to 51 Damper Only Damper Tabs Torsion Bar Damper Rod Clip Torsion Bar Damper Rod Damper Actuator Linkage Damper Actuator Rod Thermostat Coil amp Rod Assembly c w 55 Thermostat Eyelet Only Friction Spring Thermostat Access Cup Damper Handle Stub Nickel c w Set Screw Damper Link Access Panel Bottom Grate Thermostat Handle Complete Thermostat Wooden Handle Only Thermostat Handle Stub c w Set Screw Thermostat Handle Long Screw Only Catalyst Access Panel no substitute Secondary Air Probe Secondary Air Flap Secondary Air Shim Ring Secondary Air Link Secondary Air Cover Plate Glass 1 Glass Gasket With Wire Between Glass Interam Gasket 9 Under the Glass Andiron Griddle No Quads Griddle Quad Straight 1 Griddle Quad Straight 1 with Bolt Ash Pan Only Ash Pan Cover With Handle Ash Pan amp Cover Assembly 73 amp 74 Griddle Handle Complete Griddle Handle Stub
18. 87 to provide better operational tolerance and clearances and to accept heavier gasketing A single ash door hinge in and a new ash pan and cover were also provided at this time In February of 1987 the damper torsion bar was changed from cold rolled steel to stainless steel to improve reliability of damper operation over wide ranges of temperature change The thickness of the 3 damper tabs was doubled in March of 1987 to prevent the possibility of bending during assembly and or operation l 2 3 4 5 6 7 8 9 DEFIANT ENCORE Exploded View Parts Illustrations Parts List Drill and Tap Illustrations Drill and Tap Guide Individual Part Replacement Repair Procedures Complete Disassembly Procedure Complete Gasketing Procedure Complete Assembly Procedure Appendix OPIZ 8200 STAGOW 3HOON3 1NVI43G Es male MODEL FEATURES DEFIANT ENCORE 0028 2140 DEFIANT ENCORE MODEL 0028 MANUFACTURED 7 11 86 THRU 4 25 90 WITH A GEISSER TESTING LAB LABEL MODEL 2140 MAUNFACTURED 5 17 90 THRU 11 5 91 WITH A WARNOCK HERSEY TESTING LABEL CATALYST ACCESS IN THE BACK OF THE STOVE DOUBLE PANE OF GLASS IN EACH DOOR denotes dead product not available ITEM PART DESCRIPTION 4 2 OONDAKRW 4 eo 130 7410 Bottom no substitute 130 7411 Primary Air Frame Only 500 0337 Primary Air Regulatory System Includes 2 3 4 5 17 amp 120 3518 Gasket 130 7412 Primary Air Valve Only 160 1493 Primary Air Rod O
19. Black Socket Head Cap Screw replaces 120 0645 Tab Damper Eyelet Thermostat Wire Jump Ring Shell Parts Defiant Encore Model 0028 2140 130 131 132 133 134 138 139 a3 Flue Collar 1304280 2324280 1324280 1334280 1344280 N A NA alie eran e a Ma NA NA 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 34 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
20. Door Seal Test 5 Install the ash pan bracket on the ash door Secure with 2 each hex head cap screws 14 20x 2 and 4 each 2 per cap screw standard flat washers 14 Tighten the cap screws finger tight Close and open the ash door If the bracket contacts the ash drop adjust the bracket by tapping it left or right as required so that no metal to metal contact occurs when opening and closing the ash door Tighten the cap screws Insert the ash pan into the bracket and close and open the ash door If the ash pan contacts the bottom of the ash drop or the underside of the stove bottom gently bend the ash pan bracket up or down as required Install the flat grate Narrow dimension toward the rear of the stove flat side up install the andirons Secure with 2 each hex head cap screws l4 20x 2 stainless steel and 2 each stainless steel flat washers 4 Assemble the doors At this point in time the doors should have been completely disassembled stripped of old gasketing cleaned re painted and completely re gasketed Place the doors face down on a clean flat surface with a clean rag protecting the painted door faces Insert the outer glass panes Insert the Encore Gasket with wire insert pre formed spreading the gasket against the cast frame all the way around Insert the inner glass panes Secure the glass with glass retainer clips 4 per door and 4 each Phillips pan head machine screws 10 24x 4 The short glass retaine
21. Only Griddle Handle Wood Knob Only Griddle Handle Bushing Only 2 used Griddle Handle Wood Handle Screw Griddle Handle Wood Handle Nut Only Fallaway Handle Complete 85 77 78 Ceramic Handle Ceramic Part Only Ceramic Handle Chrome Nub Only Ceramic Handle Screw Only Damper Handle Wood Handle Only 1 4 SS Flat Washer 3 8 Narrow Flat Washer Kawool 3 4 x 7 4 Used Damper Handle Screw Only DEFIANT ENCORE 0028 amp 2140 HARDWARE ONLY DEFIANT ENCORE HARDWARE LIST 0028 2140 DEFIANT ENCORE MODEL 0028 MANUFACTURED 7 11 86 THRU 4 25 90 WITH A GEISSER TESTING LAB LABEL MODEL 2140 MAUNFACTURED 5 17 90 THRU 11 5 91 WITH A WARNOCK HERSEY TESTING LABEL CATALYST ACCESS IN THE BACK OF THE STOVE DOUBLE PANE OF GLASS IN EACH DOOR MODEL FEATURES denotes dead product not available ITEM PART 120 0900 120 0896 120 1374 120 1372 120 2474 120 0417 120 3210 120 3290 120 1338 120 0482 120 2488 120 1443 120 1745 160 0600 120 8610 120 0848 120 1347 120 3029 120 0991 120 2560 120 0334 120 1392 120 1376 120 1326 120 0881 120 2473 120 0907 120 3329 120 2471 120 0563 120 1243 120 2906 120 1986 120 0980 120 0993 120 1340 120 1310 120 1294 160 1396 160 1394 120 1378 120 6115 120 1846 120 2470 30001794 160 1488 120 1864 120 1985 DESCRIPTION Ya 20 x Black Phillips Round Head Screw 14 20 x 34 Black Phillips Round Head Screw Ya 20 X 34 Hex Head Cap Screw V4 20 X
