Maintenance Procedures
& Parts Lists
Gas Floor Model Kettles
For units built after April 2010
KGL-40, KGL-60, KGL-80, KGL-100
For your future reference.
KGL-40-T, KGL-60-T, KGL-80-T
Model # ______________________________________
KGL-40-SH, KGL-60-SH,
Serial # _______________________________________
KGL-40-TSH
KGL-40
KGL-40SH
KGL-40-T
™
Cleveland
1333 East 179th St., Cleveland, Ohio, U.S.A. 44110
Ph: 216.481.4900 Fx: 216.481.3782
www.clevelandrange.com
This manual is to be used in conjunction with the
“Operators Manual”. See “Operators Manual” for
safety warnings, correct operation, installation
and preventative maintenance.
SE95003-1 PRTS Rev. 8
February 2012
STATEMENT OF RESPONSIBILITIES /
DÉCLARATION DES RESPONSABILITÉS /
DECLARACIÓN DE RESPONSABILIDADES
This document is for use by experienced
and trained Qualified Cleveland Range,
LLC Authorized Service Representatives
who are familiar with both the safety
procedures, and equipment they
service. Cleveland Range, LLC assumes
no liability for any death, injury,
equipment damage, or property damage
resulting from use of, improper use of,
or failure to use the information
contained in this document. Cleveland
Range, LLC has made every effort to
provide accurate information in this
document, but cannot guarantee that
this document does not contain
unintentional errors and omissions.
The information in this document may
be subject to technical and technological
changes, revisions, or updates.
Cleveland Range, LLC assumes no
liability or responsibility regarding errata,
changes, revisions, or updates.
Qualified Cleveland Range, LLC
Authorized Service Representatives are
obligated to follow industry standard
safety procedures, including, but not
limited to, OSHA regulations, and
disconnect / lock out / tag out
procedures for all utilities including
steam, and disconnect / lock out / tag
out procedures for gas, electric, and
steam powered equipment and / or
appliances.
All utilities (gas, electric, water and
steam) should be turned OFF to the
equipment and locked out of operation
according to OSHA approved practices
during any servicing of Cleveland Range
equipment
Qualified Cleveland Range, LLC
Authorized Service Representatives are
obligated to maintain up-to-date
knowledge, skills, materials and
equipment.
Ce document est destiné à l’usage des
Représentants de Service qualifiés et
autorisés de Cleveland Range, LLC qui
possèdent l’expérience et la formation
ainsi que la bonne connaissance des
mesures de sécurité et du matériel qu’ils
entretiennent.
Cleveland Range, LLC décline toute
responsabilité pour tout cas de décès,
blessure, dommage matériel ou
dommage aux biens résultant de
l'utilisation, de la mauvaise utilisation ou
du manquement d’utilisation des
renseignements contenus dans ce
document.
Cleveland Range, LLC s’est efforcé à
fournir des renseignements précis dans
ce document mais ne peut garantir que
ce document soit exempt d’erreurs et
d’omissions non intentionnelles.
Les renseignements contenus dans ce
document peuvent être assujettis à des
changements techniques et
technologiques, des révisions ou des
mises à jour.
Cleveland Range, LLC décline toute
obligation ou responsabilité concernant
les errata, modifications, révisions ou
mises à jour.
Les Représentants de Service qualifiés
et autorisés de Cleveland Range, LLC
sont tenus de se conformer aux
mesures de sécurité normalisées de
l’industrie, y compris, mais sans s'y
limiter, les réglementations de l'OSHA,
les procédures de débranchement /
verrouillage / étiquetage relatives à tous
les services publics, dont
l’approvisionnement en vapeur, et les
procédures de débranchement /
verrouillage / étiquetage relatives aux
équipements et/ou appareils
fonctionnant au gaz, à l’électricité et à la
vapeur.
Au cours de tout entretien d’un appareil
Cleveland Range, tous les services
publics (gaz, électricité, eau et vapeur)
doivent être FERMÉS au niveau de
l’appareil et le dispositif de
fonctionnement doit être verrouillé
suivant les pratiques approuvées de
l’OSHA.
Les Représentants de Service qualifiés
et autorisés de Cleveland Range, LLC
sont tenus d’actualiser en permanence
leurs connaissances, compétences,
matériel et équipement.
Este documento está destinado para el
uso de los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC quienes cuentan con la
experiencia y la capacitación así como el
buen conocimiento de las medidas de
seguridad y de los equipos que
mantienen.
Cleveland Range, LLC, declina toda
responsabilidad en caso de cualquier
fallecimiento, lesiones, daños al equipo o
daños a la propiedad resultantes de la
utilización, del uso indebido o de la falta
de utilización de la información provista
en este documento.
Cleveland Range, LLC se ha esforzado
en suministrar información precisa en
este documento, pero no puede
garantizar que este documento esté
exento de errores y de omisiones no
intencionales.
La información contenida en este
documento podría estar sujeta a cambios
técnicos o tecnológicos, revisiones o
actualizaciones. Cleveland Range, LLC
declina toda obligación o responsabilidad
con respecto a erratas, modificaciones,
revisiones o actualizaciones.
Los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC tienen la obligación de seguir
los procedimientos estándar de seguridad
de la industria; los cuales incluyen pero
no se limitan a los reglamentos de la
OSHA (La Administración de la Seguridad
y Salud Ocupacionales), los
procedimientos de desconexión, cierre y
etiquetado relativos a todos los servicios
públicos incluyendo el suministro de vapor
y los procedimientos de desconexión,
cierre y etiquetado para los equipos y/o
aparatos que funcionan a base de gas,
electricidad o vapor.
Cuando se esté dando servicio o
mantenimiento a un aparato de Cleveland
Range, todos los servicios públicos (gas,
electricidad, agua y vapor) deben estar
APAGADOS para el equipo en cuestión y
se debe seguir el procedimiento de cierre
de operaciones de acuerdo con las
prácticas aprobadas por la OSHA.
Los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC tienen la obligación de
actualizar constantemente sus
conocimientos, destrezas, materiales y
equipamiento.
