Welbilt KGL-25-T Installation Operation & Maintenance

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Gas 25 Gallon Kettle
Installation, Operation, Maintenance, Parts & Service
This manual is updated as new information and models are released. Visit our website for the latest manual.
MODELS:
For your future reference.
KGL-25
KGL-25-T
Model # ______________________________________
Serial # _______________________________________
Model # &
Serial #.
KGT-25-T
!
Read the manual thoroughly.
Improper installation, operation or
maintenance can cause property
damage, injury or death.
TABLE OF CONTENTS
Statement of Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Part # - KE004021-2 B August 2019
KGT-25
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.
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 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, 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 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.
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.
Les renseignements contenus dans ce
document peuvent être assujettis à des
changements techniques et technologiques,
des révisions ou des mises à jour.
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.
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.
1.
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.
FOR YOUR SAFETY / POUR VOTRE SÉCURITÉ /
PARA SU SEGURIDAD
FOR YOUR SAFETY
POUR VOTRE SÉCURITÉ
PARA SU SEGURIDAD
Do not store or use
gasoline or any other
flammable liquids and
vapours in the vicinity of
this or any other
appliance.
Ne pas entreposer ou
utiliser d'essence ou
d'autres liquides ou
vapeurs inflammables à
proximité de cet appareil
ou de tout autre appareil.
No guarde ni use gasolina
o cualesquiera otros
líquidos o vapores
inflamables en las
cercanías de éste o
cualquier otro aparato.
WARNING: Improper
installation, operation,
adjustment, alteration,
service or maintenance
can cause property
damage, injury or death.
Read the installation
and operating
instructions thoroughly
before installing,
operating or servicing
this equipment.
AVERTISSEMENT : Toute
mauvaise pratique en matière
d’installation, de
fonctionnement, de réglage,
de modification, d’entretien ou
de maintenance peut causer
des dommages matériels, des
blessures ou la mort. Lisez la
totalité des instructions
d’installation et d’utilisation
avant d’installer, d’utiliser ou
d’entretenir cet équipement.
ADVERTENCIA: La indebida
instalación, operación,
ajuste, modificación,
servicio o mantenimiento
puede ocasionar daños a la
propiedad, lesiones o
muerte. Lea detenidamente
las instrucciones de
instalacion y de operación
antes de instalar, poner a
funcionar o dar servicio a
este equipo.
Do not spray aerosols in the vicinity of
this appliance while it is in operation.
This appliance is not to be used by
persons with reduced physical,
sensory or mental capabilities, or lack
of experience and knowledge, unless
they have been given supervision or
instruction concerning use of the
appliance by a person responsible for
their safety.
This appliance is not for use by
children and they must be supervised
not to play with it.
Post in a prominent location,
instructions to be followed in the event
the user smells gas. This information
shall be obtained by consulting your
local gas supplier.
Do not obstruct the flow of combustion
and ventilation air.
Retain this manual for your reference.
Ne pas pulvériser des aérosols dans le
voisinage de cet appareil alors qu'il est en
fonctionnement.
No pulverice aerosoles en las
proximidades de este aparato
mientras está en funcionamiento.
Cet appareil ne doit pas être utilisé par des
personnes dont les capacités physiques,
sensorielles ou mentales sont réduites, ou
des personnes dénuées d'expérience ou de
connaissance, sauf si elles ont pu bénéficier,
par l'intermédiaire d'une personne
responsable de leur sécurité, d'une
surveillance ou d'instructions préalables
concernant l'utilisation de l'appareil.
Este aparato no debe ser utilizado por
personas con capacidades físicas,
sensoriales o mentales reducidas, o
que no tengan la experiencia y los
conocimientos adecuados, a menos
que estas personas hayan recibido
supervisión e instrucciones en cuanto
al uso del aparato por la persona
responsable de la seguridad de ellas.
