Keystoker 90,000 BTU General instructions

© October 2017 REV 2
Installation, Operation and Maintenance
Manual
90,000 BTU & 105,000 BTU
Stoker Coal Stoves, Direct Vent
105K BTU Stove Shown

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 2 -
About Us
Keystoker had its inception in 1946.
Two electrical engineers saw the need for a way to conveniently burn anthracite coal,
which was plentiful, but heating with coal had a bad reputation of being dirty and
requiring maintenance several times a day. Our engineers developed an automatic
stoker unit equipped with a coal hopper that held enough fuel for several days. This
allowed the coal to be cleanly burned and without frequent maintenance. They then
saw the need to make a hot water boiler specifically designed to burn coal and built
them in multiple sizes to meet our customers' needs.
As prices of energy continued to escalate, Keystoker continued its research. Over 60
years of research has developed a patented feed-in system, a patented flat grate, and
a patented thermal heat exchange, which has produced the highest efficiency
possible.
Keystoker --- Made in America with American Technology and utilizing American
resources is now known internationally for its simplicity, quality, and dependability, all
this and still an economical price.
TESTED 9/89 TO ANSI/UL 1482, CSA B366-m1979 & ETLM 78-1
CONAM Inspection, Inc.
Auburn, MA 01501 STL-002

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 3 -
Table of Contents
Safety
4
Precautions & Definitions
4
General Safety Statements
4
Installation
5
Stove Placement
5
Vent Terminator Location & Direct Vent Arrangement
7
Direct Vent Completion Kit
9
Assembly
10
Fuel Type
11
Operation
12
Start-up
12
Diagram 1 - Continuous Heating
14
Diagram 2 – Intermittent Heating
15
Component Descriptions & Operation
16
Stoker Unit Components
16
Timer
19
Thermostat
20
Fan Limit Switch
20
Maintenance
21
Cleaning & Lubrication of Stove
21
Reassembly of Direct Vent Piping
22
Cleaning Stove Glass
23
Ash Pan Emptying
24
Gear Motor Removal & Installation
25
Troubleshooting Guide
27
Diagrams
29
Wiring
29
Wiring – Direct Vent
30
Stove Parts List
31
Fire Door & Ash Door Parts Lists
32
Warranty
33
Stove Information
33
Parts Ordering
33
Stove Contents Checklist
34

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 4 -
Safety
Precautions & Definitions
Our stoves have been designed for safe and reliable operation when properly used
and maintained in accordance with instructions contained in this manual. A stoker
stove is a precision system that if not properly installed or maintained can be hazardous,
cause burns, electrical shock or even loss of life. Keystoker shall not be liable for
physical injury, damage to property or death caused by a failure to observe the
instructions in this manual.
Please note the following symbols are used to denote special attention within this
manual:
Electrical Hazard. Particular care must be taken when electrical power source to
the unit is energized.
Warning. Operating procedure, practice etc. which, if not correctly followed,
could result in personal injury.
Caution. Operating procedure, practice etc. which if not followed could result in
damage or destruction of unit.
Fire. Operating procedure, practice, etc. which if not followed could result in
severe burns, bodily harm, loss of life and property damage.
Death. Critical situation or operation of unit that may cause death.
General Safety Statements:
•Thoroughly read and understand all instructions
•Always leave this manual with the owner of the stove.
•A carbon monoxide (CO) detector has been supplied with your stove.
oThe CO Detector needs to be plugged in.
oCO is colorless, odorless & tasteless gas that can be deadly if not
monitored or detected properly.
•Danger risk of fire or explosion. Do not burn garbage, gasoline, drain oil, or other
flammable liquids. Do not use chemicals or fluids to start fire.
•Stove surfaces may be hot while in operation. Keep children away. Do not touch
during operation
•Do not connect this unit to a chimney flue serving another appliance
•Please follow all local building and zoning ordinances
•Use the proper fuel type as noted in this manual