TROUBLESHOOTING AND
MAINTENANCE PROCEDURES
The following trouble shooting guide and maintenance procedures
are meant to be used by Qualified Service Technician
!
0
0
ANY REPAIRS TO THE PRESSURE VESSEL MUST BE DONE BY A CERTIFIED PRESSURE
VESSEL REPAIR SHOP AND ALL REPAIR METHODS AND MATERIALS MUST BE
APPROVED BY THE MANUFACTURER.
For periodic maintenance recommendations see “Operators Manual”.
TROUBLESHOOTING GUIDES
GENERAL
1.
3.
To turn the unit on, turn the switch to the on
position.
■ From the secondary of the 24VAC transformer
power is sent to the normally open contacts of the
air switch.
■ Power is sent to primary side of the
120vac/16vac transformer.
■ When the air from the blower closes the air
switch, 24VAC is sent to the Th terminal of the
ignition module.
■ Power is sent to the normally closed high limit.
■ From the high limit power is sent to the normally
open contacts of the 12VDC relay and the L1 and
L2 terminals of the ignition module.
2.
4.
With both 120VAC (at L1 and L2) and 24VAC (at
Gnd and Th) to the ignition module then 120VAC
will be sent to the surface igniter.
5.
After the ignition module has been energized for 24
seconds the module will send 24VAC to the gas
valve.
From the secondary of the transformer 16VAC is
sent to the controller.
■ Power is sent to the red LED (low water indicator
light) from terminal 4 of the controller.
With the contacts of the relay closed, 120VAC is
sent to the blower and primary coil of the
120VAC/24VAC transformer.
■ If the water probe is grounded through water the
LED will go off.
■ The gas will touch the hot igniter and ignite.
■ If the water probe is not grounded the LED will
remain on and the unit will not heat.
■ The kettle will build pressure until the controller is
satisfied by the thermistor at the setting of the
potentiometer.
■ If the resistance of the thermistor is higher than
the setting of the potentiometer( the unit is calling
for heat) then 16VDC is sent to the coil of the relay
and the green LED (heat indicator light)
■ The controller will then turn off the heat circuit
until the temperature of the kettle is below the
setting
■ The 12VDC relay will close until the unit reaches
temperature
TROUBLESHOOTING GUIDES (continued)
PROBLEM:
KGL
Kettle Won't
Heat
Replace
the on/off
switch (toggle
or rotary).
Does red light
come on when unit
is first turned on?
Yes
Is 16 VAC at the
secondary side of
the transformer?
No
Yes
Does red light go
off shortly after
unit is turned on?
No
Yes
Is 16 VAC
measured across
Pins 9 and 10 on
the controller?
With the
potentiometer set
at 10, is 12 VDC at
the coil of the
relay?
Yes
No
Add water to
jacket of Kettle.
Yes
No
Replace the
relay.
Replace the
transformer.
Yes
No
Is there Power to
the primary of the
transformer?
No
Does the relay pull
in?
Replace the
high limit.
Yes
Yes
Is there power to
the blower?
With the high limit
temporarily
bypassed, is
No
No
power at the
blower?
Yes
Supply power
to the kettle.
Replace
blower.
No
Does the blower
turn?
Yes
Replace the
ignition
transformer
No
Is there 24 VAC at
the secondary of
the ignition
transformer?
Yes
Is there power to
the ignition
transformer?
Yes
Replace
ignition
module.
No
Is there 120 VAC
Yes
to the igniter?
Is there 24 VAC to
the igniton
No
module?
Replace the air
switch.
Yes
Does the ignitor
glow?
No
Replace the
ignitor.
Does the gas
valve get 24 VAC
20 sec. after the Yes
ignitor is
energized?
Does the gas
valve open?
Yes
No
No
Replace gas
valve
No
Replace the
DC relay.
Replace
the wire to
the blower.
TROUBLESHOOTING GUIDES (continued)
PROBLEM:
KGL
Kettle Not
Hot Enough
See Problem:
Kettle won't
heat.
No
Does the kettle
heat at all?
With kettle pot
empty and
Yes temperature knob
set at 10, is the
temperature of the
surface of the pot
260 degrees?
Unit is
operating
properly
Yes
No
Vent
the kettle per
instructions in
the manual.
No
When unit is cold
(room temp) is the
pressure gauge in
the green?
Replace the
high limit?
Replace the
blower
No
No
Yes
When the unit is
calling for heat
(the green light is
on), is there flame
at the burner?
Replace
controller.
No
Is there voltage to
the blower?
Is the blower
turning?
Yes
Yes
Yes
Yes
Is the
potentiometer
resistance 50,000
ohms at low and 0
ohms at high?
Yes
Is the resistance of
the thermister
100,000 ohms
+10% at room
temperature?
No
Replace the
thermister.
Replace the air
switch
No
Replace the
potentiometer.
PROBLEM: KGL Kettle Has Delayed Ignition
Delayed Igniton
Is the gas
pressure to the
burner 3.5" W.C.?
Yes
Replace ignitor.
Replace blower
and air switch.
No
No
Does the ignior
glow evenly
Yes
Does the gas
valve get 24 VAC
20 seconds after
the ignitor is
energized?
Yes
Is the blower
turning?
No
No
Yes
Adjust or
replace the gas
Valve.
Replace the
ignition
module.
Replace burner
TROUBLESHOOTING GUIDES (continued)
PROBLEM:
KGL Kettle
Gets Too
Hot
The
kettle is working
properly.
Yes
With the kettle
empty and the
temperature set at
10, is the surface
temp 260-265
degrees?
No
Does the kettle
continue to call for
heat (green light
stays on) when
the kettle reaches
260-265 degrees?
Replace the
gas valve.
Replace the
Relay
No
No
Yes
Is the resistance of
;the thermister
100,000 ohms +
10% at room
temperature?
No
Yes
Is there supply
voltage to the coil
of the gas valve?
Is the resistance of
the potentiometer
50,000 ohms at
the low setting and
0 ohms at high?
Yes
Yes
Is there any DC
voltage to the coil
of the relay?
Replace the
controller
Yes
Replace the
controller
PROBLEM: Red Add Water LED Stays On
Add the proper
amount of distilled
water and rust
inhibitor.
