Vermont Castings Defiant Encore 0028 User manual

SERVICE
WL
for the
Defiant
Encore
Models:
#0028
#2140

DSFIA}{T
ENCORE
DESIGN.
CIL${GES
The Defiaac Encore daoper vas nodified ia October L986 co provide a
cast wedge
shaped sEop to preveEE
Ehe danper froo scriking or res:ing
on che caEalytic package vhea operating Ehe sEove ic che updrafi
oode. The torsioo bar slicie area ia the cencer of El:€,daoper ras
widened to preclude t,orsioo bar binding when opening and closing the
daope
r .
The asir drop asserably "ras uodified in Occober 1986 to accept a
sptit(tw<l piece) half hinge which al 1
ows 3 dineosiocal adjusEneat of
the ash door resulting in ao irprorr"d ash d,oor io ash d,rop aud scove
boccoo
se:1.
ln November 1986 the ash door handle asseobly r;as leagtheneci to
accorlnodaEe the plioth coafiguratiou and Eo iocrease Ehe safecy
faccor iiy avoidiag the possibility of scrapiog or bu:uing the
knuckles whee opeaing oE closing rhe asb, d,oor.
The secoudary air valve(f1ap) was nodified iB, Deceober of 1986 Eo
accepE, a pop riveE shich acts as a valve sEop or liuiter to prevenE
the valve fron haogiog below ics isr.ecded posicioa and eliuioace
vibraEioo of the air valve during cacalycic burn periods.
t:

DEFiANT ENCOR.E
1. Explod,ed. View Parts Illustrations
2. Parts List
3. Drill and TaP Iliustrations
4. Dri1l and TaP Guide
5. Ind,ividual Part Replacement/'Reoai-r Frocedures
5. Complete Disassenrbly Frocedure
7
. Complete Gasketing Procedure
8. Complete AssernblY Procedure
r5

p,
s
\.
'-.nfi
trtt'
\70
\, a0.€
rr30
I
:28
I

EHCCii
RtPAiR/ntpLAC:HtxTpARiS
LISi
(0007A)
0escriotfon
Iter
rn
f Part t
t
_:l
-4
-tt
-t)
-7
-t
I
-tz.
-.l3
-14
-15
-'l
9
-?a
-?1
-?2
-1J
-8 130-7436 Ash
0rop
Split Hinge,
Cast
-9 'l
30-7443 Otl Door, Cast
-10 'l
50-0653 Ash
Door
Handle
.|30-7410 Eottom,
Stove, Cast
.l30-i4ll Prinary
Air Frane, Cast
'130-741? Prinary Air Ya'lve,Cast
150-1493 PrinarY
Air Rod
f304
S.S.
1/8'0ia.
'1
20-1020 Prinary Air Rod
CliP
..l25
I.D.xZl0
0.0. S.S.
.130-74?0 Ash 0rop, Cast
130-7435 Ash
Drop
5p'l
it Hin9e,
Cast
'130-05'15 Pawl, Cast
.|20-3005 Clevis
Pin
1/4'0ia.x3-1/?'Long
'150-'1039 Ash
Pan
Bracket
i30-7405 Ash
LiP, Cast
130-74?7 Legs,
Cast
130-7407 Front, Cast
.t30-7400 Left Door, Cast
5OO-0340 Left Door Hfn9e
AssenblY
13.0-
74A? Door
Hinge Boss, Cast
l5O-04.|5 UPPer
Door
Pin
-15 l5o-o5oo 0oor
Hand'le
Insert Ho'lder
-17 5OO-547'l Cable
Asi"tblY
-'l
I l3O-7418 PrinarY
Air Tube
Cover
Plate, Cast
lq

