Keystoker A120 not pushing enough coal

Keystoker A120 not pushing enough coal

PostBy: szembek On: Tue Jan 10, 2017 7:58 pm

My a120 is on it's 10th winter here now. I've never had an issue with it, but noticed this winter that it just isn't pushing as much coal as it should. Even with the adjustment screw fully cranked it's leaving several inches of ash on the grate. I haven't changed anything this year, just did my normal cleaning of the exchange, flue, and under the grate. I did pull the stoker motor out and found that part of the bar that pushes the coal has a section that seems to be worn out on it. Not sure if this is causing the problem or a symptom of some other problem, so I'll just attach a pic. Also a pic of what the fire looks like at full tilt with the feed adjusted fully on. In the third pic I tried to show that the white plastic cam seems to have a groove wore in it too.

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Image

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Thanks for any insight. It wasn't quite keeping up when it was dipping to about 5 degrees the other night, if it drops low like it did a couple winters ago I'll be up a creek with it like this!
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

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Re: Keystoker A120 not pushing enough coal

PostBy: CoalisCoolxWarm On: Tue Jan 10, 2017 8:16 pm

I can offer this link: http://nepacrossroads.com/about43510.html

Be sure to check the gasket material on the sides of the slide, it can get bunched up and jam the feed bar. It was installed with double stick tape on the unit I worked on recently :shock:
CoalisCoolxWarm
 
Stoker Coal Boiler: Keystoker KA-6
Hand Fed Coal Furnace: old Sears rebuilt, bituminous- offline as of winter 2014
Coal Size/Type: Anthracite Buckwheat
Other Heating: Oil Boiler

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Tue Jan 10, 2017 8:26 pm

Thanks, i didn't notice anything like that with the gasket, but could have missed it.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: CoalisCoolxWarm On: Tue Jan 10, 2017 8:30 pm

When you drop the motor, the cam comes out of that hole and you *should* be able to remove the feed block, out of the back (away from firebox side)

Vacuum and clean all that up. Check the nylon screws and the gasket material on the sides.

When reassembled, it will be tight, but should slide freely with minimal resistance.
CoalisCoolxWarm
 
Stoker Coal Boiler: Keystoker KA-6
Hand Fed Coal Furnace: old Sears rebuilt, bituminous- offline as of winter 2014
Coal Size/Type: Anthracite Buckwheat
Other Heating: Oil Boiler

Re: Keystoker A120 not pushing enough coal

PostBy: WNY On: Tue Jan 10, 2017 8:30 pm

Have you replaced the CAM at all? could be worn or like the other post, the pusher block could be binding up.

do you have the feed screwed all the way in for max feed when calling for heat? should almost push hot coals off and then adjust 1/2 turn out accordingly.
WNY
 
Hot Air Coal Stoker Stove: Keystoker 90K, Leisure Line Hyfire I
Coal Size/Type: Rice
Stove/Furnace Make: Keystoker, LL & CoalTrol
Stove/Furnace Model: 90K, Hyfire I, VF3000 Soon

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Tue Jan 10, 2017 9:04 pm

WNY wrote:Have you replaced the CAM at all? could be worn or like the other post, the pusher block could be binding up.

do you have the feed screwed all the way in for max feed when calling for heat? should almost push hot coals off and then adjust 1/2 turn out accordingly.


I have never replaced the cam. It definitely has some wear I can see on it, hard to show in the photo, but it has some material wore off it. I fully removed the cam, stoker motor, pusher bar and fit it back in just a month or so ago.

Yes the feed screw is fully cranked and not pushing coals nearly like it has any of the 10 previous seasons I've burned with this.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Tue Jan 10, 2017 9:08 pm

CoalisCoolxWarm wrote:When you drop the motor, the cam comes out of that hole and you *should* be able to remove the feed block, out of the back (away from firebox side)

Vacuum and clean all that up. Check the nylon screws and the gasket material on the sides.

When reassembled, it will be tight, but should slide freely with minimal resistance.


