Desa 408030 Construction Heaters Assembly & Operating Instructions

 ASSEMBLY, OPERATING INSTRUCTIONS
AND PARTS LIST FOR
SEARS, ROEBUCK SPACE HEATER
MODEL 583.408030
(Spec. No. 2965G8)
The Model Number will be found on a plate attached to the Heater.
Always mention the Model Number in all correspondence regarding
the SEARS, ROEBUCK HEATER or when ordering repair parts.
HOW TO ORDER REPAIR PARTS
All parts listed herein may be ordered through SEARS, ROEBUCK
AND CO. or SIMPSONS-SEARS LIMITED. When ordering parts by mail
from the mail order. house which serves the territory in which you live,
selling prices will be furnished on request or parts will be shipped at
prevailing prices and you will be billed accordingly.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING
INFORMATION AS SHOWN IN THIS LIST:
1. The PART NUMBER 3. The MODEL NUMBER.
2. The PART NAME. 4. The NAME of item—
COAST TO COAST NATION-WIDE
SERVICE FROM SEARS
FOR YOUR SPACE HEATER
SEARS, ROEBUCK AND CO. and
SIMPSONS-SEARS LIMITED in Can-
ada back up your investment with
quick, expert mechanical service and
genuine SEARS, ROEBUCK replace-
ment parts.
If and when you need repairs or serv-
ice, call on us to protect your invest-
ment in this fine piece of equipment.
SEARS, ROEBUCK AND CO. - U.S.A.
IN CANADA, SIMPSONS - SEARS LIMITED
Form No. 2352A (4/68) Printed in U.S.A.
Operation and Service Manual
TABLE OF CONTENTS
Y
Table of Contents
Subject Page Subject
Section I - INTRODUCTION ............ 1 Section IV - TROUBLE SHOOTING ......
General ..e.ñx0áoscocrosroooodererao 1 General ......244 44400 4 0 5 00 00 6
Principles of Operation ............ 1 Examination ..................
Specifications = .......... 0000. 2 Test Firing ....... cco.
Trouble Shooting ...............
Trouble Shooting Chart ...........
SO operatine Cations. ete ; Section V - SERVICE AND REPAIR
me Tte INSTRUCTIONS ...........
Extension Cord Wire Sizes ......... 3
Fuel 3 General ......2.44 404 01 00 4 0050 0
LOT TT TT TT TT TT Special Tools, Equipment, and Supplies .
Starting 2.440400 000 0 0 0 0 0 0000 0 3
Stoppin 3 Thermostat Accessory ............
PRIDE creator Removal of Upper Shell ..........
Transformer ..................
Section II - MAINTENANCE .......ee.. 4 e Motor Starting Cirenits
Fuel Tank Maintenance ............ 4 OS
i . Fan Service ...Q.orecooroecooso eo
Air Filters 0000000000000 0000004 4 .
; Fuel Filter Service .............
Removing Upper Shell ............ 5 .
‚ Burner Head Service ............
Cleaning the Fan ............. .. 5 .
ns Air Pump Repair ....eeeseosrecoro
Motor Lubrication ............... 5 .
Adjustment of Pump Pressure ......
Spark Plug .................... 6
. Reassembly of Heater ............
Cleaning the Fuel Filter ........... 6 Final Check
Burner Removal, Cieaning and NS
Replacement ................. 6
Reassembly after Maintenance ....... 7 Section VI - ILLUSTRATED PARTS LIST
LEST OF ILLUSTRATIONS
Figure Page
1. Schematic Diagram Showing Principles of Heater
Operation ....Q.oxo.eoscsooodsosoroóoo ogro, 1
2. Heater Maintenance Points ............... 4
3. Removing Intake Air Filter ............... 5
4, Access to Air Filter, for Maintenance ....... 5
5. Lubrication of Motor Bearing ............. 5
6. Spark Plug Gap Setting ................. 6
7. Burner Head, Spark Plug, and Fuel Filter 6
8. Blowing out Nozzle with Compressed Air . ..... 7
9. Wiring Diagram . . . . cc ov vt vv ott vv onan 14
10 Location of Fan on Motor Shaft ............ 15
11, Checking Clearance of Air Pump Rotor ....... 16
12. Checking and Adjustment of Air Pump Pressure . 16
13. Portable Heater, Exploded View ........... 18
14. Burner Head Assembly ................. 20
15. Motor Package Assembly. . ......Qoorcrreoo 21
16. Wheels, Handles, Markings .............. 22
A1529-00 -ii-
3/68
+
Operation and Service Manual
Section I
Introduction
SECTION |
INTRODUCTION
A, GENERAL
1. Purpose of Heater. Use this heater wherever
you need temporary portable heat. It must be used
with adequate ventilation and proper electrical power.
2. Purpose of Manual. The Service Manual gives
complete instructions for operating, maintaining,
trouble shooting, and servicing the heater. A com-
plete parts list is included at the end of the manual.
B. PRINCIPLES OF OPERATION
Operation of the heater is simple. It involves
three basic systems. (See figure 1.)
1. Fuel System. An air pump on one end of the
motor shaft forces air through the nozzle. The moving
air lifts fuel from the tank by a siphon action and car-
ries it into the combustion chamber in a fine spray.
2. Ignition System. An electric arc that fires
constantly between a pair of spark plug electrodes while
the heater is in operation ignites the mixture of fuel
and air.
3. AirSystem. Afanonthe other end of the mo-
tor shaft supplies additional air to the heater. Part
of this air enters the burner through ports around its
outer edge, and helps complete the combustion of the
burning fuel-air mixture.
The rest of the air from the fan passes over and
around the combustion chamber. At the front of the
heater it mixes with the hot air coming from inside the
combustion chamber. The air then flows out of the
heater as a jet of clean, heated air.
a \ Em
a
сель 08 NS
HEATED
AIR OUT
ul
g
AVANT I 277
И
aw 8
SPARK - AIR PUMP
COMBUSTION CHAMBER PLUG
BURNER HEAD FAN INTAKE AIR
A JL / | FILTER
<a \ ~N
COOL AIR IN
<a
ab
| |
= | Î \ \—OUTPUT AIR
MOTOR
NOZZLE
022 FUEL FILTER
IGNITION
TRANSFORMER
AIR LINE
t | TO BURNER
q
A AIR FOR FUEL SYSTEM
AIR FOR COMBUSTION
AND HEATING 466
<a FUEL
Figure 1.