No
Does Red LED stay on
after adding the proper
amount of distilled
water and rust inhibitor?
Yes
Clean or
replace water
probe.
No
Is the red LED on
with probe
grounded?
Yes
Replace the
wire harness in
the trunion.
No
Does the red LED
stay on with a
jumper between
pins 5 and 7 on
the controller?
Yes
Replace the
controller.
No
Replace the
thermister.
No
Replace the
potentiometer
KETTLE SAFETY INSPECTION AND TESTING
SAFETY VALVE
INSTALLATION:
LOW WATER
LEVEL PROBE:
Probe
properly
attached
The above illustrations show
the three variations of factory
installed Safety Valves.
✔
Modifications are unacceptable.
SAFETY THERMOSTAT:
Correct
Installation
Probe
fully
inserted
in tube
Incorrect
Installations
Wiring is properly
connected
1.
Probe removed
partially
Probe bypassed by
running (A) an
additional wire
✘
✘
Probe bypassed by
(B) grounding the
connecting wire
PRESSURE RELIEF VALVE TESTING
3.
2.
Probe removed
completely
Pressure
Relief
Valve
Ring
Thermostat
electrically bypassed
Access
Panel
1. Safety thermostat probe is not completely inserted into tubing.
2. Safety thermostat probe is removed from tubing.
3. Safety thermostat electrical connection is bypassed.
WARNING: Use of gloves and eye protection to prevent
personal injury.
OPERATING
THERMOSTAT:
265º
260°260º
- 270°
F
- 270º
MAXIMUM
MAXIMUM
KETTLE
KETTLE
TEMPERATURE
TEMPERATURE
6
5
✔
7
4
8
3
If maximum temperature is not
in this range (on empty kettle),
refer to the “Calibrating
Procedure”.
9
2
1
10
1. With the kettle empty, set OnOff Switch/Temperature Control
to "10" (Max.). Allow the kettle
to heat until the unit cycles off.
2. Switch On-Off Switch/Temperature
Control to "0" (Off) and disconnect
main power at fused disconnect
switch.
OFF
3. Remove Access Panel at back
of main kettle console.
GAS KETTLE AIR SWITCH:
Correct
4.
Incorrect
5.
Pull Pressure Relief Valve Ring open for a maximum of
one second. Repeat test three to four times. Each time
the mechanism should move freely and be
accompanied by a rapid escape of steam.
Replace access panel.
IMPORTANT:
If valve appears to be sticking replace pressure relief
valve.
Wiring is properly connected
Switch electrically bypassed
If foreign material is discharged then drain kettle and
replace pressure relief valve.
0
!
CALIBRATING PROCEDURE
Solid State Temperature
Control Box
FREE AIR CALCULATION
Adjustment
Pot
Insert drager pump tube 4" down the center
of the flue and take one sample each of
Carbon Dioxide (CO2) and Carbon
Monoxide (CO) and record results.
With results obtained for CO2 use chart to
determine dilution factor for gas type used.
______________
% CO
(PPM)
______________
% CO2
___________________________
Dilution Factor
Enter these numbers in the following formula
to determine the concentration of carbon
monoxide in an air free sample of flue gas.
Dilution Factor X CO (PPM) = _____________________________
10,000
% Carbon Monoxide
Result must not exceed 0.08% carbon monoxide.
CARBON DIOXIDE IN
SAMPLE (PERCENT)
FACTOR
PROPANE GAS
FACTOR
NATURAL GAS
4.0
4.2
4.4
4.6
4.8
5.0
5.2
5.4
5.6
5.8
6.0
6.2
6.4
6.6
6.8
7.0
7.2
7.4
7.6
7.8
8.0
8.2
8.4
8.6
8.8
9.0
9.2
9.4
9.6
9.8
10.0
3.50
3.33
3.18
3.04
2.92
2.80
2.69
2.59
2.50
2.41
2.33
2.26
2.19
2.12
2.06
2.00
1.94
1.89
1.84
1.79
1.75
1.71
1.67
1.63
1.59
1.56
1.52
1.49
1.46
1.43
1.40
3.05
2.90
2.77
2.65
2.54
2.44
2.34
2.26
2.18
2.10
2.03
1.97
1.91
1.85
1.80
1.74
1.70
1.65
1.61
1.56
1.53
1.49
1.45
1.42
1.39
1.36
1.33
1.30
1.27
1.24
1.22
0
1. Insure the unit has a vacuum before you begin
calibrating procedures. If unit requires venting refer to
KETTLE VENTING INSTRUCTIONS.
2.
Set On-Off Switch/Temperature Control to "10" (Max.).
3.
Allow the unit to cycle twice.
4.
Check temperature of the inner kettle surface with a
digital surface thermometer.
5.
Temperature should be between 260°F and 265°F.
6.
Using a screw driver
adjust temperature by
turning the potentiometer
on the Solid State
Temperature Control Box.
Turn very little. Turn
clockwise to INCREASES
and counter-clockwise to
DECREASE temperature.
7.
Allow the unit to cycle
twice.
8.
Check temperature of the
inner kettle surface with a
digital surface
thermometer.
6
5
7
4
8
3
9
2
1
10
OFF
9. Repeat steps 4. through 8. until unit is calibrated.
0
!
KETTLE VENTING INSTRUCTIONS
150
200
100
250
20
50
30
10
0
REPAIRING LEAKS IN STEAM
JACKETED KETTLE FITTINGS
0
50
IR
NT A
VE
If unit will not hold a vacuum the most likely cause is a
leak at one of the fittings.
300
40
350
60
0
Often, the easiest way to eliminate a leak is reseal the
suspect areas.
400
psi
kPa
Pressure
Relief Valve
150
200
100
2. Pressure Relief Valve
30
10
0
300
40
0
IR
NT A
VE
50
A/ Inspect for signs of leaks. Replace if required.
350
60
400
psi
kPa
Access
Panel
150
Valve
Ring
200
100
250
The following
venting
procedure should be followed when the
20 30
50
Vacuum/Pressure
Gauge
needle is in the "VENT AIR" zone:
10
300
40
0
Remove,clean threads, apply teflon thread sealant
and reinstall.