Yeah I did all of that a month or so ago thinking some coal got where it shouldn't and was binding something up. Everything came out, went back together like you said, tight, but movable.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: CoalisCoolxWarm On: Tue Jan 10, 2017 9:39 pm

szembek wrote:Yeah I did all of that a month or so ago thinking some coal got where it shouldn't and was binding something up. Everything came out, went back together like you said, tight, but movable.


Did you notice the wear last month when you had it apart on the cam and push bar? Is it getting worse?

What made you tear it apart again this month? Did it jam?

Or did it finally wear down enough that it was giving you problems?
CoalisCoolxWarm
 
Stoker Coal Boiler: Keystoker KA-6
Hand Fed Coal Furnace: old Sears rebuilt, bituminous- offline as of winter 2014
Coal Size/Type: Anthracite Buckwheat
Other Heating: Oil Boiler

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Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Wed Jan 11, 2017 9:01 am

CoalisCoolxWarm wrote:
szembek wrote:Yeah I did all of that a month or so ago thinking some coal got where it shouldn't and was binding something up. Everything came out, went back together like you said, tight, but movable.


Did you notice the wear last month when you had it apart on the cam and push bar? Is it getting worse?

What made you tear it apart again this month? Did it jam?

Or did it finally wear down enough that it was giving you problems?


I noticed the wear when I took it apart, but it was warm enough outside at that point that I didn't notice it was giving significant problems, just "seemed" that it wasn't feeding enough. Figured I'd take it apart and clean it up in case some coal got where it shouldn't or something. I took the photos then because it didn't look right, but didn't worry about it too much.

Fast forward to this past week and it became obvious that it isn't feeding enough because it can't keep up with the thermostat when cranked, never a problem in previous seasons.

I'll probably call keystoker today and see what they suggest. I've heard they're helpful.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Wed Jan 11, 2017 10:16 am

To follow up, I contacted keystoker and based on my story he thinks replacing the cam and nylon guide screws will likely fix the problem, they're on the way. I'll report back if I have luck.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: CoalisCoolxWarm On: Wed Jan 11, 2017 10:17 am

szembek wrote:To follow up, I contacted keystoker and based on my story he thinks replacing the cam and nylon guide screws will likely fix the problem, they're on the way. I'll report back if I have luck.


Sounds about right. How much are they now?
CoalisCoolxWarm
 
Stoker Coal Boiler: Keystoker KA-6
Hand Fed Coal Furnace: old Sears rebuilt, bituminous- offline as of winter 2014
Coal Size/Type: Anthracite Buckwheat
Other Heating: Oil Boiler

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Wed Jan 11, 2017 11:38 am

CoalisCoolxWarm wrote:
szembek wrote:To follow up, I contacted keystoker and based on my story he thinks replacing the cam and nylon guide screws will likely fix the problem, they're on the way. I'll report back if I have luck.


Sounds about right. How much are they now?


$15 for the cam, I think $0.60 a piece for the nylon screws or something like that.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

Re: Keystoker A120 not pushing enough coal

PostBy: StokerDon On: Wed Jan 11, 2017 8:18 pm

You should have gotten 2 sets. It's a real good idea to have a spare set on the shelf for emergencies.

-Don
StokerDon
 
Stoker Coal Boiler: BairMatic BMC-500 with Van Wert VA400 Stoker, Gentleman Janitor GJ-671/EFM S-15 stoker, Van Wert VA-600
Hand Fed Coal Furnace: Harman SF3500
Coal Size/Type: Rice and Chestnut
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Re: Keystoker A120 not pushing enough coal

PostBy: szembek On: Thu Jan 12, 2017 12:27 pm

StokerDon wrote:You should have gotten 2 sets. It's a real good idea to have a spare set on the shelf for emergencies.

-Don


Yup thought of that. I'll probably order extras, as well as an extra stoker motor in the near future to be honest. It's my only source of heat and I don't want to be stranded.
szembek
 
Stove/Furnace Make: Keystoker
Stove/Furnace Model: A120

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