Cet appareil n'est pas destiné à être utilisé
par des enfants et ils doivent être surveillés
pour s'assurer qu'ils ne jouent pas avec
l'appareil.
Affichez à un endroit bien visible les
instructions à suivre dans le cas où
l'utilisateur sent une odeur de gaz. Ces
informations seront obtenues auprès de
votre fournisseur de gaz local.
Ne pas obstruer le flux d'air de combustion
et de ventilation.
Conservez ce manuel pour votre référence.
2.
Este aparato no debe ser usado por
los niños y ellos deben ser
supervisados para que no jueguen
con el aparato.
No obstruya el flujo del aire
combustión y de ventilación.
Guarde este manual para su
referencia.
! WARNING / AVERTISSEMENT / ADVERTENCIA
Improper installation, operation, adjustment, alteration,
service or maintenance can cause property damage,
injury or death. Read the installation and operating
instructions thoroughly before installing, operating or
servicing this equipment. / Toute mauvaise pratique en
matière d’installation, de fonctionnement, de réglage, de
modification, d’entretien ou de maintenance peut causer des dommages
matériels, des blessures ou la mort. Lisez la totalité des instructions
d’installation et d’utilisation avant d’installer, d’utiliser ou d’entretenir cet
équipement. / La indebida instalación, operación, ajuste, modificación,
servicio o mantenimiento puede ocasionar daños a la propiedad, lesiones o
muerte. Lea detenidamente las instrucciones de instalacion y de operación
antes de instalar, poner a funcionar o dar servicio a este equipo.
Heavy / Lourd / Pesado
Team or mechanical lift. / Équipe ou remontée
mécanique. / Equipo o elevador mecánico.
Surfaces and product may be hot! Wear protective
equipment. /Les surfaces et le produit peuvent être
chauds! Portez un équipement de protection. / ¡Las
superficies y el producto pueden estar calientes!
Utilice equipo protector.
Floor may become slippery from product spillage. /
Déversement de produit peut causer de plancher à
être glissante. / Derrame de producto puede causar
piso a ser resbaladizo.
Do not lean on or place objects on lip. / Ne vous
penchez pas sur oune placez pas des objets sur la
lèvre. / No se apoye ni coloque objetos en el labio.
Unit exhaust contains carbon monoxide. Operate only
under a properly functioning hood with adequate makeup
air. / L'échappement de l'unité émet du monoxyde de
carbone. Exploiter uniquement sous une hotte
fonctionnant correctement avec une source adéquate d'air
d'appoint. / El escape de la unidad contiene monóxido de
carbono. Operar solamente bajo una campana en buen
funcionamiento con aire de relleno adecuado.
Hot product and surfaces. / Produit et
surfaces chaudes. / Producto y
superficies calientes.
Do not touch. / Ne pas toucher. / No
la toque
Stand clear of product discharge path
when discharging hot product. /
Écartez-vous du chemin de décharge
d’un produit chaud. / Permanezca
alejado de la ruta de descarga del
producto al vaciar producto caliente.
Pressurized device. / Appareil sous pression. /
Dispositivo de presión.
Keep clear of pressure relief discharge. / Restez à
l'écart de la soupape de sureté. / Permanezca alejado
de la descarga de presión.
Keep hands away from moving parts and pinch points.
/ Gardez les mains loin des pièces mobiles et des
points de pincement. / Mantenga las manos lejos de
piezas movibles y puntos de presión muy localizada.
Do not climb, sit or stand on equipment. / Il ne faut pas
monter, s'asseoir ni se tenir debout sur l'équipement. /
No subirse, ni sentarse ni pararse sobre el equipo.
Do not fill kettle above recommended level marked on
outside of kettle. / Ne remplissez pas la chaudière en
excès du niveau recommandé marqué sur la
chaudière. / No llene la marmita arriba del nivel
recomendado marcado fuera de la marmita.