22. SERVICE MANUAL For the Vermont Castings Defiant Encore Models 0028 2140 Defiant Encore Design Changes The Defiant Encore damper was modified in October 1986 to provide a cast wedge shaped stop to prevent the damper from striking or resting on the catalytic package when operating the stove in the updraft mode The torsion bar slide area in the centre of the damper was widened to preclude torsion bar binding when opening and closing the damper The ash drop assembly was modified in October 1986 to accept a split two piece half hinge which allows 3 dimensional adjustment of the ash door resulting in an improved ash door to ash drop and stove bottom seal In November 1986 the ash door handle assembly was lengthened to accommodate the plinth configuration and to increase the safety factor by avoiding the possibility of scraping or burning the knuckles when opening or closing the ash door The secondary 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 of the air valve during catalytic burn periods The stove back and catalyst access plate was redesigned in December 1986 to allow ease of servicing the catalyst block reducing the risk of damaging the catalyst block and or the refractory access panel when performing maintenance A new ash door and ash pan bracket was introduced in January 19
23. air cover is located immediately below the catalyst access panel Remove the two Phillips pan head screws holding the secondary air cover to the back of the stove Push the secondary 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 the front doors and griddle the Encore has seals on the damper and the ash pan door that are important for proper stove performance Test the ash pan door seal by placing by placing pieces of note paper or dollar bills at three locations across both the bottom and top of the door Close and latch the door If the paper is easily moved or pulled out the door is not properly sealed and the gasket should be replaced using 3 8 fiberglass gasket To replace the gasket first pull out the old gasket Clean the channel with a wire brush Next lay the new gasket in place and trim to the correct length Place a 1 8 bead of gasket cement in the channels and press the trimmed gasket into place Close the door Seat the gasket in the door by pushing in hard against the door a rubber mallet may be used Open the door and remove any excess cement that has squeezed out around the gasket The door gasketing will compress within the first few weeks so you will need to readjust the latch To do this loosen the hex lock nut with an open end wrench and back off the striker screw Tig
24. aying particular attention to the place where a continuous gasket meets itself Clean all gasket channels and grooves with a wire brush hand or power Remove any stubborn deposits of gasket cement with the appropriate size punch drive pin or cold chisel Clean all parts to be gasketed with you shop vacuum Place clean parts on a clean level surface Select the appropriate type and size of gasket Cut to the recommended length allowing you an inch or two excess Using the 3 oz tube of gasket cement part 120 6122 place an unbroken 1 8 bead of gasket cement in the channel or groove to be gasketed Starting with one end press the gasket into the cemented channel or groove If the gasket meets itself insure that you have a good joint before trimming excess gasket with shears or side cutters Do not overlap gasket ends or leave ragged edges NOTE Gasketing is indicated by the cross hatch symbol in the illustrations STEP 7 If possible place the gasketed part firmly against its normal mating surface in order to seat the gasket evenly in its cemented channel or groove Use a 1 x 4 18 long wooden straight edge where required Remove gasketed part and clean any excess gasket cement that has squeezed out around the gasket before placing aside to dry Defiant Encore Gasket Requirements Refer to the Gasket Illustration figure numbers Griddle opening one place 4 Armaseal 5 16 diameter cored part 120 3668 Top
25. bsorbent cloth 1 Tape measure 6 1 Machinists rule 6 Pair cutting shears 6 8 Kitchen knife serrated 6 7 blade Clean rags STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 Disassembly Lift out the griddle Remove the ash pan and dump ashes in a safe container outdoors Wash the ash pan and dry it The ash pan will make a good container for screws bolts nuts washers and small hardware items during the disassembly of the stove Remove the right and left door assemblies Raise the door until the lower hinge pin clears its drilling angle the door bottom slightly outward and pull down releasing the upper hinge pin from its drilling Remove the damper handle stub with the 5 32 Allen wrench Remove the thermostat handle with the 1 8 Allen wrench Remove the flue collar 2 each Phillips round head machine screws 1 4 20x1 Remove the top 2 each 14 20 x 34 hex head cap screws and 4 each 4 flat washers right and left inside rear and 1 each 14 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 loosen the cement and remove Remove the primary air thermostat access cup 2 each 14 20x1 2 hex head cap screws Use the cold chisel in the cement seam Remove the damper link access panel 2 each 4 20x1 2 socket flat head machine screws Use the cold chisel in
