Master HG D Series User manual

HG Service Manual-D SERIES
Models: HG-201D, HG-202D,
HG-301D, HG-302D, HG-501D,
HG-502D, HG-801D

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 1 of 6
Available kits
Motor Replacement- Part No’s. 30073 (120V), 30074 (220-240V)
Element Connector Replacement–30089, 30090 (HG-801D only)
Switch & Bezel Kits Replacement–30075
Cordset Replacement-–30079 (120V 15 Amp), 30080 (120V 20 Amp),
30081 (220V UL/CUL), 30097 (220-240V EU), 30098 (220-240V UK)
Nozzle shield replacement 30077
Handle Replacement 30091
What’s in the kit
MOTOR KIT:
•MOTOR, (1)
•SCREW, #6-32 x .50 LONG (2)
•SCREW, M3 x 0.5 x 10mm LONG (1)
•CABLE TIE (2)
•SHRINK TUBE (1)
CORDSET KIT:
•CORDSET (1)
•CABLE GUARD (1)
•SCREW, #6-32 x .31 GREEN (1)
•CABLE TIE (2)
•SHRINK TUBE (1)
•CORD CLAMP, USED WITH (220 –240 VAC) units (1)
NOZZLE SHIELD KIT
•NOZZLE ASSEMBLY, (1)
•SHIELD, (1)
•SCREW, #6-32, (2)
HANDLE KIT
•HANDLE SET RT & LT (1)
•SCREWS, #6-19, (4)
ELEMENT CONNECTOR KIT:
•ELEMENT CONNECTOR ASSY (1)
•CABLE TIE (2)
•SHRINK TUBE (2)
SWITCH & BEZEL KIT:
•SWITCH/BEZEL/JUMPER ASSY (1)
•BARRIER, ELECTRICAL (1)
MASTER HEAT GUN REPLACEMENT PARTS AND ACCESSORIES ARE ENGINEERED AND MANUFACTURED TO PRECISE MASTER APPLIANCE SPECIFICATIONS. REPLACEMENT PARTS AND ACCESSORIES FROM
OTHER MANUFACTURERS ARE NOT PRODUCED TO THESE PRECISE SPECIFICATIONS. FAILURE TO USE MASTER APPLIANCE REPLACEMENT PARTS OR FAILURE TO INSTALL MASTER APPLIANCE REPLACEMENT
PARTS EXACTLY AS INSTRUCTED MAY CAUSE PHYSICAL INJURY OR DAMAGE TO THE HEAT GUN. MASTER APPLIANCE CANNOT ASSUME RESPONSIBILITY FOR PHYSICAL INJURY OR DAMAGE TO THE HEAT GUN
RESULTING FROM THE USE OF ANY OTHER BRAND OF REPLACEMENT PART OR IMPROPER INSTALLATION OF MASTER APPLIANCE REPLACEMENT PARTS OR ACCESSORIES.
WARNING: Disconnect heat gun power cord and allow the heat gun to cool before disassembly.
READ THE SERVICE INSTRUCTIONS CAREFULLY. FAILURE TO EXACTLY FOLLOW THE INSTRUCTIONS
COULD RESULT IN PERSONAL INJURY OR DAMAGE TO YOUR HEAT GUN. ALL REPAIRS MUST BE
PERFORMED BY A QUALIFIED REPAIR TECHNICIAN.
AVERTISSEMENT : Débrancher le cordon du pistolet thermique et laisser celui-ci refroidir avant de le
démonter.
LIRE ATTENTIVEMENT LES INSTRUCTIONS D’ENTRETIEN. OMETTRE D’OBSERVER EXACTEMENT CES
INSTRUCTIONS POURRAIT ENTRAÎNER DES BLESSURES OU ENDOMMAGER VOTRE PISTOLET THERMIQUE.
SEUL UN RÉPARATEUR QUALIFIÉ PEUT EFFECTUER LES RÉPARATIONS.
ADVERTENCIA: Desconecte el cable de la pistola térmica y deje que ésta se enfríe antes de desarmarla.
LEA CON ATENCIÓN LAS INSTRUCCIONES DE SERVICIO. EL NO SEGUIR EXACTAMENTE LAS
INSTRUCCIONES PUEDE RESULTAR EN DAÑO A LA PISTOLA TÉRMICA. TODAS LAS REPARACIONES DEBEN
SER REALIZADAS POR UN TÉCNICO DE REPARACIONES CALIFICADO.
Do not touch
nozzle until cool
Ne pas toucher la
buse avant qu’elle
ait refroidi
No toque
la boquilla hasta que
se haya enfriado
TOOLS REQUIRED
#1 DRIVE PHILLIPS
SCREWDRIVER
#2 DRIVE PHILLIPS
SCREWDRIVER
1/8 inch HEX KEY
(ALLEN WRENCH)
UTILITY KNIFE