250
20
50
1. Water Level Probe
NOTE: Check50for350and eliminate leaks prior to venting
60
(see REPAIRING
LEAKS IN STEAM JACKETED KETTLE
400
psi
FITTINGS).
IR
NT A
VE
0
kPa
B/ Remove, clean threads, apply teflon thread
sealant and reinstall.
3. Pressure Gauge
A/ Inspect face of gauge. If it contains moisture
on the inside of face replace.
B/ Check tightness of plumbing connection to
pressure Gauge.
3. Sight Glass
A/ Check tightness of sight glass.
1. Remove Access Panel from
back of main kettle console.
6
5
7
4
8
3
150
9
200
100
2
250
20
50
30
10
40
1
0
0
10300
IR
NT A
VE
50
OFF
60
350
400
psi
B/ Replace "O" ring if required.
2. Turn kettle ON and set temperature
control to 10, heat the empty kettle
until unit cycles off.
3. Vent kettle by pulling Valve Ring
eight to fifteen times, holding
valve open for two seconds
each time.
LUBRICATION PROCEDURE
Lubricate the following parts every three months to insure
smooth operation and reduce wear.
NOTE: If unit cycles ON, stop
venting and wait for kettle to cycle
OFF before continuing.
150
200
100
250
20
50
0
30
10
IR
NT A
VE
50
60
kPa
200
100
250
20
30
10
300
40
0
IR
NT A
VE
0
350
400
psi
50
300
40
0
150
50
60
psi
TRUNNION HOUSING,
WORM SCREW AND
TILT GEAR
kPa
350
400
kPa
4. Turn kettle OFF. Add cold water
to kettle until its surface
temperature is below 100°F. The
pressure gauge needle should
be in the green zone, indicating a
vacuum in the kettle’s jacket.
5. If needle is in the green zone then
venting was successful. If not
repeat procedure.
Adjusting
Screw
Adjusting
Screw
These parts are accessed
through the top cover of
the console.
Worm
Screw and
Worm
Tilt
Screw
and
Gear
Tilt
Gear
Cross
Bar
Cross
Bar
Trunnion Housing
Grease Nipple
Trunnion Housing
Grease Nipple
Apply grease to gear
teeth. Check for
excessive play and adjust
with adjusting screw
located on top of cross
bar.
KETTLE TRUNNIONS
On the left hand side of
the kettle there are two
grease nipples on the top
back portion of the
trunnion housing. On the
right hand side of the
kettle you must remove
the console cover to
access the two grease
nipples.
RESERVOIR FILL PROCEDURES
IMPROPER REFILLING OF KETTLE
JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
The kettle's water level must be maintained at the proper
level. Under normal operating conditions, the sealed
water reservoir should never require the addition of water.
200
If the red "low water" light comes on during use (while the
kettle is in an upright position), the water level has reached
a critically low level. The low water protection control has
psi
automatically
shut off the gas burner. The following
procedure must be completed before further use:
100
250
20
50
0
30
10
300
40
0
IR
NT A
VE
50
60
350
0
1.
Turn clockwise to relieve tension on spring.
3.
While tension is released remove one of the two
slotted screws.
4.
To prevent Allen wrench from springing back abruptly
while the second slotted screw is removed, insert a
pin (approximately 1/8") in the hole where the first
slotted screw was removed from.
5.
Remove second slotted screw.
6.
While holding Allen wrench remove pin.
7.
Turn Allen wrench clockwise to tighten or counterclockwise to loosen tension to produce desired
effect.
8.
Re-insert pin in one of the two holes.
9.
Tighten one slotted screw in the other hole (it may
be necessary to turn Allen wrench slightly to align
holes).
10.
Remove pin and repeat step number 9 for other
slotted screw.
400
NOTE: Have a qualified service
technician repair the leakage
problem and add water to the
unit. Ensure that the red "low
psi is on when the kettle
water" light
is upright. On tilting kettles, it is normal for the red light to
come on when the kettle is in a tilted position.
150
200
100
250
20
0
30
10
300
40
0
IR
NT A
VE
50
60
150
400
200
100
250
20
300
40
0
IR
NT A
VE
0
30
10
50
60
psi
350
400
kPa
1. Ensure kettle is at room temperature
and pressure gauge showing zero or
less pressure.
2. Shut off power to the kettle at the
fused disconnect switch.
Pressure
Relief Valve
Valve
Ring
Access
Panel
Console
Cover
Drain Plug Location
3. Remove Console Cover and Access Panel.
ImportantPull ring on
Pressure
Relief Valve
prior to
removal to
insure vessel
is not
pressurized.
4.
Pull Pressure Relief Valve Ring open
to insure vessel is not pressurized.
5.
Remove 1/4" copper tubing and
reducer bushing.
6. Add distilled water using a funnel if
necessary. Fill the unit to the high
level mark on the Sight Glass.
7. Apply a thread sealant (i.e. Teflon
tape) to the reducer bushing threads
and replace.
8. Replace Console Cover and Access
Panel.
9. Restore power to unit at the fused
disconnect switch.
Sight Glass
0
350
kPa
50
Insert 3/8" Allen wrench.
2.
kPa
50
3/8" Allen wrench
WARINING:
!
150
HINGE ADJUSTMENT
INSTRUCTIONS
10. The kettle must now be vented.
(Refer to the KETTLE VENTING
INSTRUCTIONS).
0
KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES
The following procedure should be preformed at least once every three years to prevent possible corrosion
and ensure the optimum life of the kettle.
!
DANGER:
RUST INHIBITOR
250
20
50
0
To ensure satisfactory mixing follow the manufacturer’s
instructions.
30
10
50
60
!
DISPOSAL - Follow all Federal, State and local codes when
disposing of product.
150
350
400
psi
kPa
WARINING:
IMPROPER REFILLING OF KETTLE
JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
200
100
250
20
0
300
40
0
50
RUST INHIBITOR CAN BE DANGEROUS.
READ LABEL AND FOLLOW SAFETY
INSTRUCTIONS.