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 5 -
Installation
Stove Placement
1. Safety inspection of a venting system should be performed before and after
installing your new stove. Procedures to follow are those recommended by
National Fuel Gas Code, ANSI Z223.1 or refer to local codes or ordinances.
2. Plan the vent system layout before installation to avoid possibility of accidental
contact with concealed wiring or plumbing inside walls.
3. Select a position on a solid level surface with direct access to a chimney. On
non-masonry floors, use an approved fireproof floor protector under stove.
Maintain 12” clearance on sides of stove to combustibles. Maintain 6” clearance
from 4” pipe to combustible. Clearance from 6” black wall pass thru pipe is 0” to
combustibles. A 2” clearance on rear and 16” clearance on front of stove.
Clearance from corners of stove is 8”. See label on stove. Refer to Figure 1a &
1b.
FIGURE 1a
•Tested 9/89 to ANSI/UL 1482, CSA
B366-m1979 & ETLM 78-1
•Chimney Type: Minimum 6”
diameter approved low heat
residential type all fuel.
•Chimney connector: 6” diameter
24 gauge blue or black steel.
•Install at least 18 inches from
ceiling. Special methods are
required when passing through a
wall or ceiling.

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 6 -
FIGURE 1b

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 7 -
Vent Terminator Location & Direct Vent Arrangement
VENT TERMINATOR MAY NOT BE LOCATED
A. Less than 1 foot above grade.
B. Above or within 3 feet horizontally of oil tank or gas meter.
C. Closer than 3 feet to inside corner of home.
D. Closer than 1 foot from any opening that gasses could re-enter home.
E. Less than 4 feet below windows.
F. Less than 1 foot horizontally of door or window.
G. Less than 3 feet above any forced air inlet located within 10 feet.
H. Less than 7 feet above grade when adjacent to public walkways
Refer to Figure 2
FIGURE 2
A
B
C
H
E
F
D
G
Note: Lettered dimensions refer to above list
Vent Terminator

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 8 -
FIGURE 3
Bottom Vent Layout
Top Vent Layout
Note: Item descriptions on next page
Note: Item descriptions on next page

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 9 -
Item #
Component
Item #
Component
1*
Sealer for All Joints
5*
4” Tee
2
Stove
6
1 Piece Wall Kit
3
Hanging Baffle
7
Stainless Steel Rain Cap
4*
Direct Vent Unit
8
4” Elbow
1* Seal All Joints: When it becomes necessary to run exhaust pipe up the interior
wall of home, every joint must be sealed with a high temperature silicone or
equivalent. This will prevent fumes from escaping into home.
4* Draft Port: It may be necessary to clean draft port (Located inside exhaust
outlet of the Direct Vent Unit) every several weeks to keep the stove from tripping
out on safety reset. Removal of the Direct Vent side plate will aide in cleaning.
Using brush (furnished with stove) remove ash pan, reach into 6” exhaust pipe, and
by using a swirling or circular motion, remove dust.
5* Tee: A tee should be used at this location. A tee will ease the cleaning of the
piping throughout the heating season.
Direct Vent Completion Kit
Item #
Component
Item #
Component
1
Direct Vent Exhaust Motor
5
4” Elbow
2
Direct Vent Unit
6
4” Stainless Steel Pipe
3
4” Stainless Steel Pipe
7
6” 24 Ga. Stainless Pipe
4
4” Tee
8
Stainless Steel Rain Cap
FIGURE 4
Direct Vent Completion Kit
Supplied with Stove
Note: Orientation of Direct
Vent Unit will vary based on
Top or Bottom Vent Stoves

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 10 -
Assembly
1. Plumb hopper end of stove with level. Hopper end of stove must be vertical.
2. Mount hopper in place and fasten securely. Carefully, reach down into bottom
of inside hopper and bend flange of hopper into throat of stoker unit.
3. After determining location of stove, (if you are going through a frame wall) cut a
hole through exterior & interior walls slightly larger than the 6” stainless steel pipe.
Put stove into position to determine stove pipe length needed to have at least 6”
of pipe extending past exterior wall.
4. Slide 6” Wall Kit through opening with screened side facing outward.
5. Insert 4” pipe through Wall Kit and attach to Venter Unit piping on inside.
a. For TOP VENT: Attach to 4” Elbow
b. For BOTTOM VENT: Attach directly to straight 4” Pipe or Venter Unit
NOTE: It is not necessary to use 6” stainless steel wall kit if 4” pipe is going through
a non-combustible wall, such as concrete or block. No barometric draft control
is required
6. On outside of home, place 4” stainless steel tee on exhaust pipe. Place 4”
stainless steel rain cap on top of 4” tee. Secure with screws. Leave bottom of
stainless tee open.
7. Depending on location of exhaust venting to outdoors, varying draft and wind
conditions may cause occasional tripping of reset button, causing fire to go out.
8. Draft and air intake settings are preset at factory and it is usually not necessary to
change for installation going straight out through the wall. It is still recommended
to check draft settings with draft gauge after starting fire.
9. If extra stove pipe must be added inside home to achieve necessary height to
go above outside grade level, it may be necessary to adjust exhaust intake
shutter located on direct vent unit, to achieve proper draft setting of -.02
The continuous running of exhaust fan is necessary to expel fumes from stove to
outside of home, eliminating the need for a chimney.
10. Timer MUST be mounted on the side of coal hopper or on rear of coal hopper.
DO NOT MOUNT TIMER ON STOVE BODY.
11. On all TOP VENT, DIRECT VENT models, the wire to exhaust motor may not be
allowed to come into contact with stove body. This would cause damage to
electrical wires.