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 2 of 6
Ⓜ
#6-32 SCREW (2)
Ⓗ
Ⓐ
SCREW, M3x0.5
x 10mm long,
UNDER MODEL LABEL
Ⓚ
Figure 1
HANDLE, RIGHT
HOUSING
SCREWS (2)
Ⓗ
ELECTRICAL
BARRIER
Ⓥ
COVER
BLOWER WHEEL
HANDLE, LEFT
GROUND SCREW, GREEN
CORDSET
CABLE
GUARD
HOUSING,
METAL
HANDLE SCREWS (4)
Ⓙ
BEZEL / SWITCH / JUMPER
NOZZLE
AND
SHIELD
NOZZLE SCREWS,
(2)
Ⓦ
ELEMENT
SHRINK TUBE
Ⓣ
ELEMENT
CONNECTOR
MOTOR
MOTOR
SCREWS
(2)
Ⓛ
Ⓖ
Ⓦ
Ⓗ
Ⓣ

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 3 of 6
DISASSEMBLY INSTRUCTIONS
UNPLUG HEAT GUN. TAKE NOTE OF WIRING LAYOUT.
To remove cover and handle halves (Figure 1)
1. Remove two (2) nozzle mounting screws Ⓦat the rear of the
shield. If nozzle mounting screws are lost or damaged, replace
only with #6-32 steel machine screws, 3/16-inch minimum length
to 1/2- inch maximum length.
2. Gently pull shield from gun housing. Shield, nozzle and mica
insulator may come apart as one unit. Pull element out of
housing.
3. Remove (2) housing screws (#6-32 x .50) Ⓗand remove cover.
4. Remove (4) handle screws (#6-19 x .63 long) Ⓙand remove
handles from housing.
To remove the motor (Figure 1)
1. Loosen the set screw in the blower wheel with a 1/8 hex key
wrench, then remove the blower wheel from the motor. Carefully
lift label and remove screw Ⓚfrom the bottom of the housing.
2. Place the heat gun on a flat surface with the motor facing
upward. Remove (2) outer screws Ⓛon the top flange of the
motor. Gently pull the motor straight up and out of the housing.
3. Cut and remove the existing cable ties and shrink tube to expose
the quick-connect terminals (Figure 3).
4. Disconnect the white lead wire of the motor from the piggyback
terminal on the white wire from the element connector (Figure 3).
5. Disconnect the black lead wire of the motor from the switch
(Figure 4).
To remove the element connector:
1. Cut and remove the existing cable ties and shrink tube to expose
the quick-connect terminals (Figure 3).
2. Disconnect the white lead wire of the element connector (with
piggyback terminal) from both the white wire of the motor and
the white wire of the cordset (Figure 3).
3. Disconnect the black lead wire of the element connector from
the switch (Figure 4).
To remove the switch/bezel assembly:
1. Lift the switch/bezel assembly away from the handle, being
careful not to break the tabs of the handle (Figure 5). Disconnect
all wires from the switch.
To remove the cordset:
1. Remove the green ground screw located near the nozzle of the
housing (Figure 6).
2. Cut and remove the existing cable ties and shrink tube to expose
the quick-connect terminals (Figure 3).
3. Remove the black cordset wire from the piggyback terminal of
the jumper, (Figure 4).
4. Remove the white cordset wire from the piggyback terminal on
the white wire from the element connector (Figure 3).
5. Lift the cable guard out of the handle and remove the cordset.
SWITCH / BEZEL
Figure 5
TABS IN
HANDLE
Figure 6
GREEN WIRE AND GREEN SCREW
ELEMENT CONNECTOR,
BLACK WIRE
ELEMENT
CONNECTOR
CORDSET, BLACK WIRE
ON TERMINAL OF JUMPER
SHRINK TUBE
JUMPER, (BLACK
WIRE)
MOTOR, (BLACK
WIRE)
Figure 4
Ⓣ
Figure 3
CABLE TIES
TERMINALS
SHRINK TUBE
Ⓣ