Erffi'E4q
Encore
Repa
ir/nep)acement
parts I r'al
Item I
-
_4t'
-48
_19
-(n
JV
-a
-)
|
a^
-- t
-t
--
-\
{
_54
'?-
-\\
JJ
-55
-s7
_58
-59
. -50
a.
-0
|
-6?
_53
-54
F.
VJ
-65
_57
-58
-59
part {
130-7417
130_7121
150_.t
488
't50_,t035
150-1035
150_1034
150-1033
500_5170
120_1985
12A
-
I
84
6
130_7415
t50-0508
t30-74?3
130-7434
500-42?4
t30-744?
150-t
489
t50-t490
120-1985
160-1491
150-1192
140-llts
5
0
0
-
?7
9
8
0escrlptlon
Upper
Ff
reback,
Cast
Danper,
Cas.t
Damper
Tab
.lA5 Thk
Torsion
gar Cllp
Tors{on
Bar,
3/g.0f
a.
Actuator Link 1/4. Thk.
x3/4.rt.
0aoPe.
!landie.Rod,
3/g. 0ia.
fhernostat Co{l & Rod
Asserab.ly
Jump
Rl'ng
Frictlon Sprf
ng
Thernostat
Access
Cup,
Cast
Danrper
handle
Sfub, Hf
ckel llate
Danper
Lf
nk accesspanel, Cast
Flat Grate,
Casi
Therurostat
Handle
Assenbly
Catalyst
Access
panel,
Cast
Secondary
/.ir probe Assernbly
Secondary
Af
r Flap
Shim
Ring, ilg !{ire
Secondary
Af
r Lf
nk
Secondary
Af
r Cover
Glasspane
l{ickel p'tate
089 lif
re
Piate
Gasket Assearbly, piefc:-seC

EXCOR,E
HARDI{ARE
t BULK ITEI{S
120-0544
Description
Socket
Head
Cap Screw
12A-0895 Phillips Round
Hd.
Hach.
Scr.
1/4-20x5/8'B'l
ack 0x.
Part
Ho.
'120-'1374
'l
20-247
4
Hex
Head
Cap Screv
114-2Ax3/4'B'l
ack 0x.
Flat Hasher
1/4" 5id.
'l
20-0417 Socket
5et Screv
1/4-20x1
/4'Knrl. Cup
Pt.
120-045'l Socket
Button
Hd. Cap
Screv
I
/4-20x3/4'
'l
20-32i
0Hex
llut-Plain
1/4-2O
'l
20-3290 Hex Toplg.ck
Jarn
llut 3/8-'l
6 z.
120-303'l Hairpin Cotter
.080x'l-3/.|5'
f'1
3 Hi
tch Pin
.l20-'l
338 Hex
HeadCap Screv
1/4-20x1
/?'B'l
k. 0x.
l?A-A48? Socket
Flat Hd. Hach.
Screw
l/4-20x1/2'81k.
0x.
'l
20-13?2 Hex
Head
Cap Screw
'l
0-24x1
/?'z.
120-2488 F'l at Hasher
3/8" 5td.
120-'1443 Hex
Head
Bo'lt
3/a-l
5x'l
-1
/4' z.
'l
20-1745 Hex
Head
Leveler
Eoit
1/4-20x1'Hickel
Plate
'l
20-0848 Phillf
ps
Flat Hd.
Hach. Screx
1/4-?0x?'B'lack 0x.
120-1347 HexHead
Leveler
Bolt
1/4-?Axl/?'Type
FH
120-099'l Phillips Pan
Hd.
Hach.
Screx
'l
0-24x3/4'2.
*?* l