A1511-00
Schematic Diagram Showing Principles of Heater Operation
-1- 3/68
+
Operation and Service Manual Section I
Introduction
C. SPECIFICATIONS
Output rating Fuel ......... Kerosene or No. 1 fuel oil only.
(BITUperhour) ................ 85,000 |
Fuel tank capacity
(U. S. gallons) .................. 9.0
Air output, approx.
(Cu. ft. per minute) ............. 200 Fuel consumption, approx.
(Gallons per hour) .............. 0.61
Amperage Voltage and cycles ....... As shown on heater
(During normal run) ............. 4 instruction plate.
Мо!от ЕРМ ...................... 3,450
Weight, approx. Shipping ........ 79
(Pounds) Net Dry) ....... 62 Duct .............. No duct recommended.
D. ACCESSORIES
| The following accessories are available for use
with the heater:
А1522-01
Thermostat, Catalog No. 4002
Safety Control Kit, Catalog No. 40021
Timer, Catalog No. 40022
3/68
Operation and Service Manual
Section II
Operation
SECTION Il
OPERATION
A. OPERATING CAUTIONS
1. Use the heater in a well-ventilated area
only. A partly-opened door or window near the
heater will give enough ventilation.
recommend the use of this heater as the primary
We do not
source of heat in sleeping quarters.
2. Use ONLY kerosene or No. 1 fuel oil. DO
NOT USE GASOLINE, AS IT IS VOLATILE AND
DANGEROUS. Do not use No. 2 or No. 3 fuel
oil, as they contain tars which will contaminate
the heater.
3. Use the heater only on the specified elec-
trical power. This is given on the heater in-
struction plate.
4. Plugthe heater into a grounded receptacle,
or use a grounding adapter. Be sure the heater
is grounded whenever it is in operation and when-
ever you are working on it.
5. Keep the heater at least 4 feet from any
combustible material.
6. Do not use the heater in the presence of
flammable vapors like those from paint or gas-
oline,
7. Do not add fuel while the heater is oper-
WARNING
The motor has an automatic thermal overload
protector. It may stop due to low voltage or
overload, then RESTART automatically. Be
sure to disconnect the heater service cord be-
fore removing the upper shell or inspecting the
motor.
B. EXTENSION CORD WIRE SIZES
Be sure to use an extension cord of the proper size
to assure adequate voltage at the heater.
100 200 300 400 500
14 12 10 8 6
Length of cord (feet)
Wire size (AWG)
C. FUEL
Be sure the tank is clean. Fill it with clean kero-
sene or No. 1 fuel oil ONLY. Do not use any other fuel.
When the heater is operated at very low tempera-
tures (beyond 10°F below zero), the fuel may congeal.
A0709-01
To prevent this, add Frostex or similar anti-icer to
the fuel, about 2 tablespoonfuls of anti-icer to each 5
gallons of fuel.
D. STARTING
Plug the heater cord into an outlet that will give
the proper voltage and frequency. The heater will
start operating immediately.
E. STOPPING
To stop the heater unplug the heater cord from
the outlet.
Operation and Service Manual
Section III
Maintenance
SECTION 11i
MAINTENANCE
Maintenance consists of the simple operations the
owner or user of the heater can perform to keep the
heater running and in good condition. If ordinary main-
tenance fails to return the heater to good operating
condition, refer to Section ГУ in this manual for check-
ing and trouble shooting. See Figure 2 for maintenance
points.
A. FUEL TANK MAINTENANCE
Drainthe fuel tank after every 150 hours of oper-
ation, andflush it out with clean fuel. Refill with new
clean fuel.
B. AIR FILTERS
1. Check and clean the intake air filter often.
The filter needs cleaning if you can see a film of dust
on it. It will need cleaning more often if the heater is
operated in dusty air. See Figure 3.
2. To clean the intake air filter, simply pull it
out of the housing. Wash it with a mild detergent and
hot or cold water. Dry it thoroughly, and replace it
in the housing.
CAUTION: Do not oil the filter element.
3. Replacethe output air filter once each heating
season.
4. Toreachthe outputair filter, remove the four
screws which attach the filter housing end cover. Lift
the output air filter out. See Figure 4,
NOTE: Cleaning the output air filter may cause a
change in the air pump output pressure. If
the heater burns improperly after cleaning,
have the air pump pressure checked. See
Section V, paragraph L.
COMBUSTION CHAMBER
SHELL ATTACHING
SCREWS „”
fs
POS
LOWER $
1 HELL «a .
\ >
>
ha
~ >
>
FUEL TANK ———"" =
>
>>
UPPER SHELL
BURNER (x)
INTAKE
AIR FILTER (%)
OUTPUT
AIR FILTER
(INSIDE HOUSING) (%)
LINT FILTER
{INSIDE HOUSING) (36)
„”
7
TRANSFORMER (#)
467A
Figure 2. Heater Maintenance Points
Symbol (*) indicates parts recommended as replaceable by owner or user of heater.
(For clarity, heater is shown without tank, wheels and handles, and with upper shell removed.)
A1335-01
_4- Rev. 2/68
+
Operation and Service Manual
416
Figure 3. Removing Intake Air Filter
5. When changing the output air filter, clean
the lint filter. Pick it out of the housing, wash with
mild detergent and hot or cold water. Dry thoroughly.
Do not oil.
6. Replace the lint filter, the output air filter,
the filter housing end cover, and the screws and wash-
ers.
C. REMOVING UPPER SHELL
NOTE: Youwill need to remove the upper shell
in order to perform the rest of the
maintenance operations. The heater
will not operate properly if the upper
shell is not in place.
Remove the upper shell by removing the six
screws (3 oneach side) that hold the upper shell to the
lower shell. Lift the upper shell off.
WARNING
With the upper shell removed and the ser-
vice cord plugged in, the heater can be
dangerous. Be careful to keep away from
the spark plug lead and the fan when the
upper shell is off.
To replace the upper shell, align the six holes
located along its lower edge over the six speed nuts on
the lower shell, and install the screws.
D. CLEANING THE FAN
Clean the fan blades after every 500 hours of op-
eration, or whenever you see that they are getting
dirty. À build-up of dirt will reduce the air supply and
cause faulty operation.