26. clock positions respectively and re tighten the lock nuts Insert the double bent end of the secondary air link through the hole in the tab end of the thermostat coil Insert the single bent end of the secondary air link through the hole in the tab on the secondary air flap Insert the secondary air probe through the drilling in the stove back and secure with 1 each Phillips pan head machine screw 10 20x 14 Secure the secondary air flap to the stove back with 1 each Phillips pan head machine screw 10 24x 14 and 1 each shim ring Tighten the screw securing the air flap until snug and back off turn Insure that the secondary air flap moves up and down freely and that the flap rests at or near the closed position STEP 32 STEP 33 See figure A 8 ri t m Fig A 8 Positioning of Secondary Air Probe Flap A Install the secondary air cover plate Secure with 2 each Phillips pan head machine head screws 4 20x3 8 Assemble and install the ash door Screw the socket button head cap screw into the stepped side of the pawl see Fig A 9 Thread the hex nut onto the end of the socket button head cap screw and tighten finger tight against the flat side of the pawl Screw the socket set screw into the handle shaft drilling of the pawl Slide the ash door handle shaft through its drilling in the ash door Slide the pawl onto the ash door handle shaft so that the pawl offset is opposite t
27. d taping the stove With the putty knife clean all outside stove seams and joints of any thermocement leakage or spillage Draw a bucket or pail of hot water and with a sponge or soft rag wash 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 cover plate and the printed plates on the catalyst access panel with masking tape Paint the stove Use Vermont Castings High Temperature Stove Paint black part 000 0031 Follow directions printed on the can and paint the entire outside of the stove Install and adjust the doors Locate the hinge pin drillings in the upper sides of the stove front Insert the upper hinge pins of each door into its drillings swing the bottom of each door against the stove front and drop the lower hinge pins into their drillings Close the doors and check the gasket seating between the doors and the stove front mating surface Both door bottoms should be level and even with each other There should be no metal to metal contact between the doors and the stove front or between the right and left doors The vertical seam between the doors should be even from top to bottom Adjust the doors by gently tapping left or right and up and down When a good gasket seal is achieved and doors are even and level tighten the leveling bolts 3 per door Install the door handle by screwing it
28. e any bent tabs or clips STEP 33 Place the doors with their outside faces down on a clean flat surface Remove the door manifold 2 each 42 x 34 glass clip Remove 3 each 10 24 x 14 Phillips pan head machine screws and 3 each glass clips Reach underneath the door and push the glass and gaskets upward and out of the frame Scrape the frame with a putty knife removing all dry cement and old gasket material Inspect and clean the glass Replace any broken or cracked glass Check the condition of the formed gasket which separates the glass panes Replace it if it is broken crushed or badly deformed Remove the hinge boss from the door frame 3 each 14 20 x V2 hex head leveler bolts and 3 each 14 flat washers Inspect the hinge pins If the pins are broken or severely bent drive them out of the hinge boss with a 1 8 punch drive pin and ball peen hammer Remove the gasketing from around the door frame Clean the gasket channels Unscrew the door handle and tab assembly Inspect the 7 16 20 x 34 socket set screw for looseness in the door and or damaged threads If defective remove with a 7 32 Allen wrench After thorough cleaning pain the outside surface of the doors and hinge bosses at this time Use Vermont Castings High Temperature Aerosol Stove Paint black part number 000 0031 and follow directions on the can STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 Gasketing Remove the old gasketing p
29. e drilling in the bottom of the air valve and just start it into the left top hinge drilling of the frame Place the air valve and rod in the frame so that the air rod hinge drillings are in alignment Push the air rod from left to right through the aligned drillings and secure the air rod in the air frame with the 1 8 friction clip see Fig A 1 Turn the assembly over and install the socket head cap adjusting screw J4 N a 20 x 3 8 in the centreof 4 the air valve finger tight Primary Air Regulatory System Assembled Install the primary air regulator system on the cemented flange of the inverted stove bottom with the hinged side down Fig A 2 protruding air rod left Secure with 2 each Phillips round head machine screws 4 20 x 5 8 Turn the stove bottom over onto its legs AM A 7 ge m Mn ON M A 4 GS Asti K n SZ 2 c en 8 E P Cable Threading Fig A 2 Primary Air Regulator System Ready to be Installed STEP 7 Thread the running end of the primary air thermostat cable down through the small hole and up through the large hole in the air valve and thread it through the small hole in the centre of the air valve Pull 6 8 of cable outside the valve and tighten the set screw finger tight see Figures A 1 amp A 2 STEP 8 Cement all channels flanges and mating surfaces indicated in Figure C 2 Do not allow any cement to contact the thermo