SERVICING / ENTRETIEN / SERVICIO
Shut gas supply off prior to servicing. / Fourniture de
gaz fermée au loin avant d'entretenir. / Suministro de
gas cerrado apagado antes del mantenimiento.
Unit must be anchored as per manual. / Unité doit être
ancrée selon les directives du manuel. / Unidad debe
estar fijado según el manual.
Remove electrical power prior to servicing. / Coupez
l'alimentation électrique avant l'entretien. / Desconecte
la energía eléctrica antes de darle servicio.
Keep appliance and area free and clear of
combustibles. / Gardez l'appareil et son entourage
libre de tous combustibles. / Mantenga el aparato y el
área libres de combustibles.
Risk of electric shock. / Risque de choc électrique. /
Riesgo de choque eléctrico.
Do not attempt to operate this appliance during a
power failure. / N’essayez pas de faire fonctionner cet
appareil lors d'une panne de courant. / No intente
poner en marcha este aparato durante un fallo de
suministro eléctrico.
0
Inspect unit daily for proper operation. / Inspectez
l’unité tous les jours pour son bon fonctionnement. /
Inspeccione diariamente el funcionamiento correcto de
la unidad.
Ensure kettle is at room temperature and pressure
gauge is showing zero or less prior to removing any
fittings. / Assurez-vous que la chaudière est à
température ambiante et que le manomètre est à zéro
ou moins avant de retirer des accessoires. /
Asegúrese de que la marmita esté a temperatura
ambiente y el manómetro esté mostrando cero o
menos antes de retirar cualquier accesorio.
Have a qualified service technician maintain your
equipment. / Demandez à un technicien en entretien
et en réparation qualifié d’effectuer l’entretien de votre
équipement. / Haga que un técnico de servicio
calificado mantenga su equipo
3.
INSTALLATION
GENERAL
1. Carefully cut any straps
from container.
Insure gas and electrical supplies match rating plate.
Installation of the kettle must be accomplished by qualified
installation personnel working to all applicable local and
national codes.
Model/
Serial#
2. Lift off carton.
3. Inspect for hidden
damage.
If found refer to
“SHIPPING DAMAGE
INSTRUCTIONS”.
This equipment is built to comply with applicable standards
for manufacturers. Included among those approval agencies
are: UL, NSF, ASME/N.Bd., CSA, ETL, and others. Many local
codes exist, and it is the responsibility of the owner/installer to
comply with these codes.
4. Cut strap holding unit.
5. Remove lag bolts from
feet.
Observe all clearance requirements. Do not obstruct the flow
of combustion and ventilation air.
6. Remove manual from
kettle pot. Write down
the model # and serial #
of the unit onto the front
of this manual.
RECEIVING INSPECTION
Before unpacking visually inspect the unit for evidence of
damage during shipping.
If damage is noticed, do not unpack the unit, follow shipping
damage instructions.
7. Lift kettle off skid and
move kettle to its
installation location.
SHIPPING DAMAGE INSTRUCTIONS
8. Discard packaging
material according to
local and or state
requirements.
If shipping damage to the unit is discovered or suspected,
observe the following guidelines in preparing a shipping
damage claim.
Model/
Serial#
1. Write down a description of the damage or the reason for
suspecting damage as soon as it is discovered. This will
help in filling out the claim forms later.
2. As soon as damage is discovered or suspected, notify
the carrier that delivered the shipment.
3. Arrange for the carrier's representative to examine the
damage.
VENTILATION
Gas fired kettles are only to be installed
under a ventilation hood in a room which
has provisions for adequate make up air. Further information
can be obtained by referring to the U.S.A. National Fire
Protection Associations NFPA96 regulations. These standards
have also been adopted by the National Building Code in
Canada.
4. Fill out all carrier claims forms and have the examining
carrier sign and date each form.
APPROXIMATE WEIGHTS
Model #
KGL-25
KGL-25-T
Unit
320 lbs.
320 lbs.