200
100
IR
NT A
VE
Use a “radiator rust inhibitor” that can be purchased at your
local automotive centre. It should not contain any antifreeze and preferably no lubricant.
150
30
10
300
40
0
IR
NT A
VE
50
60
350
400
psi
kPa
PROCEDURE
0
!
1. Ensure kettle is at room temperature
and pressure gauge showing zero or less
pressure.
2.
Shut
off and disconnect gas supply.
psi
3. Remove electrical plug from power
source.
4. Remove bolts holding kettle to tabletop.
5. Pull ring on pressure relief valve to insure there
is no pressure within the kettle jacket.
6. Remove pressure relief valve.
7. Replace pressure relief valve with street elbow (see
above illustration).
8. Remove sight glass from left side of kettle.
9. Tilt kettle on its side (sight glass opening facing
downwards) and allow to drain. Flush out with water.
0
10. Tilt kettle upright, apply a thread sealant (i.e. Teflon tape)
to the sight glass threads and replace.
150
200
100
250
20
50
30
300
40
0
IR
NT A
VE
0
10
50
60
350
400
kPa
Pressure
Relief
Valve
0
Valve
Ring
11. Refer to chart below to determine the required volume
of water.
Kettle Size
Console
Cover
6 U.S. Gal.
12 U.S. Gal.
Access
Panel
Volume of Mixture
U.S. Gal.
Liters
1.6
5.8
2.2
8.3
12. In a separate container mix water with the required
rust inhibitor.
Drain Plug Location
13. Fill jacket via the street elbow with the mixture.
14. Remove street elbow.
15. Apply a thread sealant (i.e. Teflon tape) to the pressure
relief valve and replace.
0
16. Reconnect gas and electrical supplies.
17. Turn kettle on, vent and heat to high for 1/2 hour.
18. Cool kettle.
19. Repeat steps 5-15.
20. Replace bolts holding kettle to tabletop.
21. Reconnect gas and electrical supplies.
22. Turn kettle on and vent kettle.
TOP
COVER
NATURAL GAS TO PROPANE
CONVERSION KIT
For Floor Model Gas Kettles (except KGL-25/T)
UNIT EXHAUST CONTAINS CARBON MONOXIDE.
OPERATE ONLY UNDER A PROPERLY FUNCTIONING
HOOD WITH ADEQUATE MAKEUP AIR.
THIS CONVERSION KIT SHALL ONLY BE INSTALLED BY A
QUALIFIED SERVICE AGENCY
For use at 0-2000 feet elevation on Honeywell valves Model
8305. For higher elevations consult the factory.
“O” RING
Conversion Parts Required
GAS ORIFICE
SPRING
KGL-40 (Kit Service #KE003716-5)
Part No.
Description
KE603911-5
Conversion Label
1
KE53403-5
Gas Orifice
1
FA05002-29
“O” Ring
1
PLUG
Quantity
KGL-60 to 100 (Kit Service #KE003716-4)
Part No.
Description
KE603911-4
Conversion Label
Quantity
1
KE53403-7
Gas Orifice
1
FA05002-29
“O” Ring
1
KE603910-3
Instruction Seet
1
Air Intake Washer (KE54420-1) is required for 50Hz units - see conversion kits
KE003716-6 & KE003716-7.
INSTRUCTIONS
WARNING
This conversion kit shall be installed by a qualified
service agency in accordance with the manufacturer’s
instructions and all applicable codes and requirements
of the authority having jurisdiction. If the information in
these instructions is not followed exactly, a fire, and
explosion or production of carbon monoxide may result
causing property damage, personal injury or loss of life.
The qualified service agency is responsible for the
proper installation of this kit. The installation is not proper
and complete until the operation of the converted
appliance is checked as specified in the manufacturer’s
instructions supplied with the kit.
CAUTION
The gas supply shall be shut off prior to disconnecting
the electrical power, before proceeding with the
conversion.
NOTE: Use thread sealant compatible with propane gas
on all threaded piping connections.
1.
Disconnect electrical connection.
2.
Shut off main gas supply and disconnect kettle from
supply line.
3.
Remove TOP COVER.
4.
Remove PLUG and SPRING.
5.
Remove GAS ORIFICE and “O” RING.
6.
Replace with new GAS ORIFICE and “O” RING.
7. Replace SPRING and PLUG.
8. Replace TOP COVER.
9. Check inlet pressure is between 12-14 inches W.C.
10.. Check input rate of unit.
11. On the underside of the console cover with indelible
marker place the following information: Company,
Name, Address & Date of Conversion.
12. Replace TOP COVER.
13. Place gas conversion label next to rating label.
14. Reconnect electrical and gas supplies.
KE603910-3
SERVICE PARTS
WARRANTY
Our Company supports a worldwide network of Maintenance and Repair Centers. Contact your nearest Maintenance and Repair Centre for replacement parts,
service, or information regarding the proper maintenance and repair of your cooking equipment.
In order to preserve the various agency safety certification (UL, NSF, ASME/Ntl. Bd., etc.), only factory-supplied replacement parts should be used. The use of other
than factory supplied replacement parts will void warranty.
14
13
FAUCET ASSEMBLY
13
11
1
10
2
6
3
9
8
7
5
4
12
6
8
ITEM #
7
5
PART #
DESCRIPTION
SPK2
DPK2
SINGLE PANTRY FAUCET for KGL60/80T (includes items 1-10)
DOUBLE PANTRY FAUCET for KGL60/80T (includes items 1-8 & 11)
SPK3
DPK3
SINGLE PANTRY FAUCET for KGL40T & KGL40TSH (includes items 1-10)
DOUBLE PANTRY FAUCET for KGL40T & KGL40TSH (includes items 1-8 & 11)
SPK5
DPK5
SINGLE PANTRY FAUCET for Stationary Kettles (includes items 1-10)
DOUBLE PANTRY FAUCET for Stationary Kettles (includes items 1-8 & 11)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
KE50825-2
KE50825-3
KE50825-5
FA95007-10
FA05002-19
KE51736
KE54159
FA11258
FA31029
FA210028
KE51401
KE50335
KE51403
SE50447
SE50021
3/4" SPOUT for - SPK2 & DPK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3/4" SPOUT for - SPK3 & DPK3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3/4" SPOUT for - SPK5 & DPK5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LONG FAUCET NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FAUCET MOUNTING BRACKET for Tilting Kettles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SINGLE PANTRY BODY (c/w item 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ADAPTER WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DOUBLE PANTRY BODY (c/w item 13 & 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
REPLACEMENT HORSESHOE WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
REPLACEMENT STEM ASSEMBLY, COLD WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
SE50020
REPLACEMENT STEM ASSEMBLY, HOT WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
QTY.