30. end of the fishing tool and close the loop with your pliers Reach inside the stove and pull the fishing tool until the new cable comes through the thermostat pocket Clean the primary air frame thermostat access cup and their mating surface of all old furnace cement Apply new furnace cement to the thermostat access cup and the primary air frame and proceed to steps 20 thru 22 of the assembly section of the manual Replacing or Servicing the Damper Linkage Tools Required e Allen Wrench 5 32 e Cold Chisel 12 e Caulking Gun Frame e Hammer Ball Peen 12 oz e Thermocement 11 oz tube e Safety Goggles STEP 1 Place the damper in the open or updraft position and remove the damper STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 handle stub Remove the damper link access panel Use the cold chisel in the lower cement seam to loosen Reach inside the damper linkage opening and while holding the damper actuator link with one hand pull 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 wear plate With the actuator link rotate the damper towards the closed position and disengage the actuator link from the damper torsion bar Service and or replace the damper handle rod actuator link and the 3 8 flat washer Clean the cement groove of the damper linkage access panel and its mating
31. ess panel refractory against the catalyst block and push in gently so that the access panel is flush with the edges of the refractory assembly tape in place with masking tape Place the stainless steel refractory cover on top of the combustion package assembly so that the cover edges are even with the front and back edges of the refractory assembly Tape the cover in place with masking tape STEP 19 Place the combustion package assembly into the stove back between 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 assembly effectively isolating the secondary air passage from the right and left exhaust passages STEP 20 Assemble the thermostat and cable Open the jump ring and hook the loop on the end of the thermostat cable and the loop on the end of the thermostat actuator rod onto the jump ring Squeeze the jump ring completely closed with pliers Holding the thermostat assembly so that the limiter bar is on top of the rod swing the cable actuator rod over the top of the thermostat shaft as gt shown in Figure A 5 Place the friction spring on the thermostat shaft and slide the spring up to the shaft stops Holding the thermostat assembly in the left hand and insuring E that the limiter bar is on top of the shaft and parallel with the s m 2 S SFR Ke Ni stove top insert the end of the s
32. haft cable and actuator rod S through the hole in the centre of the thermostat pocket of the right air wear plate Loosen the set screw on the primary air 1 valve and gently pull the slack out of the cable while ij maintaining your grip on the thermostat shaft protruding out Fig A 5 Assembled Thermostat Might stove end STEP 20 Cont When the slack is out of the cable tighten the set screw on the air valve STEP 21 STEP 22 Push the thermostat shaft from inside the stove until stiff resistance is felt from the friction spring slip the thermostat handle stub on the end of the shaft and push the handle stub tight against the outside of the right stove end Tighten the set screw in the handle stub against the flat side of the shaft Cement the mating surface of the thermostat access cup Fig C 11 Place the 4 stainless steel flat washer on the thermostat shaft and slide it against the limiter bar Insert the thermostat access cup over the thermostat shaft rotate the access cup to its proper position aligning the drillings in the access cup with the tapped holes in the right air wear plate Secure with 2 each hex head cap screws 4 20 x 2 Adjust the primary air system Loosen the set screw on the primary air valve Holding the cable in one hand move the thermostat handle through its full range of movement insuring that all the slack is out of the cable and that the cable is responding to the move
33. he handle curve see Fig A 9 Insure that the pawl is against the ash door and Fig A 9 Ash Door Handle Assembly STEP 33 Cont that the handle turns without binding Tighten the set screw in the pawl STEP 34 Thread the hex toplock jam nut onto the handle shaft and tighten it against the pawl With your 7 16 wrench tighten the 3 cap screws attaching the split half hinge to the ash drop slightly just past finger tight Tighten the two cap screws holding the split half hinge together in the same manner Install the ash door hinge drilling into the clevis of the split half hinge Insert the clevis pin through the clevis from the bottom Insert the hair pin cotter through the drilling in the top of the clevis pin Adjust the ash door The design of the ash door split half hinge allows three dimensional adjustment of the ash door The 3 drillings in the ash drop through which the 4 20x 34 cap screws pass before threading into the rear half of the split half hinge are drilled oversized allowing vertical up and down and depth in or out adjustment The 2 drillings in the rear half of the split half hinge through which the 14 20 34 cap screws pass before threading into the front clevis half of the split half hinge are also drilled oversized allowing vertical up and down and horizontal side to side adjustment Close the ash door tightly and re open it Check the gasket area of the door to insure that the gasket mates e