0escription
120-3251 Hex
Hut 10-21 p'l
ain
120-24?3 t{asher
SAE
f't
0
120-'13'10 S'lot
Pan
Hd.
Hach. Screw
1/4'-20x3'Black
0x.
'l
20-1294 Slot. 0val Hd. Screx
1/+-
20x3
-3/B'
120-3588 Thernocord
Gaskec
5./15'5
Needie
120-447O Thermocenent,
ll oz.
'l
20-3589 Therurocord
Gasket
3/8'4 lleedje
Lorr0ensity
120-4867 Control
Cab'l
e 1/3?'S.S.
'120-4874 0val Copper
S'leeve
1/3?.
.I20-6.I51 6asket
Cement,
3 oz.
Part ll
9.
1:2
0-3
55
5
.l20-5.l04
120-3537
.l60-1396
160-'l
394
120-3658
'l
?0-1899
Thernocord
Gasket
1/8'
Titebond
Glue
Interan
Gasket
3H
Glass
Clip .049 S.5. 1/?'x
3/4'
G'l
ass
Clip .049
S.S. 1/Z'x
5/g'
Aroaseai
Gasket
S/16' v/core
Hole
Plug,5/16'
I 15

OEFI^Hi EHCORE
DR,
ILL AXO
TAP
GUiD:
0epth Tap
5f
ze
):ey 0ri'l'l
13/54'
1??
t??
J7)
25
/
64
"
13/54'
13/64',
13/
54'
13/54'
'1
3/64'
13/54'
l3/54'
3/l {5'
5/15'
3/15'
1/8"
5/16'
1/g'
'll'
tG'
3/8'
1/4'
Ncte: llhen threading to
vith a bottonring
Tap
iyoe
n
Thru
1
/
?'
3/8'
Thru
Thru
1!2'
5/8'
3/g'
7/16"
II
/l5'
?7/1?
'
-.1--
3/4'
Thru
Thru
'11/'16"
1/?'
Th
ru
Thru
Thru
Thru
Th
ru
Thru
1/4':20
l0-24
'l
0-24
l0-24
7
/16'-20
1
/
4
-20
1
/
4
-ZO
1
/
4.-?a
1
/
4
-20
1/q-zo
1
/
1-?0
1
/
1-?A
3/8-15
Taper
Eottoming
Boi"onring
Taper
Taper
Eoitoming
Eottonin,3
Eoitorn{ng
Eottorain13
Boitoraing
Bottoaring
Eottoming
J
r.i
R
the bottora
of a bi ind
'.ap
after clea'ning the
Taper
always
finish
of a'l
I chiPs.
hole,
hole

A
I
DEFIANT ENCOR.E
DiTILL & TAP ILLUSTB.AIIONS
Front (iaside view)
o
lillllll
illlillllllll
--+5
Scove Fronc (oucside viev)
lla

rY\d
_tt it l[ il
r5
l:;i'iANT EN
COF.E
DR.iLL & TAP ILi,USTT.ATIO}iS
Darup
er
Gricidle (bocEom view)
TherEoscaE, Access Cup
l21
N
I
I
re Top (bo
crocr
view)

N_J)+o
DR.II.L
& TA? ILi,USTR.AIIONS
Flue CoIlar (
rop view)
S
cove Bot cotr (
cop view)
A-->>
Stove Boccolr (bocEolo view)
| 4J

A: IANT ENCOR.F
D3.ILL & TAP ILLUSTR.ATIONS
Splic HaIf H,i.nge Splic Half Hinge
Clevis Half
Lef c End (
iaside view) Righc End (inside vier.r)

Scep# 2. R.emove
Ehe trhertosEat access cup.- It Bey be Eecessary Eo use
Ehe cold chisel aad harnner aE the Eating seain Eo looseq.
Scepf 3. Reoove the cherrrosEat, scalaless sreel sasher and spriog froo
the thermostaE pocket by pulliag scraighr ouE.
Scep# 4. Reoove the prinary air fraoe and valve assenbly. It Eay be
Becessary Eo use Ehecold chisel aad ha'ner aE the nating.seaq
to loosea. PulJ tbe fraroe away fron Ehe stove boEton and to
the righc gently, to protect Ehe prlnary air rod.
Step# 5 . Reoove the old cable f roo elther the al-r valve or theraos tat
junp ricg.
scep# 6. Fabricate a cable fishing tool froo the L/L6" dianerer x 36-
gas welCing rod as sb.orrnin f igure R-I. Hake the 2" bead and
the L/4" loop oB tbe opposite end of the rod on' che sane plaoe.
e.|
*Y +
I
L/
4" Ioop'
Fig. R-t Cable f ishing cooI, 36" gas selding rod, L/L6" d:-a-
127