13
CONSOLE
CONTROLS
3
5
4
7
6
3
5
7
2
KE
95
55
5-1
6
8
1
9
OF 10
F
0A
12
11
4
10
0
50
15
0
10 20
0
20
0
30
25
0
40
VE
NT
AIR
0
30
0
50
ps60
i
35
0
kP 40
a 0
10
ITEM NO.
PART NO.
DESCRIPTION
QTY.
3.
SE00114
POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #4 . . . . . . . . . . . . . . . . .1
4.
KE51005
RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE50569-1
KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE55486-2
INDICATOR LIGHT, RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.
KE55486-3
INDICATOR LIGHT, GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10.
KE50429-6
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
KE95555-10
LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE603836
BRACKET, LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.
FA21006
#10-24, HEX NUT, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SIGHT GLASS
ITEM ON.
PART NO.
DESCRIPTION
QTY.
HI
1.
KE50955
RETAINING COVER . . . . . . . . 1
2.
KE52871
GASKET . . . . . . . . . . . . . . . . . 1
LO
3.
KE51053
SIGHT GLASS . . . . . . . . . . . . 1
4.
FA05002-30
”O” RING . . . . . . . . . . . . . . . . 1
4
3
2
1
ELECTRICAL COMPONENT BOX 115 VOLT UNITS
8
38
6
4
7
22
16
9
17
19
IT E M
2
1
PART #
23
28
D E S C R IP T IO N
Q TY.
1
K E 003654
C O M P O N E N T B O X W E L D M E N T ; K G L/-T
2
4
K E 53469-5
K E 53838-20
IG N IT IO N C O N T R O L ; K G L/T
T R A N S F O R M E R ;1 20 V P R IM A R Y /2 4 V S E C O N D A R Y 6
, 0H Z , 20 V A
1
1
6
K E 53838-27
7
K E 603765
T R A N S F O R M E R ;1 20 V P R IM A R Y /1 4 V S E C O N D A R Y6, 0H Z , 20 V A
TRANSFO RM ER BRACKET
1
1
(C S A /C E /A G A A P P R O V E D )
1
1
8
K E 00458-1
KETTLE CO NTRO L BO X
9
K E 50303-1
E LE C T R O N IC B O X H O LD E R
1
10
K E 53599-1
G A S K E T ; K G L /K G L-T
1
16
K E 55069-6
T H E R M O S T A T ;S A F E T Y (K G T /K G L)
1
17
K E 54833-3
S N A P -IN B U S H IN G ; 0.875 D IA .
1
18
K E 53440
C O V E R ; C O M P O N E N T B O X (K G L/-T )
1
19
K E 53620
BRACKET FOR COM PO NENT BOX
1
22
K E 55501-1
T U B E ; A IR S W IT C H
1
23
K E 50753-7
R E L A Y ; S P D T /1 0A /1 2V D C # M JN 1C F -D C 12
1
24
F A 150 18-4
S C R E W ; P H ILIP S 8-32X 3 /8"L
4
25
F A 150 18-3
S C R E W ; P H ILIP S 8-32X 1 /4"L
6
26
F A 10243
S C R E W ; S LO T 8 -32 X 3/4"L
2
27
F A 150 18-7
S C R E W ; P H ILIP S 6-32X 1 /4"L
2
28
K E 02400-1
A IR P R E S S U R E S W IT C H A S S E M B L Y ; D O M E S T IC A N D C E
1
29
K E 54662-1
H E A T S H IR IN K A B LE T U B IN G ; 3/1 26 ID 12" LO N G
1
30
K E 54661-2
V A R F L O S L E E V IN G 1 2" LO N G
1
31
N P N 0 0163
CONNECTOR; M ARR NO. 2
1
32
K E 54668-1
T E R M IN A L; F U L LY IN S U L A T E D A M P #2 -5 20181-2 O R 182-2
2
33
K E 50988-1
P O T E N T IO M E T E R ; C /W O N /O F F S W R E V LO G T A P E R
1
34
K E 50567-1
L IG H T ; R E D -W A T E R IN D IC A T #2 49 -7 867-3331-504
1
35
K E 50567-3
L IG H T ; G R E E N -H E A T IN D IC A T # 24 9-7967-3332-504
1
36
K E 51005
R O T A R Y S E A L; #N 9 030 X 1/4 (A M P -H E X S E A L)
1
37
K E 52412
CONNECTOR; M ARR NO. 1
2
38
W H K G LT
W IR IN G H A R N E S S ; K G L 40-100
1
Items #10, 18, 24-27, 29-37 not show for clarity.
KE01422
GAS CONTROL ASSEMBLY
19 GAS ORIFICES
NATURAL
GAS
KE53403-8
Sea level up to 2,000', 40 gal.
PROPANE
GAS
KE53403-5
Sea level up to 2,000', 60 - 100 gal.
KE53403-6
KE53403-7
2000' up to 4,000', 40 gal.
KE53403-8
KE53403-9
2000' up to 6,000', 60 - 100 gal.
KE53403-10
KE53403-11
4000' up to 6,000', 40 gal.
KE53403-12
KE53403-13
4000' up to 6,000', 60 - 100 gal.
KE53403-10
KE53403-14
1
Stationary Models
21
25
22
2
23 24
3
26
4
27
22
16
17
18
19
7
20
5
28
6
29
4
37
8
11
34
28
10
12
13
14
30
9
15
59
40 41
43
60
38
42
56
25
31 Tilting
39 Models
32
33
52
53
51
34
55
54
Tilting
Models
30
29
35
57
58
GAS CONTROL ASSEMBLY
ITEM ON.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
20.