34. hten the screw until the door seals securely and the latch still operates Then tighten the hex lock nut CHECK THE DAMPER The Encore s damper is designed to snap into a locked position When closing the damper push the handle past the point at which you feel resistance until it snaps into the locked position Place several pieces of note paper along the top and bottom of the damper and lock the damper As with the ash pan door if the pieces can be easily pulled out very little resistance replace the 5 16 gasket This is most easily done through the flue collar opening the flue collar may also be removed Pull out the 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 the stove CLEAN THE GLASS The Encore s glass is designed to stay free of carbon deposits even under low fire conditions However periodic cleaning is necessary to prevent permanent etching of the glass with fly ash or carbon Use a commercial wood stove glass cleaner supplied by your dealer or you may with to make your own cleaning paste Take a damp cloth and dip it into the fine grey ash in the ash pan Wipe the glass with this and a paste will form and continue until the glass is cleaned Buff with a clean cloth
35. illustrations Pay strict attention to the type size and number of fasteners called for in the exploded view drawings parts list and text Place the stove bottom upside down on a flat surface Install 4 each hex head leveler bolts 4 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 14 and 4 each standard flat washers 3 8 Place the stove handle holder between the flat washer and the bolt head on the left front leg right front leg when the bottom is turned over to its normal position Assemble the two piece half hinge using 2 each hex head cap screws 4 20 34 and 2 each standard flat washers 14 finger tight Install the two piece half hinge on the ash drop clevis facing the door opening with 3 each hex head cap screws l4 20x 34 and 3 each standard flat washers 14 finger tight Cement the stove bottom at points indicated in Figure C 1 Place the ash drop on the stove bottom and secure with 4 hex head cap screws 14 20 x 34 and 4 each standard flat washers 14 Fig C 1 LIA OC 7 Bottom bottom view QM nl STEP 4 STEP 5 STEP 6 Place the ash lip on the stove bottom and secure with 2 each socket flat head machine screws 14 20x V2 Assemble the primary air regulator system Place the primary air frame face down on a flat surface drilled bosses up Thread the primary air rod through th
36. ment at the joints and mating surfaces with a cold chisel and ball peen hammer Drive a 42 cold chisel between the rear flange extreme top and bottom of the wear plate and the stove end and gently pry loose see fig D 1 n 12 Coal Chisel Fig D 1 Separating Air Wear Plate from Stove End STEP 16 STEP 17 STEP 18 STEP 19 STEP 20 STEP 21 Remove the left air wear plate 2 each 4 20x1 hex head cap screws Chip away the cement at the joints and mating surfaces with a cold chisel and ball peen hammer Drive the 42 cold chisel between the rear flange extreme top and bottom of the wear plate and the stove end and gently pry loose see fig D 1 Remove the stove front 1 each 14 20 x 4 hex head cap screw and 1 each 14 flat washer holding the front to the left end 1 each 14 20 x 34 hex head cap screw and 1 each 14 flat washer holding the front to the right end 1 each 14 20 x 1 hex head cap screw and 1 each 14 20 hex nut holding the front to the bottom Strike the air manifold with a rubber mallet sharply at the right and left joints and remove the front with the air manifold and andirons attached Remove the right end 1 each 14 20 x 34 hex head cap screw and 1 each 14 flat washer located at the centre of the inside bottom flange Rock the end loose and remove Remove the left end 1 each 14 20 34 hex head cap screw and 1 each 4 flat washer locate at the cen
37. ment of the thermostat handle without catching or binding With the thermostat handle in the closed position towards the rear of the stove and the cable set screw loose the primary air valve will fall freely to the closed position Gently pull the cable until the primary air vale just begins to open Pull the air valve closed by pulling the set screw in the centre of the air valve until the valve seats in the air frame Tighten the set screw Move the thermostat handle to the full open position towards the front of the stove Check the air valve to be sure it is in the open position Sleeve and cut the excess from the primary air system cable Thread the copper sleeve over the end of the cable Loop the free end of the cable back through the copper sleeve and pull the sleeve and loop up within 1 of the air valve set screw as shown in Fig A 6 Insure that the sleeve and the cable loop will not interfere with the closing of the primary air valve Crimp the copper sleeve with pliers and cut off the excess cable f gt ES 5 E G COR pe eend Fig A 6 Adjusting and Sleeving the Primary Air System Cable Nm Fig C 11 Thermostat Access Cup so EIA ENT El STEP 23 Install the lower fireback Cut 2 each 7 strips of 34 square kaowool Place the kaowool strips between the outer ribs of the reverse side of the fireback left and right as shown in Fig A 7 Place the lower fireback
38. nly 30001794 Socket Set Sc Cable Adjust rep 120 0645 130 7420 Ash Drop 130 7435 Ash Drop Split Hinge Upper 130 7436 Ash Drop Split Hinge Lower 130 7443 Ash Door obsolete 160 0622 Ashdoor Handle Shaft Only 160 0663 Ashdoor Wood Handle Only 500 4024 Pawl Assembly 120 3290 Large Jam Nut for Pawl Assembly 120 3004 Cash Door Hinge Pin 120 3031 Cotter Pin 13 160 1039 Ash Pan Bracket See Chart Ashlip See Chart Leg 160 0600 Handle Bracket 500 5471 Primary Air Cable c w 2 Sleeves 130 8609 Primary Air Cover Plate rep 130 7418 See Chart Front See Chart Left Door Only 160 1396 Glass Clip Long 75 130 7402 Door Hinge Plate 160 0416 Upper Door Hinge Pin 160 0417 Lower Door Hinge Pin 120 1985 Jump Ring 130 7403 Left Door Manifold See Chart Right Door Only 160 1394 Glass Clip Short 62 130 7404 Right Door Manifold 30001759 Handle Stub w Set Screw rep 500 4225 130 7424 Front Air Manifold obsolete See Chart Left End See Chart Right End See Chart Top See Chart Back See Chart Flue Collar 130 7413 Left Air Wear Plate 130 7414 Right Air Wear Plate 160 8629 Left Deflector 160 8630 Right Deflector 500 4600 Refractory Assembly w Access Panel 160 2503 Access Panel Only 30001152 Catalyst Block 160 2506 Heat Exchanger 160 2507 Refractory Cover SS Piece On Top 130 7416 Lower Fireback ITEM PART 47 130 7417 500 0335 48 130 7421 49 160 1488 50 160 1036 51 160 1035 52 160 1034 53 160 1033 54 500 5470 55 120 1864 56 120 1