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 4 of 6
INSTALLATION INSTRUCTIONS
To install the MOTOR:
1. Connect the black wire from the motor to the switch Ⓢ(Figure
8).
2. Connect the white motor wire to the piggyback terminal of the
white element connector wire (Figure 8).
3. Slide shrink up over both white wires and connect white wire
from cordset. Position shrink tube Ⓣover all 3 terminals
(Figure 8).
4. Assemble motor into housing and with (2) #6-32 x .50 long
screws Ⓛ(Figure 1). Torque to 16 –20 in-lbs.
5. Assemble (1) M3 x 0.5 Ⓚ(Figure 1) through back side of
housing and into motor frame at a torque of 2-5 in-lbs.
Excessive torque will warp the motor frame, resulting in reduced
air flow and damage to the motor.
6. Assemble blower wheel onto shaft of motor and tighten set
screw with 1/8 inch hex key. Top of blower wheel hub must be
flush with top of motor shaft. Must not rub against frame of
motor and must not rub against wiring (Figure 9).
7. Ensure electrical barrier Ⓥis between wiring terminals and
metal enclosure (Figure 8).
To install the ELEMENT CONNECTOR:
1. Connect the black wire from the new element connector to the
switch Ⓝ(Figure 7 & 8).
2. Connect the white motor wire to the piggyback terminal of the
white element connector wire (Figure 8).
3. Slide shrink tube up over both white wires and connect white
wire from cordset (Figure 8). Position shrink tube Ⓣover all 3
terminals.
To install the CORDSET:
1. Install new cable ties in metal housing (figure 1).
2. Connect the green cordset wire to the enclosure’s ground post
using the green screw (Figure 6).
3. Connect the black cordset wire to the jumper’s piggyback
terminal attached to the switch (Figure 8).
4. Connect the white motor wire to the piggyback terminal of the
white element connector wire (Figure 8).
5. Slide shrink tube up over both white wires and connect white
wire from cordset (Figure 8). Position shrink tube Ⓣover all 3
terminals.
6. On 220-240V cordsets use supplied cord clamp (figure 10).
To install the SWITCH / BEZEL ASSEMBLY:
1. Connect the wires to the appropriate switch terminals per
instructions above (Figure 8). The black jumper wire is to wrap
around the white wires from the motor and element connector,
and the green wire from the cordset.
SWITCH
TERMINALS
ELEMENT
CONNECTOR
MOTOR
BLACK WIRE
Ⓢ
JUMPER
BLACK WIRE
BLACK
JUMPER
WIRE
Figure 7
Ⓝ
Figure 9
SHAFT FLUSH WITH
TOP OF FAN HUB
WARNING: Failure to cover the terminals with
shrink tubing
Ⓣ
could result in electrical short
WARNING: Failure to insulate switch & wire terminals
from metal enclosure could result in electrical short
JUMPER, (BLACK WIRE)
WHITE WIRES FROM ELEMENT
CONNECTOR (PIGGYBACK TERMINAL)
MOTOR & CORDSET
SHRINK TUBE
CORDSET BLACK WIRE
ON PIGGYBACK
TERMINAL OF JUMPER
Ⓝ
ELEMENT
CONNECTOR
MOTOR BLACK WIRE
Figure 8
Ⓢ
ELECTRICAL BARRIER
Ⓥ
Ⓣ
WARNING: Failure to cover the terminals with
shrink tubing
Ⓣ
could result in electrical short
WARNING: Failure to cover the terminals with
shrink tubing
Ⓣ
could result in electrical short