21.
22.
23.
24.
25.
26.
27.
28.
30.
34.
36.
37.
38.
40.
41.
42.
43.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
PART NO.
KE53441
KE53441-1
KE54420
KE54420-1
KE54239
KE01426-4
KE01426-1
KE01426-2
KE01426-3
KE53582
FI05156
KE53402-4
KE53402-1
KE53402-2
KE53402-3
KE01449
KE53618
KE53617
KE53619
KE00515
KE50556-2
KE53437-3
KE53570
FI05257
FI05213
KE53422
FA05002-4
FA05002-29
FI05226-4
FI00073
FI00133
KE93909
FI00040-1
N0440C4
N0440C3-875
KE55004-3
N0640C2
F01518-1
KE55240R
N0640C1-5
KE01500-5
KE01500-1
KE53397
KE601085
RB018151
KE601081
FA15005
FI00040-1
N0440C8
FI05231
FI05222
FI05223-6
KE55240R
F01518-1
KE000960
FA30505-1
FA11256
DESCRIPTION
QTY.
BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BLOWER, 220V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR INTAKE WASHER (NATURAL GAS, 50hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR INTAKE WASHER (PROPANE, 50hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MIXING CHAMBER, 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MIXING CHAMBER, 60 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MIXING CHAMBER, 80 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MIXING CHAMBER, 100 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TUBING 1/4 INCH SILICONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HOSE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR ORIFICE, 40 GALLON KETTLES (60hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR ORIFICE, 60 - 100 GALLON KETTLES (60hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR ORIFICE, 40 GALLON KETTLES (50 HZ BLOWER) . . . . . . . . . . . . . . . . . . . . . . . . . .1
AIR ORIFICE, 60 - 100 GALLON KETTLES (50 HZ BLOWER) . . . . . . . . . . . . . . . . . . . . . .1
BLOWER MOUNTING PIPE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SIGHT GLASS GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SIGHT GLASS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WATER LEVEL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GASKET FOR IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SHUT-OFF COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 1/2" NPT, 5 5/16" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNION, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ELBOW, 1/2", STREET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
STRIP, TO HOLD BLOWER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 1/2" NPT, 4" LONG, KGL-60-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 1/2" NPT, 4" LONG, KGL-80-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RETAINING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 1/2" NPT, 2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS SHUT-OFF VALVE, 3/4" (NOT FOR FRENCH CE KETTLES) . . . . . . . . . . . . . . . . . . . .1
GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 3/4" NPT, 1 1/2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER, 40 GALLON KETTLES, 140,000 BTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER, 60-100 GALLON KETTLES, 190,000 BTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GASKET, BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COVER FOR GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GASKET FOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE, 1/2" NPT, 8" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS SHUT-OFF VALVE, 3/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE PLATE WELDMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WASHER, 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HEX BOLT, 1/4-20 X 1/2, 18-8 SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
GEARBOX ASSEMBLY
8
4
5
5
9
5
4
1
3
7
5
6
6
2
42
26 27 28
39
41
10
40
25
14
30
32
15
23
24
33 34
35 36
13
11
12
38
37 31
32
21
16 19 20
22
GEARBOX ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
KE503752
KE50315
FA95005
KE52193-1
KE52192
KE52191
FA30088
FA95008
KE55057-4
FA95062
KE00508
FA19501
KE51730
FA19177
FA20047
KE003209-11
TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LID FOR GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PAN HD. PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HANDWHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HANDWHEEL ALLEN SCREW, HEX SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . .2
TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HEX SOCKET SET SCREW 5/16-24 X 1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
JAM NUT 5/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Complete Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE603208-4
Momentary Switch Activator*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE603208-7
Contact Section Holder, Latch*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE603208-9
Contact Block*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
***NOTE: for units built prior to Dec. 2006 order Complete Switch KE003209-11
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
KE50580
FA05002-34
KE50579-1
KE51007
FA10139
KE50498
FA32004
KE50582-1
FA95055-6
KE50583-1
KE52832-1
FA10487
FA31008
FA20026
KE517112
KE517111
KE51712
KE001234-2
FA10772
FA20030
FA95007-4
FA95055-1
FA19201
KE50581
KE54535
KE50753-10
KE50473
WATER RESISTANT BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
"O" RING, CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MACHINE SCREW #6-32 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MICRO SWITCH INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOTH LOCK WASHER #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CPLG. ONTARIO BELTING #G-100 5/8 BORE . . . . . . . . . . . . . . . . . . . . . . . . . .2
SQUARE KEY 3/16 X 3/16 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RUBBER INSERT, ONTARIO BELTING "BUNA N" . . . . . . . . . . . . . . . . . . . . . . . .1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX HD SCREW 1/4-20 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPLIT LOCKWASHER 1/4" DIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HEX NUT 1/4 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
LEFT HAND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RIGHT HAND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GREASE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MICRO SWITCH TRIGGER/WORM GEAR WELDMENT . . . . . . . . . . . . . . . . . . .1
SOCKET HD. CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX SOCKET SET SCREW 3/8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
EDGE CONNECTOR (11 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GROUND LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
For tilting units
with covers
TRUNNION ASSEMBLY
ITEM PART
NO. NO.
DESCRIPTION
1.
TRUNNION BEARING ASSEMBLY . . . . . .1
(INCLUDES PART # 3, 4 & 6)
KE00354
1
QTY.
2.
KE00351
TRUNNION BEARING ASSEMBLY . . . . . .1
(INCLUDES PART # 3, 4 & 6)
3.
KE51711
ROLLER BEARING . . . . . . . . . . . . . . . . . 2
4.
KE51571-1
BEARING WASHER . . . . . . . . . . . . . . . . . .1
5.
FA95081-3
BOLT, 5/16-18 X 1/2" . . . . . . . . . . . . . . . . .1
6.
KE51886
GREASE NIPPLE . . . . . . . . . . . . . . . . . . . .2
7.
FA11326
BOLT, 5/16-18 X 1 1/2" . . . . . . . . . . . . . .4/2
8.