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 11 -
12. Ensure all power for this unit is turned off. Locate thermostat in an area where
heat from stove can be freely reached. Mount plastic wall plate of thermostat.
Connect thermostat wires to screws on lower portion of wall plate. According to
instructions, run terminal Red & White thermostat wires to Relay on stove and
connect wires to terminals marked T.T. (note: color coding of thermostat wires is
unimportant.) Be sure to snap thermostat securely onto wall plate.
13. Ensure all terminals are properly connected. Plug power cord into 115 volt
grounded wall outlet. Combustion blower should be running. Turn the thermostat
up to make the feed motor operate and you are now ready to start a fire.
Fuel Type
1. Burn rice Anthracite coal only.
Danger risk of fire or explosion. Do not burn garbage, gasoline, drain oil, or other
flammable liquids. Do not use chemicals or fluids to start fire.

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 12 -
Operation
Startup
1. To start a fire, fill hopper with coal, reach in through fire door and pull coal
down to cover entire grate area. Place kindling (charcoal supplied) into a full
sheet of newspaper, crumble paper, and dig kindling deep into coal in the
center of grate. Light newspaper with match and plug power cord into
outlet. NEVER USE GASOLINE OR LIGHTER FLUID TO START FIRE. When kindling is
burning well, place a few small shovels of coal onto the fire.
NOTE: The coal feeder adjustment nut is PRESET and may not need to be
changed. If it becomes necessary to adjust coal feed, the white nut on stoker
unit may be turned CLOCKWISE for MORE coal feed and COUNTER-CLOCK WISE
for LESS coal feed. NEVER USE A WRENCH ON COAL FEED ADJUSTMENT NUT (USE
FINGERS ONLY).
When stoker unit is running to satisfy thermostat, you should have a full grate of fire,
except for the bottom 2” of grate. The lower part of the grate should have ash covering
it. (Refer to pages 12 & 13, Diagrams 1 & 2)
When thermostat is satisfied, the gear motor will not run continuously, gear motor will
only run intermittently. During the time when thermostat does not call for heat, the timer
will turn feed motor on to maintain a small fire approximately 2” in length. Settings of
timer may be adjusted.
To increase size of fire bed or to reduce coal feed, adjust white nut (coal feed
adjustment nut). To start another fire, it is not necessary to adjust coal feed. Some
smoke may be visible when starting a fresh fire, but should not persist.
After a fire, has been established and the stove is warmed up, a draft reading should
now be taken. Remove set screw in ash door and insert draft gauge. Draft gauge
should read between -.02 to -.04. The combustion air shutter is preset at factory.
If any further adjustment is needed to obtain proper draft reading . . . slide adjusting rod
(located in venter) in or out to obtain proper draft. Secure adjustment rod with set
screw.
Failure to install, maintain, and/or operate the venting system in
accordance with manufacturer’s instructions could result in conditions
which may produce injury and/or property damage.
Cont’d next page