А1336-01
Section HI
Maintenance
LINT FILTER
OUTPUT
(AIR FILTER
AIR INTAKE
FILTER
FILTER
HOUSING
END COVER 417
Figure 4. Access to Air Filter for Maintenance
Toclean, wipe the blades with a cloth moistened
with kerosene or solvent. Be careful not to bend the
blades. Dry the fan thoroughly.
E. MOTOR LUBRICATION
The ball bearing on the pump-end of the motor
is lubricated for the life of the motor. Do not lubricate
it.
Oil the sleeve bearing on the fan-end of the motor
(See Figure 5) once each heating season with a few
drops of No. 30 oil, Arctic C oil, or electric motor
oil. Do not over-oil.
OIL FAN-END MOTOR
BEARING HERE
419
Figure 5. Lubrication of Motor Bearing
2/68
Operation and Service Manual
BEND HERE FOR PROPER
GAP SETTING
| e
le
0.045—0.055 IN. GAP
(USE A DIME AS A THICKNESS GAGE)
202A
Figure 6. Spark Plug Gap Setting
F. SPARK PLUG
WARNING
Be sure the heater is not plugged into the
outlet. The spark plug wire carries high
voltage during heater operation.
1. Disconnect the spark plug wire.
2. Remove the spark plug from the burner head,
and check the gap between the electrodes. The gap
must be within the limits shown in Figure 6. This is
the thickness of a dime.
3. Adjust the gap by bending the outside elec-
trode.
4. Reinstall the spark plug if no further main-
tenance is needed for the burner head. Tf you do not
install the spark plug immediately, protect it from
damage until it is reinstalled.
G. CLEANING THE FUEL FILTER
The fuel filter is the tube which leads up from
the fuel tank to the burner.
son, or if the Trouble Shooting Chart indicates.
1. Toremove the fuel filter, loosen the hex nut
that attaches it to the burner, and slide the nut back
on the tube. Then turn the tube to one side, and pull
it up out of the tank. See Figure 7.
2. Rinse the fuel filter several times in clean
fuel. Blow it dry through the fitting end.
3. Blow the filter dry through the fitting end.
4. When reinstalling the filter, moisten it with
fuel so it will slip into the grommet in the fuel tank
top. Position the filter carefully, so the hex nut will
Clean it twice each sea- -
line up properly with the threads of the elbow installed .
in the burner. Then tighten the nut securely.
NOTE: If the burner head is to be removed for
maintenance, do not reinstall the fuel
filter until ready to reinstall the burner.
A1337-00
Section III
Maintenance
COMBUSTION
CHAMBER
BURNER A
HEAD A.
FUEL
FILTER
414
Figure 7. Burner Head, Spark Plug, and Fuel Filter
H. BURNER REMOVAL, CLEANING AND REPLACEMENT
1. Besuretheheater cordis unplugged, and re-
move the lead wire from the spark plug. Remove fuel
filter from burner head. Disconnect the air line from
the fitting in the right side of the nozzle adapter.
2. Loosen the screws that fasten the burner
head to the rear of the combustion chamber.
3. Remove the nozzle carefully, using a socket
wrench. Hold the nozzle adapter with another wrench
while removing the nozzle.
CAUTION: Do not attempt to open the nozzle
passage with a steel drill, a wire
or any other tool, as you will dam-
age it beyond repair. Protect the
nozzle face from damage while the
burner is out of the heater. This
is important!
4. Soak the remaining parts of the burner head
assembly for one hour in non-flammable liquid clean-
ing agent. (DO NOT use kerosene or fuel oil.) Blow
dry through fittings in rear of burner. Blow the noz-
zle dry through the face (OUTLET) end ONLY. See
Figure 8.
5. Re-check the spark plug electrode setting
after cleaning the burner. See Paragraph F of this
Section. :
6. Whenreinstalling the burner, place it on the
back of the combustion chamber so the fitting for the
fuel filter is down, and the spark plug is just above
center, on the right. Install the attaching screws and
tighten.
Operation and Service Manual
RUBBER SLEEVE
SEAL WASHER
SPRING
SEAL WASHER
OO NOZZLE FACE
Wy
A NOZZLE PASSAGE
AIR HOSE
214
Figure 8. Blowing out nozzle
with compressed air.
A1338-00
Section IH
Maintenance
7. Connect the fuel filter and the air line from
the filter housing, to their respective fittings on the
nozzle adapter.
8. Imstall the spark plug, and snap the spark
plug lead onto the terminal. It must snap, or it may
not be tight enough to prevent loosening as the heater
is moved.
CAUTION: Do not attempt to repair the nozzle,
as a part of routine maintenance.
If the nozzle needs to be repaired,
see Section V of this manual.
I. REASSEMBLY AFTER MAINTENANCE
Put the heater back together in the reverse order
of disassembly. Be sure all parts are in place and all
screws and electrical connections are tight, before at-
tempting to use the heater.
Operation and Service Manual
Section IV + —-
Trouble Shooting
SECTION IV
TROUBLE SHOOTING
A. GENERAL
If normal maintenance fails to keep a heater in
good operating condition, it probably requires repair
or replacement of some parts. Examine it and test-
fire it to gain first-hand knowledge of why the service
might be needed.
This section tells how to examine and test-fire the
heater. It also contains a Trouble Shooting Chart for
help in diagnosing heater troubles and finding the re-
medies.
B. EXAMINATION
1. Check the fuel tank for sludge and water. If
you find it, expect to find a dirty nozzle and/or fuel
filter.
2. Spinthefan to be sure it turns freely. If it is
stiff, lookfor a worn or dry bearing on the fan-end of
the motor, or for a binding pump rotor.
3. Checkthe heater for dirt and foreign materials
around the pump, fan, and air filters. Be sure the
heater is reasonably clean before test-firing it.
4. Check the heater cord for obvious breaks or
other unsafe conditions. If the cord is doubtful, repair
it or install a new one before test-firing.
C. TEST-FIRING
1. Clean the fuel tank and fill it with at least 3
gallons of fuel. A minimum of 3/4 gallon of fuel must
be in the tank for proper test-firing.
2. Clean the air intake filter. (See Section III,
paragraph B.)
3. Check and adjust the air pressure, as de-
scribed in Section V, paragraph L, except that fuel
must be used for test-firing.
NOTE: Itisnot possible to test-fire a heater prop-
erly if this adjustment cannot be made.
4. Allow the heater to run for 15 minutes. Ob-
serve its operation during the test-run.