KE50666
SPHERICAL WASHER . . . . . . . . . . . . . . . .1
6
For tilting units
without covers
3
4
2
5
7
8
6
TANGENT DRAW-OFF VALVE
5
4
3
2
1
ITEM NO.
PART NO.
DESCRIPTION
Complete
Valve
KE50972-B
KE50973
KE02044-2
KE02044-4
2”
3”
2”
3”
1.
FA95049
FA21501-2
FA21501-1
WING NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ACCORN NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ACCORN NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE52755
SE50018
KNOB, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KNOB, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
FI05180-1
FI05180-2
HEX NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE52753
SE50013
RETAINER, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RETAINER, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE52752
SE50010
PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
FA05002-24
FA05002-38
"O" RING, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
"O" RING, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DRAW-OFF
DRAW-OFF
DRAW-OFF
DRAW-OFF
ASSEMBLY
ASSEMBLY
ASSEMBLY
ASSEMBLY
QTY.
(TD-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
(TD-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
(TD-2A with ACME THREAD) . . . . . . . . . . . . . . . . .1
(TD-3A with ACME THREAD) . . . . . . . . . . . . . . . . .1
PRESSURE RELIEF
ASSEMBLY
4
5
2
3
6
8
7
ITEM NO.
PART NO.
DESCRIPTION
QTY.
PRESSURE RELIEF VALVE ASSEMBLIES
1.
KE01450
FOR ASME KETTLES (INCLUDES #2-6)
1
KE01450-1
FOR CE KETTLES (INCLUDES #2-6)
1
2.
FI05049
MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE
1
3.
KE600812-1
STREET ELBOW, 90°, 1/2", BRASS
2
4.
KE600814-1
TEE, 1/2" FPT, BRASS
1
5.
KE54941-5
SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA)
1
KE54941-31
SAFETY VALVE, 50 PSI, 1/2", (EUROPE)
1
6.
KE54223
BLOW DOWN TUBE
1
7.
KE54864
ACCESS PANEL
1
8.
FA11518-4
THUMB SCREW, 10-32 X 1/2" L
2
SAFETY VALVES
HINGE ASSEMBLY
9
4
7
11
8
6
10
1
9
5
12
ITEM NO.
PART NO.
DESCRIPTION
13
2
3
QTY.
Hinge Assembly
1. - 11
KE00597-1
KGL40/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-2
KGL60/80/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-3
KGL100/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50597-4
KGL40SH/TSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
KE50822
Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE51217
Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE50121-2
Hinge Spring, Light - for KE00597-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50121-1
Hinge Spring, Heavy - for KE00597-2, KE00597-3, KE00597-4 . . . . . . . . . . . .1
4.
KE50823-1
Hinge Pin, Light Spring, LHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE50824-2
Hinge Bearing, Heavy Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE50819-1
Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE50820
Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE50819
Hinge End Piece, RHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FA11284
Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
10.
FA11507
Cutting Screw,
11.
KE54907-10
Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE50151-2
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cover Handle Assembly (consult factory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00587
WRAP COVERS
BACK
WRAP COVER GASKET
TOP
LEFT SIDE
RIGHT SIDE
FRONT
TRANSFORMER
COVER & GASKET
FRONT
LEFT
SIDE
RIGHT
SIDE
BACK
SERVICE
WRAP
COVER
GASKET
KE01479-X
KE53483-4
KE54253-X
KE01432-X
KE02186-1
KE54419-1
KE53871
RB01851 (1ft.)
KGL-60
KE01479-1
KE53483-5
KE54253-1
KE01432-1
KE02186-2
KE54419-2
KE53871
RB01851 (1ft.)
KGL-80
KE01479-2
KE53483-6
KE54253-2
KE01432-2
KE02186-3
KE54419-3
KE53871
RB01851 (1ft.)
KGL-100
KE01479-3
KE53483-7
KE54253-3
KE01432-3
KE02186-4
KE54419-4
KE53871
RB01851 (1ft.)
KGL-40-T
KE01479-X
KE53483-X
KE54253-X
KE01432-X
KE02186-1
KE54419-1
KE53871
RB01851 (1ft.)
KGL-60-T
KE01479-1
KE53483-1
KE54253-1
KE01432-1
KE02186-2
KE54419-2
KE53871-1
RB01851 (1ft.)
KGL-80-T
KE01479-2
KE53483-2
KE54253-2
KE01432-2
KE02186-3
KE54419-3
KE53871-1
RB01851 (1ft.)
KGL-40-SH
KE01479-6
KE53483-5
KE54253-1
KE01432-1
KE02186-2
KE54419-2
KE53871
RB01851 (1ft.)
KGL-60-SH
KE01479-5
KE53483-7
KE54253-3
KE01432-3
KE02186-4
KE54419-4
KE53871
RB01851 (1ft.)
KGL-40-TSH
KE01479-6
KE53483-1
KE54253-1
KE01432-1
KE02186-2
KE54419-2
KE53871-1
RB01851 (1ft.)
KETTLE
TOP
(c/w gasket)
KGL-40
TRANSFORMER
TRANSFORMER
COVER
COVER
GASKET
WIRING DIAGRAM - 110-120V, 60 HZ.
SPARE PARTS LIST
The following is a spare parts listing of parts that wear during normal us or are apt to be
misplaced during normal operation. These parts should be kept on hand to prevent loss
time due to a minor problem.
PART NUMBER
DESCRIPTION
QUANTITY
KE00458-1
KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50753-7
RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE55069-6
SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SE00114
POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50569-1
KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00515
THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
The following is a recommended list of space parts that may be required if the service
agency is of some distance away or if down time must be kept to a minimum and spare
parts are required for the service agent on site.
PART NUMBER
KE54941-5
DESCRIPTION
QUANTITY
1/2" FPT, 50 PSI., FOR ASME KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54941-31
1/2" FPT, 50 PSI., FOR CE KETTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53838-27
TRANSFORMER, 120-14V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53469-5
IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00458-1
KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE024004
AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53838-20
TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE52752
PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SE50010
PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE55486-2
KE55486-3
KE50429-2
L.E.D., RED
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L.E.D., GREEN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53437-3
IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1