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 13 -
The stove is equipped with a safety fume switch. If hot coal gases are not vented
outdoors, the safety switch will trip out on reset, which will shut off stoker unit. The fire will
go out and cannot be restarted until reset button on safety switch cools down. Then the
button must be manually reset. If safety switch trips out frequently, it may be caused by:
1. Restricted or blocked vent tube between stove and exhaust fan. SOLUTION: Pull
power plug from receptacle, remove ash pan, and using brush supplied with
stove, reach brush into exhaust pipe. Move brush in a circular motion to clean
pipe and exhaust area. Plug power cord back in.
Note: On Top Vent models, remove power and cleanout plate. Brush down pipes
in back of stove.
2. Restrict or blocked exhaust pipe from stove to outside of home. SOLUTION: Clean
exhaust pipe.
3. Accumulation of dust on exhaust fan blade. SOLUTION: remove screws on motor
mounting bracket and thoroughly clean fan blades on exhaust motor.
4. Extreme windy conditions outside of home blowing against exhaust air.
5. Safety switch defective. SOLUTION: Replace safety switch.
Do not allow ashes to overflow out of ash pan, this can cause blockage in
exhaust system causing safety switch to trip, resulting in loss of fire. Blockage will
have to be cleared before pushing reset button and re-starting fire

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 14 -
Diagram 1 – Continuous Heating
Depicts what fire should look like when thermostat calls for heat for extended period:
A. Unburned fresh coal supply from coal hopper
B. Burning Coals
C. Ash on lower end of grate (around 2”)
The actual length of burning coals will vary as heat demand increases or decreases. If
burning coals fall off grate, reduce coal feed by turning white adjustment nut in a
counter clock-wise direction 1 or 2 full turns. Wait at least 1 hour before making any
more adjustments.
When thermostat is calling for heat, the gear motor will be in continuous run, but if the
fire bed remains small, increase the coal feed by turning white adjustment nut clock-
wise.
Under normal draft conditions, when fire bed has reached its maximum length (with 2”
of ash) flames should be touching top of interior stove plate. If flame is not reaching top
of stove:
1. Fire bed may be too thick.
2. Reduce coal feed.
3. Hopper end of stove is not plumb.
4. Burrs may be stuck on grate, scrape grate until it is smooth.
5. Not enough air flow, adjust air intake shutter on combustion motor
A.
UNBURNED
COAL
B.
FIRE
C.
ASH
DIAGRAM 1
Air Intake Shutter

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 15 -
Diagram 2 – Intermittent Heating
Depicts what fire size should look like when thermostat has not called for heat for
extended periods:
A. Unburned fresh coal supply from hopper.
B. Burning coal (about 1-1 ½” to 2”) (low flames).
C. Ash on lower end of grate
A.
UNBURNED
COAL
B.
FIRE
C.
ASH
DIAGRAM 2

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 16 -
Component Descriptions & Operation
Stoker Unit Components
Item #
Component
Item #
Component
1
Stoker Sub-frame
10
Stoker Grate # 2
2
Side Rail, Left
11
Stoker Grate # 4
3
Side Rail, Right
12
Screw, ¼-20UNC x 2.00” Long
4
Washer, 5/16”
13
Square Nut, ¼”
5
Nut, 5/16”
14
Pusher Bar Subassembly
6
Combustion Blower
15
Top Plate Subassembly
7
Coal Level Plate
16
Drive Screw ½” x ¾” Long
8
Screw, #10-24UNC x ½” Long
17
Stoker Motor Subassembly
9
Stoker Grate # 1
FIGURE 5
105K BTU Unit Shown

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 17 -
PUSHER BAR SUBASSEMBLY: Moves in a reciprocating motion. Activated by cam on gear
motor to force coal from hopper onto grate and pushes ashes off grate into ash pan.
Length of stroke is adjustable by turning white coal feed adjustment nut.
Item #
Component
Item #
Component
1
Movable Plate 2
7
Insulation Strip
2
Movable Plate 1
8
Stoker Bar
3
Screw, #10-24 x ½” Long
9
Threaded Rod, ¼”
4
Screw, #6-32 x 1.00” Long
10
Cap Nut, ¼”
5
Nylon Screw, #10-24 x ½” Long
11
WHITE Coal Feed Adjustment
6
Nylon Screw, #10-24 x ¾” Long
12
Nut, ¼”
WHITE COAL FEED ADJUSTMENT (ITEM # 11): Turn clockwise for more coal feed, turn
counterclockwise for less coal feed.
NYLON ADJUSTING SCREWS (ITEM #’s 5 &6): To eliminate metal on metal contact. There
are 8 nylon screws on the pusher bar, 4 on each side. The 4 nylon screws pictured on
diagram are used to adjust the amount of sideward movement of pusher bar. When
nylon screws are properly aligned, the pusher bar will slide in and out freely and have
only a slight sideward movement.
FIGURE 6

