Vermont Castings Deviant Encore 0028, Deviant Encore 2140 Service Manual

For the Vermont Castings

For the Vermont Castings

Defiant Encore Models:

Defiant Encore Models:

#0028

#0028
#2140

#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 1987 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.

DEFIANT ENCORE

1. Exploded View Parts 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. Complete Assembly Procedure

9. Appendix

e

#

#

y

y

y

DEFIANT ENCORE

MODEL #: 0028 / 2140 DEFIANT ENCORE
FEATURES: 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 availabl

ITEM # PART

1 130-7410* Bottom (no substitute) 47 130-7417 Upper Fireback Only
2 130-7411 Primary Air Frame Onl

500-0337 Primary Air Regulatory System 48 130-7421 Damper Onl

(Includes #2,3,4, 5, 17, & 120-3518 Gasket) 49 160-1488 Damper Tabs

3 130-7412 Primary Air Valve Only 50 160-1036 Torsion Bar (Damper Rod) Clip
4 160-1493 Primary Air Rod Onl
5 30001794
6 130-7420 Ash Drop 53 160-1033 Damper Actuator Rod
7 130-7435 Ash Drop Split Hinge Upper 54 500-5470 Thermostat Coil & Rod Assembly c/w #55
8 130-7436 Ash Drop Split Hinge Lower 55 120-1864 Thermostat Eyelet Only
9 130-7443 Ash Door (obsolete) 56 120-1846 Friction Spring

10 160-0622 Ashdoor Handle - Shaft Only 57 130-7415 Thermostat Access Cup

160-0663 Ashdoor Wood Handle Only 58 500-4265 Damper Handle Stub Nickel c/w Set Screw

11 500-4024 Pawl Assembly 59 130-7423 Damper Link Access Panel

11a 120-3290 Large Jam Nut for Pawl Assembly 60 130-7434 Bottom Grate

12 120-3004 Cash Door Hinge Pin 61 500-4224 Thermostat Handle Complete

12a 120-3031 Cotter Pin #13 160-0660 Thermostat Wooden Handle Only

13 160-1039 Ash Pan Bracket 500-4264 Thermostat Handle Stub c/w Set Screw
14 See Chart Ashlip 120-1243 Thermostat Handle Long Screw Only
15 See Chart Leg 62 130-7442* Catalyst Access Panel (no substitute)
16 160-0600 Handle Bracket 63 160-1489 Secondary Air Probe
17 500-5471 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 Link
20 See Chart Left Door Only 67 160-1492 Secondary Air Cover Plate
21 160-1396 Glass Clip Long .75" 68 140-1115 Glass (1)
22 130-7402 Door Hinge Plate 69 500-2789 Glass Gasket With Wire (Between Glass)
23 160-0416 Upper Door Hinge Pin 120-3537 Interam Gasket 9" Under the Glass
24 160-0417 Lower Door Hinge Pin 70 130-7419 Andiron
25 120-1985 Jump Ring 71 130-0797 Griddle (No Quads)
26 130-7403 Left Door Manifold 72 130-0809 Griddle Quad Straight (1)
27 See Chart Right Door Only 000-4444 Griddle Quad Straight (1) with Bolt
28 160-1394 Glass Clip Short .62" 73 160-1025 Ash Pan Only
29 130-7404 Right Door Manifold 74 160-1027 Ash Pan Cover With Handle
30 30001759
31 130-7424 Front Air Manifold (obsolete) 75 500-4022 Griddle Handle Complete
32 See Chart Left End 160-0658 Griddle Handle Stub Only
33 See Chart Right End 160-0661 Griddle Handle Wood Knob Only
34 See Chart Top 120-1900 Griddle Handle Bushing Only (2 used)
35 See Chart Back 120-1308 Griddle Handle Wood Handle Screw
36 See Chart Flue Collar 120-3210 Griddle Handle Wood Handle Nut Only
37 130-7413 Left Air / Wear Plate 76 000-4342 Fallaway Handle Complete (#85, #77, #78)
38 130-7414 Right Air / Wear Plate 77 160-0620 Ceramic Handle - Ceramic Part Only
39 160-8629 Left Deflector 78 160-0650 Ceramic Handle Chrome Nub Only
40 160-8630
41 500-4600 Refractory Assembly (w/ Access Panel) 80 160-0664 Damper Handle Wood Handle Only
42 160-2503 Access Panel Only 81 120-2471 1/4" SS Flat Washer
43 30001152 Catalyst Block 82 120-2560 3/8" Narrow Flat Washer
44 160-2506 Heat Exchanger 83 120-6115 Kawool 3/4" x 7" (4 Used)
45 160-2507 Refractory Cover (SS Piece On Top) 84 120-1310 Damper Handle Screw Only
46 130-7416 Lower Fireback

DESCRIPTION ITEM # PART

500-0335Upper Fireback Ass'y (#47 to #51)

51 160-1035 Torsion Bar (Damper Rod)

Socket Set Sc Cable Adjust (rep 120-0645) 52 160-1034 Damper Actuator Linkage

Handle Stub w/ Set Screw

Right Deflector 79 120-1294 Ceramic Handle - Screw Only

(repl 500-4225)

500-5746Ash Pan & Cover Assembly (#73 & # 74)