5. After makingthe pressure check, adjustment,
and test-firing, remove the gage and reinstall the plug.
6. If any troubles show up during the test-firing,
refer to the Trouble Shooting Chart to find out how to
correct them.
D. TROUBLE SHOOTING
The following chart lists the problems you might
find in a heater. For each problem, there is a list of
"Possible Causes’. The "Remedy" column tells you
how to correct the problem, or telis you by means of
a section and paragraph number where to find detailed
instructions for correcting it.
In trouble shooting, remember that the air pump
is part of the fuel system, because the air it supplies
lifts the fuel from the tank and pushes it through the
nozzle.
NOTE: Be sure to follow all cautions and warnings.
They will help you prevent damage to the
heater or injury to yourself.
TROUBLE SHOOTING CHART
PROBLEM POSSIBLE CAUSE
FOR FURTHER
DETAILS SEE:
REMEDY
1. Motor does not Electrical Troubles
start; thermostat
(if used) is set to
call for heat,
a. No power or low voltage
at heater.
Be sure power is reaching heater;
check condition of heater cord.
Repair or replace as needed.
Use extension cord with wires
heavy enough to carry the elec-
trical load of the heater.
Sec. II,
Para. B.
Be sure voltage at outlet is same
as shown on heater instruction
plate.
A0387-02
Rev, 2/68
“ Operation and Service Manual
TROUBLE SHOOTING
Section IV
Trouble Shooting
CHART (Continued)
FOR FURTHER
PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE:
1, (Continued) b. Defective motor or motor Check motor and starting relay. Sec. V,
Motor does not starting relay; binding Para. F.
sta rt, thermostat fan-end bearing; binding Replace a defective motor or Sec. V,
(it used) is set pump. motor starting rela Para. F
to call for heat. 5 y o
Lubricate motor (Fan-end only). Sec. IH,
Para. F.
Rebuild motor. Motor Mfr's
Instructions
Rebuild or replace a binding pump. Sec. V,
Para. K.
c. Thermostat (if used)
damaged.
Replace.
Mechanical Troubles
d. Dry bearing on fan-end Lubricate motor. H lubrication does Sec. III,
of motor. not solve problem, check pump. Para. F.
e. Pump rotor binding or Rebuild pump. Sec. V,
carbon blades worn out. Para. K.
f. Fan obstructed by mech- Check for bent outer shell. Sec. V,
anical damage or dirt. Para. H.
Check for damaged fan; replace
if defective.
Check for damaged motor mount.
2. Heater will not Fuel System Troubles
se but motor a. Fuel tank empty, water Check for water in tank: Clean
| in fuel, wrong fuel. tank and fuel filter if water is
found. (Water in the tank will
form globules in the bottom,
which you can see.)
Fill tank with new, clean kero-
sene or No. 1 fuel oil.
b. Fuel filter clogged. Remove and wash in clean fuel. Sec. III,
Blow dry and replace. Para. E.
с. Nozzle plugged or de- Clean by blowing compressed Sec. II,
fective. air through nozzle from outlet Para. G.
end of nozzle.
Replace nozzle if cleaning does Sec. V,
not solve the problem. Para. J.
d. Low air pump Check pressure; adjust, rebuild, Sec. V,
pressure. or replace air pump as needed. Paras. K&L
Check rubber sleeve around Sec. V,
shank of nozzle; replace if Para. J.
leaking.
A1523-00 -9- 3/68
Operation and Service Manual
TROUBLE SHOOTING CHART (Continued)
Section IV
Trouble Shooting
FOR FURTHER
PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE:
2. (Continued) d. Low air pump pressure. Check to be sure all air line con-
Heater will not (Continued) nections from pump to burner are
ignite, but motor secure.
runs.
Check to be sure air filter end
cover is securely fastened, with-
out air leaks.
Be sure air filters are clean. Sec. III,
Para. B.
Check fuel filter for air leaks
e, Air leak at fuel and for tightness of fitting where
filter. filter is connected to burner
head.
Ignition Troubles
e. Defective spark Measure gap between electrodes, Sec, III,
plug. (Wrong gap, using thickness of a dime as a Para. F.
plug wet with fuel gage. Adjust electrode gap.
or electrode S car- Inspect plug for broken porcelain
, OT PIUS or electrodes, Discard a damaged
damaged.) spark plug.
f. Spark plug wire Disconnect heater cord!
disconnected from
plug or from terminal Check at plug and transformer to
of transformer, be sure wire is tight at both ends.
g. Defective Disconnect spark plug wire from Sec. V,
transformer, transformer, and check trans- Para, E,
former for spark; replace if no
spark can be obtained,
3. Heater burns, but |Improper Fuel-Air Mixture (Not enough fuel)
puffs of smoke can
be seen; heater a. Heater running out of fuel; Shut heater off; check fuel tank,
will not burn water condensation in If you can see globules of water
steady; heater fuel tank; wrong fuel. in the bottom, drain and flush
burns with odor, the tank and filter with clean fuel,
heater smokes
continuously. Refill with new, clean kerosene
or No. 1 fuel oil.
b. Dirty air filters causing Remove and clean the air filters. Sec. III,
reduced air flow through Para. B.
nozzle, resulting in low Be sure air intake is not blocked.
fuel flow. |
с. Fuel filter loose, leaky, Remove and wash fuel filter in Sec, III,
or dirty. clean fuel. Para. E.
Check condition of connection Sec. V,
between fuel filter and burner Para. I.
head.
Replace with new filter and
fitting if connection can't be
tightened without leaks.
A1340-00
-10-
Operation and Service Manual
TROUBLE SHOOTING CHART (Continued)
Section IV
Trouble Shooting
FOR FURTHER
PROBLEM POSSIBLE CAUSE | REMEDY DETAILS SEE:
3. (Continued) d. Dirty nozzle. Remove and clean the burner Sec. III,
Heater burns, but head. Para. H.
puffs of smoke can
be seen; heater Blow compressed air through
will not burn nozzle from outlet end.
steady; heater
burns with odor, Never use a drill, wire, or other
heater smokes tool to open a nozzle passage.
continuously.
Replace a defective nozzle. Sec. V,
Para. J.
e. Low pump output pres- Check and adjust pump output Sec. V,
sure. (Low motor speed, pressure; repair or replace Paras. K & L.
worn pump, pump out of pump if adjustment cannot be
adjustment. ) made,
Check to be sure that no dirt or
trash (or dirty fan blades) could
be causing motor slowdown.