39. nto its cement channel in the stove top Align the drillings in the upper fireback with the tapped holes in the right and left air wear plates Secure with 4 each hex head cap screws 14 20x1 and 4 each standard flat washers 14 Install the damper actuator link and the damper handle rod Place the long end of the actuator link with the short curved end pointing towards the stove front and down onto the end of the damper torsion bar Move the bar behind the ear of the damper linkage access opening in the left air wear plate Place 1 each narrow flat washer 3 8 on the long end of STEP 26 Cont the damper handle rod Insert the long end of the damper handle rod through its drilling in the left stove end Insert the shot end of the damper actuator link Align the linkage properly and check operation for binding and or stoppage STEP 27 Install the damper handle stub Place the damper in the updraft position While maintaining pressure on the damper handle rod from inside the stove slide the damper handle stub onto the opposite end of the handle rod and align the damper stub with the open or updraft mark on the stove end Tighten the set screw in the handle stub with the 5 32 Allen wrench Move the damper handle from the full open updraft position to the full closed and locked catalytic burn position Linkage should move freely until approaching the locked position The damper should seat fully into the fireback when locked If
40. ocedures are covered in the Cementing and Re Gasketing sections of this manual There are however certain techniques and procedures outlined below and on the following pages which will save the mechanic both time and effort CAUTION When reassembling a part requiring gasketing or cementing both the part being replaced or reassembled and the entire mating surface to which it is attached must be thoroughly cleaned to bare metal of old furnace and or gasket cement 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 Tools Required e 7 16 Combination wrench box e 1 16 diameter Gas Welding amp open end Rod 36 e Phillips Screw Driver 2 tip e Caulking Gun Frame Type e Needle Nose Pliers 6 e Allen Wrench 1 8 e Cold Chisel 12 e Thermocement 11 oz tube e Hammer Ball Peen 12 oz e Safety Goggles e Drop Light or Flash Light STEP 1 Remove the primary thermostat handle STEP 2 Remove the thermostat access cup It may be necessary to use the cold chisel and hammer at the mating seam to loosen STEP 3 Remove the thermostat stainless steel washer and spring from the thermostat pocket by pulling straight out STEP 4 Remove the primary air frame and valve assembly It may be necessary to use the cold chisel and hammer at the mating seam to loosen Pull the frame away from
41. r clip goes on the lower centre of each door The upper centre glass retainer on the right door is secured by the right door manifold Install the right and left door manifolds Screw the Phillips pan head machine screw 10 20 34 all the way into the narrow end of each manifold until it seats STEP 38 Cont Back each screw out of its manifold 4 complete turns Screw the manifold STEP 39 STEP 40 STEP 41 to the door until snug Secure the wide end of each manifold to the inside door face with 2 each Phillips pan head machine screws 10 20x 34 Remember to place the upper centre glass retainer clip under the wide end of the right door manifold Install the right and left door hinge bosses Centre the bosses and secure with 3 each hex head leveler bolts 4 20x V flat head and 3 each 34 o d flat washers 4 Tighten just past finger tight Install the upper long hinge pins in the right and left hinge bosses by tapping them into their drillings with a brass faced hammer Install the jump rings on the upper shoulder of the lower short door pins and tap the pins into their drillings in the bottom of the right and left hinge bosses with a brass faced hammer Insert the socket set screw 7 16 20x1 into its tapped hole in the top centre of the right door Screw the set screw through the door from inside until the socket end is flush with the bottom of the gasket channel Re cement the gasket Cleaning washing an
42. rons 1 each 14 20 x 1 2 hex head cap screw and 1 each 14 flat washer per andiron Remove the two piece half hinge from the ash drop 3 each 14 20 x 34 hex head cap screws and 3 each 14 flat washers Take the split half hinge apart 2 each 14 20 x 34 hex head cap screws and 2 each 14 flat washers Remove the ash pan bracket from the ash door 2 each 14 20 x 42 hex head cap screws and 2 each 4 flat washers Remove the handle from the ash door 1 each 3 8 16 hex toplock jam nut on the pawl Loosen the 1 4 20x 14 socket set screws on the pawl Remove the pawl and pull the handle out Remove the damper from the upper fireback 3 each 14 20 x hex head cap screws and 3 each flat damper tabs Lift out the damper Remove the torsion bar 1 each 14 20 x 32 hex head cap screws and 1 each torsion bar clip Pull the torsion bar from the upper fireback Remove the primary air valve from the primary air frame Pry the air rod clip from the end of the rod Push the air rod through its drillings and remove the valve and rod from the frame STEP 29 STEP 30 STEP 31 STEP 32 Examine the combustion package assembly Check the heat exchanger for distortion loose spot welds etc Check the right and left heat deflectors for distortion Check the refractory stainless steel cover for distortion Replace any defective parts Check the catalyst block for general deterioration Check the refractory chamber