REPhCING ORSARViCiNG
T:iE DA}{?LR
LircGE
T00tS REQUIRED: AILen i{reach , 5
/32"
Caulklng Gun Fraroe
therrnocetreqt, 11 oz. tube
CoId C'hlsel
, I/ 2"
llarnmer,
BaIl peen, LZ az.
Safety GoggJ.es
Scep# 1. Place the damper Ln the open or updrafc postlEoo aod re.ove Ehe
d."-per handle stub
Step# 2- Re.ove the daoper link access paael. Use tbe cold chisel lu
the lower ceBeBE seaq co loosen. ,
S
cep# 3. Reach iBsiCe the danper linkage opeaing and rhile hold,ing rhe
danper acEuacor lls,k wlEh ooe hand., pull the Canper bandle rod,
frou ics drilling in the lefc stove end and the for-nard,
drilling is, che actuator Lis.k \ritrb, the other b,and. Do sot d.rop
the 3/8- flat washer betweea the stove end and,
Ebe air/rrear
Plate.
Scepf 4. I{ith the actuaEor liak, rotate the d.anper tosard.s Ehe closed,
positlon and diseogage the actuator LLnk froo che dau,oer
Eorsloa bar.
t29

RTPI-ACI}{G
OR SERVICI{G DAHPER
TAsS AbTo
ToRSION 3LR CIJP
T00LS R,-EQUI!{ED Rarchec Handle, L/4" drlve
7/L6" Sockec
, Lf4' drlve
2" Erteasioo, L/4" drive
Screwdrlver, phillips, #Z Tip
7/L6" Conblnacioa llrench(bor anC opeu)
Scepf I. Rernove
che flue collar.
Step# ?- Replace agd/or se:rrlce che d,aoper Eabs aad,
-corsloo. bar clip.
Reasserqble and check d,amper operacioa for a good daoper seal
an,d ease of moveoest.
Scep# 3- R.eplace the flue co] lar. I.i rhe fJ.ue coJ-J.ar
gaskec is d,rieC
out aod/or coopressed to'the polot wb,ere
roecal Eo neEal coctact
is uoEed beEveen, the flue collar aod che scove back, replace
the flue collar gasket. Refer co the gaskeciug sectioa of this
maaual for inscruccions.
I

-v-tv
T00Ls R-EQUI8.ED: l/t0" Coorbinarlon
ln/reoch(bor
& opeo)
CoId Chlsel , L/Z"
Haooer, Ball Peeo, LZ oz.
Caulklng Guu Fraroe
IhernoceoeaE, 11 oz. tube
Hasking Tape
Tape
Heasure, 6'
Shears, 10" LZ"
Safety Goggles
step#
1.
Scep#
2.
S
ceprl
3.
Step#
4.
Srepf
5.
Reoove the 5 cap scress Ehat fasceo, the scove back to che rlght
and left st,ove ends.
Tap the cold cb.isel inEo tb.e 6eao where the botton.flaage of
che stove back joias che stove bocEosr Eo break the ceBeEE seal.
Li.fc tb,e sEove back up ouE of its ceoetrE groove in the sEove
bottoq asd puIL tb,e back frou the sEove, bottoo firsi.
Replace aod/or senrice Lb,e re.fraccory packager cBtalyst block,
heag exchaoger, heac deflectors aad refracEory cover. Cleao
che catalysc block aud refraccory package wlch low Pressure air.
Reasseoble the refract,ory assenbly. Tape the heaC exchaager,
catalyst block access paoel aod refractory cover ic place wich
roasklng Eape. .