Lubricate fan-end bearing of Sec. III,
motor. Para. E.
Í. Loose air output line con- Be sure connections are tight.
nections between filter
housing and burner.
g. (Remote possibility) If heater puffs intermittently, Sec. V,
Rubber sleeve on shank replace the rubber sleeve, Para. J.
of nozzle is leaking, (Handle parts carefully to
prevent damage; assemble
them carefully to preserve
airtightness.)
h, (Remote possibility) Tighten screws. н parts are warped
Combustion chamber not from heat, replace warped parts.
tight against burner head, There must be no air gap
allowing too much air to tween face of burner head
enter combustion and back of combustion
chamber. chamber,
4, Flames come out Improper Fuel-Air Mixture (Too much fuel, or not enough air for
front of heater. amount of fuel being supplied.)
a. Dirty fan, or air passage- Clean the fan, Be sure the air
way through heater blocked | passageway through the heater is
by dirt or trash, clean. Keep the heater clean,
b. Pump output pressure is Check and adjust pump output Sec. V,
too high, causing too much pressure. Para. L.
fuel to be supplied,
c, Fan loose or improperly Check fan; correct if not right. Sec. V,
located on shaît. Para. H.
d. Bent or damaged fan. Replace. Donotattempt repair
of fan.
A1341-01 -11- Rev. 2/68
| Operation and Service Manual Section IV
| Trouble Shooting
TROUBLE SHOOTING CHART (Continued)
FOR FURTHER
PROBLEM POSSIBLE CAUSE REMEDY DETAILS SEE:
о. Heater cycles in- Electrical System Troubles
termittently.
a. Thermostat (if used) set Set thermostat to a higher tem-
too low. perature for more even operation.
b. Defective thermostat (if Replace a defective thermostat. Sec. V,
used). Para. C.
c. Low voltage causing trip- Check power line voltage.
out of motor overload pro-
tector. Use extension cord with proper Sec. II,
size wire. Para. B.
d. Defective electrical sup- Be sure extension cord and heat-
ply or defective connec- er service cord are in good con-
tions. dition, without intermittent open
circuits.
Check mechanical and electrical
soundness of all wiring connec-
tions in the heater and service
cord.
e. Motor overload protector Lubricate fan-end bearing. Sec. III,
tripping out due to motor Para.D & Е.
trouble or binding pump. Keep motor and fan area clean.
Replace defective motor or re- Sec. V,
build defective pump. Paras. F, G,
& K.
CAUTION: Keep fingers away
from fan when heat-
er service cord is
plugged in.
A1342-00 -12-
Operation and Service Manual
Section V
Service and Repair
SECTION V
SERVICE AND REPAIR INSTRUCTIONS
A. GENERAL
This section covers replacement of parts, repair
and rebuilding of heater components, and the making
of adjustments. Check to be sure the maintenance of
the heater has been done, before going into the more
extensive service operations. The heaters canbe com-
pletely rebuilt and checked in less than one hour.
Whenever a part needs to be replaced, you can
identify it on the exploded view in the Parts List por-
tion of this book, Section VI. Order any needed part
by name and part number.
B. SPECIAL TOOLS, EQUIPMENT, AND SUPPLIES
The following tools, equipment and supplies
should be available for complete servicing of the heater.
1. Air Gage. PartNo. M9148, or any gage with
a 15 pound pressure range and 1/4 pound divisions,
able to indicate 4-1/4 pounds accurately, plus fittings
for installation into a 1/8 inch standard pipe-threaded
hole.
2. Oil Burner Nozzle Wrench, or any deep 5/8
inch socket wrench.
3. Cleanfuel, either kerosene or No. 1 fuel oil.
4. Non-flammable liquid cleaning solvent, such
as carbon tetrachloride.
CAUTION: Fumes are poisonous; use with
GOOD ventilation!
о. Compressed air is advisable, but not ab-
solutely necessary.
C. THERMOSTAT ACCESSORY
If you suspect that thermostat failure is prevent-
ing the heater from starting, and the thermostat is set
to call for heat, check it as follows:
1. Turn the knob from OFF to ON, slowly,
through the full range of the thermostat, two or three
times. (The thermostat has positive OFF and ON
positions.) If the heater does not start, proceed as
follows:
2. Unplug the heater service cord from the
Thermostat Accessory outlet, to take the thermostat
out of the circuit.
3. Plug the heater service cord into an outlet.
If the heater motor starts, the thermostat is defective
and must be replaced. If the motor does not start,
the thermostat is probably not the cause.
A1343-00
-13-
D. REMOVAL OF UPPER SHELL
It will be necessary to remove the upper shell in
order to perform the rest of the service operations on
the heater. See Section III, paragraph C.
WARNING
With the upper shell removed and the ser-
vice cord plugged in, the heater can be
dangerous. Be careful to keep away from
the transformer leads and the fan when the
upper shell is off.
E. TRANSFORMER
Check the transformer as follows:
WARNING
Be EXTREMELY careful when checking the
transformer. A transformer in good con-
dition produces VERY high voltage at the
output terminals.
1. Connectthe transformer lead to a properly-
gapped spark plug. The gap should be 0.050 inch,
plus or minus 0.005 inch. See Figure 6.
2. Establish a good ground between the spark
plug and the heater. Be careful not to let any part of
your person become a portion of the ground circuit.
3. Plugthe heater cord into an outlet of the pro-
per voltage. Observe the spark between the plug's
electrodes. If the spark does not jump between the
electrodes, and the ground is good, the transformer is
defective. Replace it. |
4. Toreplace the transformer, take out the two
screws which attach it to the motor mounting bracket.
Make sure that the new transformer mounting tabs are
free of paint, to assure a satisfactory ground.
5. Reinstall the attaching screws, and make
wiring connections in accordance with Figure 9.
6. Snap the spark plug lead tightly onto the plug
terminal, to prevent its coming loose when the heater
is moved.
F. CHECKING THE MOTOR STARTING CIRCUITS
In case the motor fails to start when the cord is
plugged in or the thermostat is set to call for heat,
check the motor and its starting circuit components as
described in the following paragraphs.
Operation and Service Manual
WARNING
The motors contain an automatic thermal over-
load protector. This may stop the motor, due
to overload or low voltage, then RESTART it
automatically. Be sure to disconnect the heater
before inspecting the motor.