43. roove evenly all the way around and trim off the excess Install the left door and proceed with the door adjustment outlined in step 41 of the assembly section of this manual Defiant Encore Complete Disassembly Tools Required 1 Drop cloth 8 x 8 minimum size 1 Pair of safety goggles 1 Respirator dust amp mist 1 Wire brush 1 x 6 13 overall 1 7 16 Combination wrench box amp open end 1 9 16 Combination wrench box amp open end 3 8 Drive ratchet handle Wrench socket 7 16 deepwell 3 8 drive 1 Wrench socket 9 16 deepwell 3 8 drive 1 Common flat blade screwdriver 6 long 1 Common flat blade screwdriver 8 long 1 Phillips screwdriver 2 tip 6 long 1 Phillips screwdriver 3 tip 8 long 1 Hex 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 knife 1 Shop type vacuum cleaner with attachments 1 Ball peen hammer 12 oz or 16 oz 1 Hammer brass face 12 oz or 16 OZ 1 Rubber mallet 4 lbs dead blow 1 Cold chisel 12 1 Cold chisel 3 8 1 Cold chisel 5 8 1 Punch Drive pin 1 8 1 Punch Drive pin 14 1 Punch Drive pin 3 8 1 Caulking gun frame 1 Rolling head pry bar 2 x 15 1 Pinch bar 12 x 15 1 Water pail 2 gallon or larger 1 Sponger or water a
44. rubber mallet as necessary Secure the top to the stove front with 1 each Phillips flat head machine screw 147 20 x 34 Secure the top to the rear of the stove ends with 2 each hex head cap screws 147 20 x 34 and 4 each standard flat washers 14 2 per cap screw Fig C 8 Top bottom view I e A 3 STEPIS A Cement the mating surfaces on the reverse side of the left d i air wear plate as indicated in Figure C 9 Insert the front mating A DAN surface of the left air wear plate against the left end of the front 4 hamme gt air manifold and the front of the left stove end at a 30 degree g E angle Holding the wear plate as close to the stove top as E possible swing the back of the wear plate against its mating A 7 surface back of the left stove end Tap into proper position with 7 the rubber mallet so that the top and bottom drillings in the wear f j plate align with the tapped holes in the stove end Secure with 2 Lo each hex head cap screws 14 20 x 1 Fig C 9 Left Air Wear Plate STEP 16 Cement the mating surfaces on the reverse side of the right air wear plate as indicated in Figure 4 C 10 Place the right air wear plate inside the Ad A stove in an upright position Thread the primary j Nc air system cable through the hole in the centre of Qa 4 the thermostat pocket of the wear plate see 5 Figure A 3 Insert the front mating surface of Zi 4 the right
45. stat cable Place the primary air tube cover plate in position on the stove bottom and secure with 3 each Phillips flat head machine screws 14 20 x 2 X CN DSSS Fig C 2 Bottom top view EEKE SN S SS i grs lt NNT o Sta gt a SS SS hm AL STEP 9 Place the stove front in its cemented channel on the stove bottom Figure C 3 and secure with 1 each hex head cap screw 4 20 x 1 and 1 each hex lock nut 14 20 centre bottom of the stove front AZ O AIT e A pe SS ay A A C A Fig C 3 Bottom with Air Tube Cover Fig C 4 Front Plate in Place STEP 10 Cement all mating surfaces on the stove front as indicated in Figure C 4 Place the front air manifold in position on the inside of the stove front and secure with 1 each hex head cap screw 14 20 x 2 STEP 11 Cement mating grooves on both ends of the front air manifold as indicated in Figure C 7 Cement channels and mating surfaces on the left stove end as indicated in Figure C 5 Fig C 5 Left End Fig C 7 Front Air Manifold STEP 11 Cont Place the left stove end firmly into its mating channel in the stove front swing the back of the end onto the stove bottom so that the drilling in the inside bottom flange of the end aligns with the tapped hole in the stove bottom Secure the end to the bottom and the end to the front with 2 each hex head cap screws 14 20 x 34 and 2
46. the stove bottom and to the right gently to protect the primary air rod STEP 5 STEP 6 Remove the old cable from either the air valve or thermostat jump ring Fabricate a cable fishing tool from the 1 16 diameter X 36 gas welding rod as shown in figure R 1 Make the 2 bend and the 4 loop on the opposite end of the rod on the same plane gt 1 4 loop Fig R 1 Cable fishing tool 36 gas welding rod 1 16 dia STEP 7 STEP 8 STEP 9 STEP 10 Remove the stove griddle and the first section of stove pipe above the flue collar Insert the cable fishing tool into the primary air frame opening from right to left with the 2 bend at between 1 and 2 o clock Force the fishing tool by pushing and twisting it slightly around the inside of the primary air tube and up between the right stove end and the right air wear plate While pushing the fishing tool look into 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 thermostat pocket with the needle nose pliers and pull about 2 4 of the fishing tool inside the firebox If you do not succeed on the first attempt remove the fishing tool from the stove straighten it maintaining the 2 150 degree bend and try again Slip the looped end of the new primary thermostat cable over the looped
