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If it's completely dead (no lights or anything) then check the fuse in the plug by placing a new one in (same rating, probably 13 amp) and testing. If it's not that then suspect either the heat control (thermostat) or the element. These aren't your basic DIY things to mess with unless you know what you are doing.
Yes, tear it down as far as you can and make sure there are no obstructions- take it apart as shown in the manual and run warm water through all the hoses to clear them.
They're like an artery and the more they get clogged the more heat the motor will have to generate to make suction.
Also check the beater bar and make sure there's no strings, etc. hung up under there- use a box cutter to carefully cut any tough strings and see how you do.
What is a flush door, where is it used, and how is it constructed. Flush doors are commonly used in houses and security places.Metal flush doors are commonly used in higher security settings in motel construction where every guestroom can be accessible via an open-air catwalk.
given the potential danger, and relative low expense, would you just consider trashing this and buying a new one? I don't intend to sound short or sarcastic....it's just with the burning smell I would prefer you either return it for refund, call the manufacturer or trash it for a different iron. Looking at epinions.com there is a comperable iron for around $40-$50 with 24 reviews and 3.5 stars out of 5. http://www.epinions.com/prices/pr-Black_Decker_D2030_Iron
The SHARK ELECTRONIC Iron is equipped with an electronic auto-off. The electronic auto-off switches the iron off if it has been left standing unmoved in any position (sideways, flat or upright) for approximately 7-9 minutes. A red light on the LED display panel will flash when the iron switches itself off. (Fig. 7) To switch the iron back on, just shake the iron side-to-side several times.
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