1. Mechanical Check. Spin the motor by turning
thefan blades by hand. If the motor turns freely, make
the electrical checks as described in paragraph 2. Any
stiffness of the motor indicates mechanical troubles.
See "Motor Service", paragraph G of this Section.
2. Electrical Check. These heaters have 1/8
horsepower motors and separate starting relays. (See
the Wiring Diagram, Figure 9.)
NOTE: 'Therelayis "position-sensitive' and must
be tested in the same position as when in-
stalled in the heater (with the contacts at
the top).
a. Take the relay out of the heater by taking
out the screw which holds its bracket to the left side
of the lower sheli, near the motor.
Section V
Service and Repair
CAUTION: Avoid touching the bare wires or the
exposed wire terminals.
b. Takethe black motor wire off its terminal
on the starting relay. Touch this wire to the terminal
of the red motor wire, at the relay. The motor should
start. As soon as the motor reaches operating speed,
remove the black wire from contact. The motor should
continue to run.
c. If the motor starts, install a new relay,
and reconnect the wiring according to the Wiring Dia-
gram, Figure 9.
d. I the motor fails to start, or if it fails to
continue running when the black wire is taken away, it
is defective. Repair or replace it. See paragraph G
of this Section.
NOTE: Whensendingthe motor away for repairs,
remove the fan, the air filter housing, and
the pump end cover. Take outthe rotor and
carbon blades. (See paragraph K for pump
service instructions. )
G. MOTOR SERVICE
1. Apply a few drops of oil to the fan-end bearing
of a stiff motor. If this fails to correct the starting
difficulty, rebuild the pump, as described in paragraph
K of this Section.
G.E. RELAY
MOTOR
BLACK
MOTOR|M SÓ
RED Lo
| LINE
INTERNAL GRAY > LINE
GROUND xo
KLIXON
Pq
BLACK RELAY
TRANSFORMER RED
|
BLACK q
WHITE _L WIRE что 17
W
HITE GREEN
BLACK
M12634 521
Figure 9, Wiring Diagram
A1530-00 -14- 3/68
Operation and Service Manual
SETSCREWS MUST REST
IN INNER GROOVE IN
MOTOR SHAFT
OUTER GROOVE
FAN HUB
MOTOR
283
Figure 10, Location of Fan on Motor Shaft.
2. During rebuilding of the pump, checkthe motor
again for stiffness. If stiffness still exists, rebuild the
motor according to the manufacturer's instructions.
3. Whenever a motor has been rebuilt, be sure to
check the pump rotor clearance as described in para-
graph K-4 of this Section, before reassembling the mo-
tor into the heater.
4. When you install the motor, insert the spacers
between the ends of the motor mounting clamps,
H. FAN SERVICE
Replace a damaged or bent fan. Do not attempt
repair except as a temporary emergency measure.
Loosen two setscrews to remove the fan from the mo-
tor shaft.
Be sure the replacement fan has the same blade
pitch as the fan that was removed. This is important
in order to retain the air flow and combustion charac-
teristics of the heater.
Check for proper fan location of the motor shaft.
Make sure the fan is in the same position and location
as before it was removed. See Figure 10,
|. FUEL FILTER SERVICE
1. Remove the fuel filter from the heater and clean
it, as described in Section III, paragraph G.
2. Before reinstalling the fuel filter, check the
rubber bushing where it enters the fuel tank. Be sure
the bushing is in good condition -- not cut or cracked.
Replace a damaged bushing.
A1345-00
-15-
Section V
Service and Repair
3. Reinstall the fuel filter according to Section
III, paragraph G. Replace witha new filter if the con-
necting parts are damaged to prevent a tight connection.
J. BURNER HEAD SERVICE
1. Takeout the spark plug and remove the burner
head, Clean the entire burner head, as described in
Section II, paragraph H.
2. If there is any sign of damage to the nozzle,
or if it is impossible to clean out the nozzle by blowing
compressed air into it through the outlet-end, replace
with anew nozzle. Always blow a nozzle out thoroughly
with air, from the outlet-end, before installing it into
the burner.
CAUTION: NEVER try to open a nozzle passage
with a drill. Any change in the size or
shape of the passage will damage the
nozzle beyond repair. Donotdisassem-
ble the nozzle, as flow characteristics
are changed by disassembly. Protect
the passage from damage whenever you
work on the burner or nozzle.
3. Always install a new rubber sleeve whenever
you install anozzle into the burner. The sleeve is the
part that helps maintain the needed pressure difference
between the air and fuel chambers of the burner head.
If bubbles have appeared in the fuel tank during opera-
tion, the rubber sleeve is probably leaking and should
be replaced.
4. Be sure the seal washer, spring, and second
seal washer are in place on the nozzle before you in-
stall the rubber sleeve.
5. When seating the nozzle firmly against the
burner head, do not apply too much pressure with the
wrench, or the nozzle could be distorted.
6. Adjustthe spark plug gap as explained in Sec-
tion III, paragraph F.
K. AIR PUMP REPAIR
NOTE: Because of the close tolerances and criti-
cal positioning of the parts, we recommend
that only skilled mechanics attempt any re-
pair of the air pump.
The heater's air pump consists of a rotor with
four carbonblades, rotating inside a pump body. The
rotor is driven directly by the motor, and is supported
by the ball-bearing end of the motor. One of the pump
end plates is the motor's back end plate. The other
pump end plate is part of the housing for the air intake
and outlet filters.
Handle all pump parts with care and keep them
clean. The parts are made with close tolerances. Dirt
and oil on pump parts will hinder the performance of
the pump.
If pump repair is required, you may order a com-
plete pump package, or individual parts, as shown in
the Parts List, Section VI.
Operation and Service Manual
1. Disassembly.
CAUTION
Do not take the pump apart any further than
you need to in order to reach the parts which
must be replaced.
a. Remove the end cover and take out the in-
take and outlet air filters and the lint filter. Discon-
nect the air line from the elbow on the remaining por-
tion of the air filter housing.
b. Holdaclean, dry clothunder the pump, and
remove the six screws that hold the end cover to the
pump body. Catch the carbon blades in the cloth, if
they fall out as the pump body is removed.
с. Take all four carbon blades out of the rotor.
Pull the rotor and the spring off the motor shaft.