47. top thoroughly paying particular attention to the right and left corners Cement the upper fireback channel in the underside of the stove top and proceed to steps 24 thru 28 of the assembly section of this manual Replacing or Servicing Damper Tabs and Torsion Bar Clip Tools Required e Ratchet Handle 14 drive e 2 Extension 14 drive e 7 16 Socket 14 drive e Screwdriver Phillips 2 tip e 7 16 Combination Wrench box and open STEP 1 Remove the flue collar STEP 2 Replace and or service the damper tabs and torsion bar clip Reassemble and check damper operation for a good damper seal and ease of movement STEP 3 Replace the flue collar If the flue collar gasket is dried out and or compressed to the point where metal to metal contact is noted between the flue collar and the stove back replace the flue collar gasket Refer to the gasketing section of this manual for instructions Replacing or Servicing the Refractory Assembly Tools Required e 7 16 Combination Wrench box e Thermocement 11 oz tube amp open e Masking Tape e Cold Chisel 12 e Tape Measure 6 e Hammer Ball Peen 12 oz e Shears 10 12 e Caulking Gun Frame e Safety Goggles STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Remove the 6 screws that fasten the stove back to the right and left stove ends Tap the cold chisel into the seam where the bottom flange of the stove back joins the stove bottom to break the
48. tre of the inside bottom flange Rock the end loose and remove Remove the primary air tube cover plate 3 each 4 20x2 Phillips flat head machine screws To loosen the screws place a 3 Phillips screwdriver top into the screw and strike the screwdriver handle sharply with a ball peen hammer Chip the furnace cement loose from the seams and gently pry the cover plate loose Remove the primary air regulator system 2 each 14 20 x 5 8 Phillips round head machine screws Tap the air frame gently at the seams and remove STEP 22 STEP 23 STEP 24 STEP 25 STEP 26 STEP 27 STEP 28 Remove the ash drop assembly Remove the hairpin cotter from the upper end of the ash door clevis pin Pull the ash door clevis pin down disengaging the hinge Remove the ash door assembly Remove the flat ash grate Turn the stove bottom over and remover 4 each 14 20 x 34 hex head cap screws and 4 each 14 flat washers holding the ash drop to the stove bottom Gently tap and pry the ash drop loose Remove the ash lip 2 each 14 20 x 1 2 socket flat head machine screws Remover the 4 stove legs and handle holder 4 each 3 8 16 x 114 hex head bolts and 4 each 3 8 flat washers Remove the primary air manifold from the stove front 1 each 14 20 x 2 hex head cap screw at the centre of the manifold Chip cement at the joints with a cold chisel and ball peen hammer Pry the manifold loose with a pinch bar Remove the andi
49. venly 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 to side and up and down with the rubber mallet When the door is properly centered tighten the two 14 20x 34 cap screws that fasten the split half hinge together Close and latch the ash door Starting at the handle right side of the ash door face rap the door face sharply from right to left across the lower face of the door with the rubber mallet at approximately a 45 degree angle Tighten the three 1 4 20x 34 cap screws that fasten the split half hinge to the ash drop Adjust the ash door pawl assembly for a good firm latch by turning the socket button head cap screw in or out and locking it with the lock nut Test the door seal by placing 6 pieces of note paper evenly spaced 3 pieces along the top and 3 pieces along the bottom of the door between the door and the ash drop edge and closing and latching the door see Fig A 10 Attempt to move the pieces of note paper from side to side Attempt to pull the note paper out of the joints The note paper should not move at all from side to side and should rest being pulled out of the joints almost to the point of tearing If the note paper moves from side to side or can easily be pulled out of the joints the door is not properly sealed Re adjust the ash door following the above procedure STEP 35 STEP 36 STEP 37 STEP 38 Fig A 10 Ash
50. y section of this manual and steps 31 and 32 of the assembly section of this manual Eliminating Air Leaks at the Ash Door Tools Required e 7 16 Combination Wrench box e 9 16 Socket 3 8 drive amp open e 1 8 Allen Wrench e Ratchet Handle 3 8 drive e Rubber Mallet 4 lbs dead blow e Extension 3 3 8 drive e Wire Brush e 7 16 Socket 3 8 drive Refer to steps 33 thru 35 of the assembly section of this manual Eliminating Air Leaks at the Fire Door Tools required e 7 16 Combination Wrench box e Wire Brush amp open e Rubber Mallet 4 lbs dead blow e 9 16 Combination Wrench box e 7 32 Allen Wrench amp open e Flat file medium cut e Gasket Cement 3 oz tube Refer to step 41 of the assembly section of this manual If a good door seal cannot be achieved remove the doors and re gasket them following the instructions in the gasketing section of this manual If the right fire door seals and the left does 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 1 8 thermocord gasket and place it in the bottom of the groove Press the gasket into the groove evenly and trim off the excess Apply an unbroken bead of gasket cement onto the 1 8 thermocord gasket and the sides of the gasket groove Cut a 4 length of 5 16 thermocord gasket and place it in the g
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