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 18 -
NYLON CAM: located on gear motor. To give
reciprocating motion to pusher bar shown below.
GEAR MOTOR: The drive shaft turns approximately
1RPM. The nylon cam on drive shaft will, when moving
inward, force coal from hopper onto grate. When
withdrawing, will allow coal to fall in front of pusher bar
for preparation of next inward stroke. The gear motor
will only run when activated by a call for heat from
thermostat or when timer turns it on.
AIR INTAKE ADJUSTMENT SHUTTER: Adjusts amount of air flow through fire.
COMBUSTION MOTOR: Combustion motor will run all the time to force air through holes
in grate to burn coal. The constant running of motor will assure the maximum amount of
heat is gained and will aid in a more complete burning of coal. The motor has an
adjustable air shutter for regulating air flow through fire.
Nylon Cam
Gear Motor
Adjustment Shutter
Adjustment Screw
FIGURE 7
FIGURE 8
FIGURE 9
Oil Ports

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 19 -
TIMER: Unless your stove had been a special order, it will be equipped with our
patented flat grate stoker unit and a timer. The timer is shown on the bottom of this
page.
The purpose of a timer is to maintain a minimum fire when the thermostat is not calling
for heat.
The timer is factory set to run 1 ½ minutes every 10 minutes. The timer activates the gear
motor, which will cause the pusher bar to move in a reciprocating motion, forcing coal
onto grate.
The timer has a large yellow wheel that makes 1 revolution every 30 minutes. Pins can
be inserted or removed from yellow wheel. Each pin equals about 15 seconds, if
needed, extra pins can be added to the present groups of pins or pins can be inserted
anywhere in yellow wheel.
This section ONLY pertains to periods when thermostat is not calling for heat. If
the fire goes out, you will have to add more pins to timer OR increase coal feed.
The burning coals should be the width of the grate and about 1 ½” to 2” in length. If the
burning coals get any less than 1 ½” the fire may go out. SOLUTION: Increase coal feed.
A weak draft can also cause the fire to go out, if fire appears to be very dull, add as
many extra pins to timer as needed, until fire stays lit.
IF FIRE STAYS LIT, BUT STOVE IS TOO HOT
If the convection blower cycles on
and off often and produces too much
heat, ether the fire bed is too long or
timer is running too long. If you reduce
coal feed or remove timer pins, do not
make radical changes. Reduce coal
feed 1 or 2 turns OR remove 1 pin from
timer. Then wait several hours before
making any more reductions. A
sudden radical change may be too
much and cause fire to go out.
Once the coal feed and timer are set
and fire stays lit, without convection
blower running too much, it is usually
not necessary to make any more
changes.
FIGURE 10
Turn
Clockwise
Only
0
25
20
10
5
15
Micro
Switch
Ground
Screw
Switch
Common
Normal
Closed
Normal
Open
Clock

Keystoker – Schuylkill Haven, PA 17972 90,000 BTU & 105,000 BTU Stoker Coal Stoves, Direct Vent
© October 2017 REV 2 - 20 -
THERMOSTAT:Top pointer is to be set at warmth
desired in home. Bottom pointer is the present
temperature in room. When room temperature
(bottom pointer) falls below desired room
temperature, (top pointer), this will send a signal to
the Relay control to activate gear motor to push fresh
coal onto grate
FAN LIMIT SWITCH:
1. HIGH LIMIT POINTER-is a safety switch that
stops gear motor from pushing coal onto
grate at 200 degrees (If stove gets too hot,
this switch will turn off gear motor).
2. CENTER POINTER-turns convection blower
on when internal air temperature reaches this
setting (normally set around 160 degrees, but
is adjustable).
3. LOW POINTER-turns convection blower off
when internal air temperature falls to this
setting (normally set around 120 degrees, but
is adjustable).
4. Whatever number on silver dial is directly
above this point is temperature of internal air.
5. WHITE BUTTON-pull out for automatic
operation of convection blower. Push in for
constant running of convection blower.
6. On this application, the JUMPER PIN is left
intact
RELAY: Receives signal from 24V thermostat to turn on or turn off gear motor.
CONVECTION BLOWER: When running, it will take cool air from room, and force it
through heated air chamber inside stove, and return heated air into room. Blower can
only be activated by Fan Limit Switch.
Load
Fan
Line
Load
Fan
Line
Load
Limit
Line
Break Off
Jumper for
Low Voltage
4
5
1
2
3
FIGURE 11
FIGURE 12