2. Replacing Carbon Blades.
‘a. Wornor sticking carbon blades cause loss
of air pressure, If the blades are worn, or are stick-
ing inthe rotor slots, replace them. (It is not neces-
sary to remove the rotor or the pump body to replace
the carbon blades.)
b. Washthe rotor, end cover, and pump body
in non-flammable cleaning solvent and blow them dry
before you install new blades.
с. Install the carbon blades into the slots, with
the notched ends of the blades inside the slots and the
rounded ends toward the outside.
3. Replacing the Rotor.
Use a new rotor only if deep grooves or uneven
PUMP ROTOR MOTOR END
— SHIELD
MOTOR SHAFT
0.005"
CLEARANCE -
MEASURE WITH
FEELER GAGE
>= SCREWS
2178
Figure 11, Checking Clearance of Air Pump Rotor
A1546-00
-16-
Section V
Service and Repair
wear appear on the surfaces. Check the spring for
wear, and replace it if worn or loose.
To remove the rotor, first remove the pump body.
When installing the rotor, take care to keep it perpen-
dicular to the motor shaft.
4, Reassembly of Air Pump.
a. Install the spring inthe pump rotor as shown
in Figure 11, then assemble rotor onthe motor shaft.
Attach the pump body to the motor with the two top and
bottom recessed screws which were removed to take
it off.
b. Adjust the pump body to provide 0.003 to
0.005 inch clearance at the point shown in Figure 11.
Measure the clearance with a feeler gage. Spin the
motor by hand to be sure the rotor does not rub on the
pump body. The proper clearance must be maintained.
Be sure the screws are tight after adjusting the clear-
ance.
с. Insert carbon blades as described above.
d. Install the end cover, using the six screws
whichwere removed. Reconnectthe air line to the el-
bow in the end cover.
L. ADJUSTMENT OF PUMP PRESSURE
1. Remove the plug from the air filter housing,
and install the pressure gage (listed in paragraph B
of this Section) into the hole. See Figure 12.
2. Starttheheater. (Youdo not need to have fuel
in the tank for this pressure check and adjustment.)
3. Pump pressure must be 4 pounds per square
inch, plus or minus 1/16 pound. If the pressure is not
within this range, adjust the pressure relief valve.
Figure 12. Checking and adjustment of Air Pump Pressure
3/68
Operation and Service Manual
4. To adjust, back off the locking nut 1/4 turn.
Screw the valve stem in to raise the pressure; out to
lower it. Tightenthe locking nut securely and recheck
the pressure.
5. Remove the gage and replace the plug.
M. REASSEMBLY OF HEATER
1. Put the heater back together in the reverse
order of disassembly.
2. Check all wiring to be sure it agrees with the
wiring diagram. Be sure all electrical connections
are tight.
A1347-00
-1"7-
Section V
Service and Repair
3. Tightenthe connections at both ends of the cop-
per air line, and tighten the connection where the fuel
filter is assembled to the burner head.
4, Make sure the spark plug lead is snapped onto
the terminal.
9. Be sure all parts are in place and the screws
are tight before attempting to use the heater.
N. FINAL CHECK
Put at least two gallons of fuel in the fuel tank and
test-fire the heater for a few minutes, after all service
has been completed, to be sure it will operate satis-
factorily.
Operation and Service Manual Section VI
Illustrated Parts List
MODEL 583.408030 BASIC HEATER ASSEMBLY
541
Figure 13. Model 583. 408030 Portable Heater, Exploded View
A1524-00 -18- 3/68
ee
Operation and Service Manual
This section contains a list of all replaceable parts used
inthe heater covered by this manual.
recommended for replacement by the heater's owner or user
SECTION VI
ILLUSTRATED PARTS LIST
are indicated by the symbol (*).
Specify color when ordering painted parts.
The only parts that are
Section VI
Illustrated Parts List
To order paris, first check the nameplate decal for the
correct model number and Spec. No. of the heater.
INCLUDE
THE MODEL AND SPEC. NUMBER WHEN ORDERING
PARTS, Order parts by part name and part number only. Do
not use the index numbers from the illustration when ordering
parts.
MODEL 583.408030 BASIC HEATER ASSEMBLY
Index Part
No. Number Part Name Quan.
1 M13134G3 Shell, Upper 1
2 Not Used
3 M16781G1 Combustion Chamber 1
- M11084-27 Screw, Seli-tapping, hex hd, No.
10-12 x 1/2 in., Type A (Com-
bustion Chamber attaching,
| front) 2
- M11084-29 -Screw, Self-tapping, hex hd, No.
10-12 x 3/4 in. , Type À (Com-
bustion Chamber attaching,
о rear) 2
4 M15995 Plug Button 1
5 M16786G2* Burner Head Assembly (See
Figure 14) 1
- M11084-27 Screw, Self-tapping, hex hd,
No. 10-12 x 1/2 in., Type A
(Burner Head to Combustion
Chamber) 3
6 M16879 “Air Line 1
M15807 Strap, Retainer 1
M11084-27 Screw, Seli-tapping, hex hd, No.
10-12 x 1/2 in., Type A (Re-
) tainer Strap to Lower Shell) 2
8 M14529 Fan, 16 Pitch 1
- Nonumber . Setscrew, Soc. hd., cup pt,
1/4-28 (Fan to Motor Shaft) 2
9 M18146G1 Motor Package Assembly (See
Figure 15) 1
10 M16661 Clamp, Motor 4
11 M13620 Spacer, Motor Clamp 2
12 HC4-10C Screw, Hex hd, 1/4-20 x1-1/4in.,
(Motor Clamps) 2
13 WLM-4 Lockwasher, 1/4 in. , (Motor Clamps) 2
14 NPC-4C Nut, Hex, 1/4-20 (Motor Clamps) 2
15 M16777 Shell, Lower 1
16 MIi1084-27 Screw, Self-tapping, hex hd, No.
10-12 x 1/2 in., Type A
(Upper Shell to Lower Shell) 6
17 M11271-6 Nut, Tinnerman (Upper Shell to
Lower Shell) 6
18 M12330 Bracket, Shell Support 1
— M11084-27 Screw, Self-tapping, hex hd,
No. 10-12 x 1/2 in. , Type A
(Support Bracket to Lower Shell
and Fuel Tank) 4
* Parts recommended for normal service replacement.
A1525-00
Index Part ;
No. Number Part Name Quan.