DESCRIPTION

#

}

r

DEFIANT ENCORE HARDWARE LIST

MODEL #: 0028 / 2140 DEFIANT ENCORE

FEATURES: 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

1 120-0900
2 120-0896

120-1374

3
4 120-1372
5 120-2474 Washer, Zinc
6 120-0417
7 120-3210
8 120-3290

9 120-1338
10 120-0482
11 120-2488 Washer, Zinc
12 120-1443
13 120-1745
14 160-0600 Handle Holder
15 120-8610
16 120-0848
17 120-1347
18 120-3029 Pin, Cotter .080 x 1 9/16”
19 120-0991 10-24 x
20 120-2560 Washer,
21 120-0334 7/16-20 x 1” Socket Set Screw
22 120-1392
23 120-1376
24 120-1326
25 120-0881
26 120-2473 Washer, Black
27 120-0907
28 120-3329 Nut,
29 120-2471 Washer,
30 120-0563 5/16-16 x 5/16” Socket Set Screw
31 120-1243 8-32 x 2” – Z Slot Round Head
32 120-2906 Rivet, Pop
33 120-1986 Shim Ring, 18 Ga Nickel
34 120-0980 10-24 x
35 120-0993
36 120-1340
37 120-1310
38 120-1294
39 160-1396 Glass Clip, Long .75”
40 160-1394 Glass Clip, Short .62”
41 120-1378
42 120-6115 Kawool
43 120-1846 Friction Spring
44 120-2470 Washer,
45 30001794
46 160-1488 Tab, Dampe
47 120-1864 Eyelet, Thermostat Wire
48 120-1985 Jump Ring

DESCRIPTION

¼ -20 x ¾” Black Phillips Round Head Screw
¼ -20 x ⅝” Black Phillips Round Head Screw
¼ -20 X ¾” Hex Head Cap Screw
¼ -20 X ⅝” Hex Head Cap Screw

¼” Flat
¼ -20 x ¼” Knl Cup Point Socket Set Screw
¼ -20 Hex Nut

⅜-16 Toplock Z Hex Head Jam Nut

¼ -20 x ½” Hex Head Cap Screw
¼ -20 x ½” Socket Flat Head Screw

⅜” Flat
⅜ -16 x 1 ¼” Zinc Hex Head Bolt

¼ -20 x 1” Zinc Hex Head Leveler Bolt

⅜ -16 x 1¼“ Socket Head Allen Bolt

¼ -20 x 2” Black Phillips Flat Head Screw
¼ -20 x ½” Hex Head Leveler Bolt

¾” Zinc Phillips Pan Head Screw

⅜” Narrow

¼ -20 x 2” Zinc Hex Head Cap Screw Gr 2
¼ -20 x 1” Hex Head Cap Screw
¼ -20 x 1” Black Hex Head Cap Screw Gr 2 (or sub 120-1376)
¼ -20 x ¾” Phillips Flat Head Screw

¼” Narrow Flat

¼ -20 x 1” Black Phillips Round Head Screw

¼ -20 Plain Square

¼” Flat .294 id x .620 od Stainless Steel

⅛ dia x ⅛ Grip {or use #6 x ¼” Round Head Screw

¼” Phillips Pan Head Screw
¼ -20 x ⅜” Phillips Pan Head Screw
¼ -20 x ½” Stainless Steel Hex Head Cap Screw {replaced 120-1373 - 5/8” May 03}
¼ -20 x 3” Zinc Slotted Pan Head Screw
¼ -20 x 3⅜” Zinc Slotted Pan Head Screw

¼ -20 x 1¼” Hex Head Cap Screw

¾” x 7”

¼ Plain Flat

¼ -20 x ⅜” Black Socket Head Cap Screw {replaces 120-0645}

Shell Parts - Defiant Encore Model #0028 / 2140

A

A

AN/AN/A

Part Name Classic Red Sand Blue Midn't

(130) (131) (132) (133) (134) (138) (139) (136)

Flue Collar
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

1304280 2324280* 1324280 1334280 1344280 N/A N/A N/A

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

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

Shelf 1302208 1312208 1322208 1332208 1342208 N/A N/A N/A

Dagon Bracket 1302220 1312220 1322220 1332220 1342220 N/

nt Grn Ant Brn Gray

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

nt Grn Ant Brn Gray

Defiant Encore Drill and Tap Guide

Key Drill Depth Tap Size Tap Type

A 13 / 64" Thru 1 / 4" - 20 Taper
B # 22 1 / 2" 10 - 24 Bottoming
C # 22 3 / 8" 10 - 24 Bottoming
D # 22 Thru 10 - 24 Taper
E 25 / 64" Thru 7 / 16" - 20 Taper
F 13 / 64" 1 / 2" 1 / 4 - 20 Bottoming
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" Thru
O 3 / 16" 11 / 16"
P 1 / 8" 1 / 2"
Q 5 / 16" Thru 3 / 8 - 16 Taper
R 1 / 8" Thru
S " W " Thru
T " G " Thru
U 3 / 8" Thru
V 1 / 4" Thru

*Note :

When threading to the bottom of a blind hole, always finish with a
bottoming tap after cleaning the hole of all chips.