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 5 of 6
2. Attach the piggyback terminal of the jumper to the switch, and
the other end of the jumper to the switch (Figure 8).
3. Place the electrical barrier Ⓥbetween the switch and the
housing.
4. Align the three holes of the bezel with the three tabs in the
handle and gently press the switch / bezel assembly into position
as shown (Figure 4).
5. Position the shrink tube over the piggyback terminal and over
the white wire terminals from the motor and from the cordset.
Use cable ties to hold in place (Figure 10).
To install the HANDLES and COVER: (Figure 10)
1. Hook the left handle onto the handle portion of the metal
housing.
2. Install switch bezel assembly per above.
3. Ensure the electrical barrier Ⓥis positioned between the
terminals of the switch and the housing.
4. Align the three holes of the switch bezel with the three tabs in
the handle and gently press the switch / bezel assembly into
position as shown (Figure 5).
5. Route wires in channels (Figure 10) and tighten cable ties to
hold wiring in place.
6. Ensure all wiring clears the screw holes of the handles and
gently assemble the right handle onto the housing (Figure 10).
Retain with #6-19 x .63 screws Ⓙ(4) (Figure 1). Tighten to 12 –
15 in-lbs torque.
7. Assemble cover onto housing and retain with housing screws,
#6-32 x .50 screws, Ⓗ(2) (Figure 1). Tighten to 16 - 20 in-lbs
torque.
To install element nozzle and shield: (Figures 11 & 12)
1. Gently insert new element into housing, with contacts of element
contacts inserted fully into the contacts in the housing.
2. Wrap the mica insulator around coils of heater element, ensuring
all coils are covered.
3. Gently slide nozzle straight on, aligning ceramic element wings
with front nozzle indents and two (2) nozzle screw holes.
4. Slide shield over nozzle, aligning mounting holes.
5. Install two (2) nozzle screws Ⓦloosely until started, and then
tighten.
AFTER HEAT GUN IS COMPLETELY ASSEMBLED, CONDUCT
FINAL ADJUSTMENT AND TEST:
1. Plug your Master heat gun®into a properly rated electrical
outlet.
2. Run in cool mode, gently tap bottom of unit to align motor
bearings unit until motor noise stabiles.
3. Switch unit to “Hot”. Hot air should be blowing from nozzle.
Element
Mica
Nozzle
Indents align with element
wings.
Shield
Figure 12
Ⓦ
Ⓦ
WARNING: Failure to insulate switch & wire terminals from
metal enclosure could result in electrical short
ENSURE WIRES STAY
CLEAR OF SCREW
HOLES AND HANDEL
PINCH POINTS TO
AVOID PINCHING
WIRES BETWEEN
HANDLES
ENSURE BARRIER
IS BETWEEN
TERMINAL AND
METAL HANDEL
ELEMENT
CONNECTOR
Figure 10
Ⓥ
CORD CLAMP BETWEEN
CORDSET AND METAL HOUSING,
ONLY USED ON EUROPEAN, U.K.,
AND 220-240V CORDSETS
WARNING:
Failure to properly cover coils
with mica insulator could result in electrical short
WARNING: Failure to insulate switch & wire terminals from
metal enclosure could result in electrical short
New element
Element wings
Insert into contacts
Contacts in housing
New mica
Roll mica over coils of
element
Figure 11

“D SERIES” HG
Master Appliance Corp.
2420 18th St.
Racine, WI 53403-2381 USA
Tel: [phone]
Email: [e-mail]
www.masterappliance.com
58278E REV A
pg. 6 of 6
TROUBLESHOOTING GUIDE
SYMPTOM
CAUSE
SOLUTION
Excessive Vibration
Motor screw not tight or missing
Recheck that all screws are present and tighten
to correct torque
Blower wheel loose or damaged
Tighten or replace blower wheel if damaged
Unusual Noise
Blower wheel not positioned correctly
on motor shaft
Ensure top of motor shaft is flush with top of
blower wheel hub
Wires rubbing on blower wheel
Ensure wires are in proper position and out of
way of blower wheel
Motor does not run
and element does not
heat
Unit is not plugged in
Plug in unit
Outlet is non-functional
Ensure outlet is live
Switch is not wired properly
Ensure switch is wired properly
Switch is damaged
Test switch and replace if defective
Motor does not run
but element heats
Switch is not wired properly
Ensure switch is wired properly
Switch is damaged
Test switch and replace if defective
Motor is damaged
Replace motor
Motor runs but no
heat
Heating element not install properly
Ensure male terminals of element were fully
seated in female contacts of element connector
Heating element damaged
Check element to see if coils are open, replace if
defective
Element connector damaged
Inspect element connector to see if damaged, if
damaged replace
Element connector or switch not wired
correctly
Ensure element connector and switch are wired
properly
Switch damaged
Test switch and replace if defective