R.EPIICTNG]}IE SECobiDAS_y
Ait rltERIOSTrf, ;f-A-p AlrD LTIfia\CE
T00LS
RIQUIR.E!
: Screwdriver, phllllps , {tZ
Eip.
Refer to step 30 of the disassernbly sectloa of chis oaoual and,
sEeps
31
and 32 of the asseobly secEiou of this manual.
ELIHINATI.}iG AIX. LEAKS AT TTIEASH DOOR
TOOLS
REQUIRED 7
/ L5" coobina tion wreu,ch
(
box & opeo)
Racchec
Handle, 3/8" drive
Exteaslon, 3" , -3/8- drive
t /rc" Sockec, 3/
8' drlve
9/L6" Socker
, 3/8" drive
. t6F
U8'- A].len k'reacb.
Rubber nal.lec, 4 Ib. dead blow.
llire Brush
Refer to steps 33 tb,ru 35 of the asseobly sectioo of thLs Ean.ual.
t35

C
OI.{IIITE DISAS
SE53LY
(0003A)
TOOL
REQUIREMENTS:
I Drop cloth, 8':<8' (oiuiuruo size)
I Pair safety goggles
I R.espiraE,or,
Dusc & Hist
1 lJire brush L-L/2"x6', 13" overall
1 7/L6" CorobioaEion
wren,ch(box and open end)
1 9/L6' CoobLaaEioasreach (box aad opeB ec.d)
3/8" Drlve raccirec handle
1 Wrench, sockec
, 7
/L6" , deepwell, 3
/g- d,rive
1 Llrench, sockec, giL6-, deepvell , 3/d- d.rive
I Comnon
fLat blade screrdriver 6" loag
I Commoa
flac blade screwdriver B" loag
1 Phillips screwdriver #Z tip, 6" long
t Phillips scresCriver {3 Eip, 8- long
I Hex key (Allea) rrencb, L/8"
1 llex k"y (Allec) rceach 5/32"
I Hex key (aUea) wrench 3/L6"
I l{ex key (Alleo) wreoch 7
/ 32'
l Drop
lighc A.C.40-60 waEc,
15'-25'cord
I PaiJ- elecEricians sLde cutting pliers 6"
I Pucty knife
I Shop type vacuuo cleauer wlth attachoeats
I BaJ.l peen baoser, LZ oz. or 16 oz*
I lla--er, brass .faceLZ oz.. or 16 oz.

S:ep l'1. Lif c ouc cire griciSle. R.eoove
che ash paa and dunp ashes in a sa
jr:
concliner ouccioors. I+ash
che ash pan and ciry ic. Tne ash pan r+i-Ll
nake a gooi container for screws, boIcs, nucs, washers and saall
ha:ii-*are iceos during che disassenbly o.f the scove.
Scep {?- R.eoove
che righc and lefc d,oor
assenblies. Raise the door uotil
che lower hinge Pin clears its drilring, aogle the door boccoq
sigircly oucward and puII down, releasing Ehe upper hinge pin fros
ic's cirilling.
Scep fi3. Reroove
the danper handle stub wirit rhe S/32" Allen wrench.
Scep #4. Renove the EhernosEaE
hand,le wich che L/8" Allen wrench.
Step #5- Reoove the flue collarr 2 each, PhiU.ips round, head nachine scre's,
L/ 4" -20x1" .
Scep #6. Renove
che Eop, 2 each, L/4"-2Qt314" hex head,
cap screws and 4
each, L/4" flat sashers, righc aod Left iuside rear and,
L each,
L/4"-20x3/4- Phillips flat head machiue screw, cenEer.fronc und,er
che griddle handle inden:. Scrike che cop upward wirh the rubber
oallec to loosen the celnent and retrove.
Scep#7. Renove
the pr:uary air thernostac access cup, 2 each
, L/4"-?LxL/2"
hex head cap scress. Use the cold chisel in the ceoeaE seao.
l3