- Mi1084-29 Screw, Self-tapping, hex hd,
No. 10-12 x 3/4 in., Type A
(Lower Shell to Support Bracket) 2
19 1000576 Grommet (Ignition Cable to
Lower Shell) 1
20 M15809 Plug Button 1
21 Not Used
22 Not Used
23 Not Used
24 M16646 Bracket, Motor Support . 1
- M11084-27 Screw, Self-tapping, hex hd,
No. 10-12 x 1/2 in., Type A
(Motor Bracket to Lower Shell
and Fuel Tank) 6
25 1000576 Grommet (Motor and Capacitor
leads thru Motor Bracket) 2
26 M16697 Transformer (Alternate: M17795) 1
- M11084-27 Screw, Self-tapping, hex hd,
No. 10-12 x 1/2 in., Type A
(Transformer to Motor Bracket) 2
27 M11954 Bushing, Strain Relief |
(Service Cord) 1
28 M10813G33 Extension (Service) Cord 1
29 M13942-4 Connector (Wire nut) 2
- M9900G62 Wire Assy (to Capacitor) 1
30 M16797G1 Fuel Tank 1
31 M3353 Cap, Fuel Tank 1
32 M10990-3 Bushing, Rubber, (Fuel Filter/
Fuel Tank) 1
33 M13990 Plug, Pipe, 1/4 in. , Sq. hd.
(Fuel Tank drain) 1
34 Not Used
35 Not Used
36 M11952 Bracket, Starting Relay Mounting 1
- M11084-27 Screw, Seli-Tapping, Hex hd. ,
No. 10-12 x 1/2 in., Type A
(Relay Mounting Bracket to
Lower Shell) 1
37 M12462-5
- RC2-2C
- WLI-2
- ST2-2AC
Starting Relay (Alternate: M12462-2)
Screw, Rd. hd., No. 8-32 x 1/4 in.
(Starting Relay to Mounting
Bracket)
Lockwasher, No. 8
Screw, Rd.hd., No. 8-15 x 1/4in.
(Grounding)
el
3/68
Operation and Service Manual
Section VI
Illustrated Parts List
BURNER HEAD ASSEMBLY
Index Part Index Part
No. Number Part Name Quan. No. Number Part Name Quan.
M16786G2 Burner Head Assembly 1 5 M5976 . . Connector, Male 1
1 M16789G2 . Filter Assy, Fuel 6 M8882 . . Sleeve, Nozzle Seal 1
(Alternate: M16790-2 7 M10659-1 . . Washer, Nozzle Seal 2
and M17460) 1 8 M10809-1 . . Spring, Nozzle Seal 1
2 M13849 . Nut, Flared 1 9 M18048 . . Nozzle 1
3 M16741-18 . Ring, Retaining 1 10 M16535 . . Adapter, Nozzle 1
- M16787G4 . Nozzle Adapter Assy 1 11 M16895G1* . Spark Plug Assy 1
4 M16791 . . Connector, Male 1 12 M16534 . Body, Burner Head 1
* Parts recommended for normal service replacement.
3
Figure 14. Burner Head Assembly
Al526-01 -20- 3/68
. «#
Operation and Service Manual Section VI
Hlustrated Parts List
MOTOR PACKAGE ASSEMBLY
Index Part Index Part
No. Number Part Name Quan. No. Number Part Name Quan.
- M16146G1 Motor Package Assembly 10 M8643 . Blade 4
(Alternate: M16783G1) 1 11 M11959 . Rotor 1
- M16675G2* . Pump and Filter Parts 12 M11966-5 . Spring 1
Package 1 13 M8645 . . Pump Body 1
14 FHPF3-4C* . Screw, Fil hd, 10-32 x
1 M16545 . . End Cover 1 1/2 in. 2
2 M12461-31* . . Screw, Hex hd, 10-32 x 15 M5976 . Connector, Male 1
1 in. 4 16 M10837 . Pipe Plug 1
3 WLI-3* . Lockwasher, Internal 17 M10992-1 . Screw, Pressure
No. 10 4 Adjustment 1
4 M12179* . . Intake Filter 1 18 M10993-1 . Spring, Compression 1
5 M12244G1* . . Filter Assy 1 19 M8940 . . Ball, 1/4 in. dia. Î
6 M11637* . Filter, Lini 1 20 M17941 . Motor (Alternate: M11938
7 M12233 . End Cover, Pump (Port used with M16783G1
plate) 1 Motor Package Assy.) 1
8 M12461-32* , . Screw, Hex hd, 10-32 x — M8608 . End Shield, Motor
1-1/8 in, 6 (Pump-end) 1
9 WLI-3* . . Lockwasher, Internal - M17316 . End Shield, Front
| No. 10 6 (Fan-end) 1
* Parts recommended for normal service replacement.
373B
A1527-00
Figure 15. Motor Package Assembly
-2
1-
3/68
Operation and Service Manual Section VI
WT. aidan ve Zn
Ilustrated Parts List
WHEELS, HANDLES, MARKINGS
Index Part Index Part
No. Number Part Name Quan. No. Number Part Name Quan.
1 M12634 Decal, Wiring Diagram (inside 8 M12345-31 Screw, Oval hd. mach.,
Upper Shell) 1 No. 10-24 x 1-1/4 in. 2
2 M10302-2 Decal, Trade Name 2 9 M12345-34 Screw, Oval hd. mach. ,
3 M17157 Decal, Private Label 1 No. 10-24 x 2 in. | 8
4 M17034 Decal, Nameplate and Operation 10 WP-3C Washer, Flat, No. 10. 2
Instructions 1 11 NTC-3C Nut, No. 10-24, Torque- Lock 10
M18081-8 Decal, Model 1 12 M16802 Hub Cap 2
5 M15131 Handle, Rear 1 13 M16741-15 Ring, Retaining 2
6 M15808 Handle, Front 1 14 WP-8C Washer, Flat, 1/2 in. 2
7 M12342 Frame, Wheel Support 1 15 M16746 Wheel 2
16 M16801 Axle 1
* Parts recommended for normal service replacement.
465
Figure 16. Wheels, Handles, Markings
TOUCH-UP PAINT
M13386-13 Red Touch-up Paint, Aerosol Can
M13386-7 White Touch-up Paint, Aerosol Can
M13386-8 Black Touch-up Paint, Aerosol Can
A1528-00 ~22-
3/68