Unit with
shipping
box
360 lbs.
360 lbs.
POSITIONING
UNCRATING
This unit must be installed in accordance with the clearances
shown on the rating label which is adhered to the unit.
Caution:
Straps under tension and will
snap when cut.
1. Position the unit in it's permanent location, and level the
unit by turning the adjustable feet.
Carton may contain staples and
Skid contains Nails.
2. Once positioned and leveled, permanently secure the
unit's flanged feet to the floor using 5/16" lag bolts and
floor anchors (supplied by the installer). Three bolts are
required to secure each of the flanged feet.
Use proper safety equipment
and precautions.
3. Seal joints of flanged feet with a silicone sealant.
Unit is heavy use adequate help or lifting equipment as
needed.
4. Remove any protective material covering the stainless
steel panels.
4.
2. Feed permanent copper wiring through the cut-out in the
rear or bottom of the console, and fasten to the terminal
block. Be sure to connect the ground wire to the separate
ground terminal connector (ground lug).
NOTE: Units are tested on a in-house ground fault system.
However, there is no guarantee the unit will work on all
ground fault systems. If you are having problems you can
hard wire the unit.
GAS
ENSURE THE GAS SUPPLY MATCHES THE KETTLE'S
REQUIREMENTS AS STATED ON THE RATING PLATE.
Installation must conform, with local codes or in the absence
of local codes, with the National Fuel Gas Code ANSI
Z223.1/NFPA 54, or the Natural Gas and Propane Installation
Code, CSA B149.1.
The appliance and its individual shut-off valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
1/2 psi (3.45 kPa).
The appliance must be isolated from the gas supply piping
system by closing its individual manual shut-off valve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 psi (3.45 kPa).
It is recommended that a sediment trap (drip leg) be installed
in the gas supply line. If the gas pressure exceeds 1/2 psi
(3.45 kPa) water column, a pressure regulator must be
installed, to provide a maximum of 1/2 psi (3.45 kPa) water
column gas pressure to the gas control valve.
Use a gas pipe joint compound which is resistant to L.P. gas.
Test all pipe joints for leaks.
1. Removed supplied manual shut-off valve and establish
mounting location.
2. Add union and
GAS
SUPPLY
piping as required.
NIPPLE
SHUT-OFF
3. Connect the gas
UNION
VALVE
line to the manual
shut-off valve.
WATER
The sealed jacket of the gas-fired kettle is precharged with
the correct amount of a water-based formula, and therefore,
no water connection is required to the kettle jacket. The kettle
can be equipped with optional hot and cold water taps,
requiring 1/2" copper tubing as supply lines.
INSTALLATION CHECKS
BACK OF KETTLE
Although the kettle has been thoroughly tested before leaving
the factory, the installer is responsible for ensuring the proper
operation of kettle once installed.
1. Before turning the kettle on, read the vacuum/pressure
gauge. The gauge's needle should be in the green zone.
If the needle is in the "VENT AIR" zone, follow air venting
procedure.
2. Unit has been thoroughly checked for gas leaks at the
factory however the installer should check all connections
for any leaks which may have resulted from shipping or
installation.
3. Supply power to the kettle by placing the fused
disconnect switch to the "ON" position.
4. Open gas shut-off valve to turn on main gas supply.
5. Turn the temperature control knob to "1" (Min.). The green
LED light should remain lit, indicating the burner is lit, until
the set temperature is reached. Then the green light will
cycle on and off, indicating the burner is cycling on and off
to maintain temperature.
6. Tilt the kettle forward. After a few seconds the red "LOW
WATER" light should be lit when the kettle is in a tilted
position. This light indicates that the burner has
automatically been shut off by the kettle's safety circuit.
This is a normal condition when the kettle is in a tilted
position.
7. Raise the kettle to the upright position. The red "LOW
WATER" light should go out when the kettle is upright.
8. Turn the temperature control knob to "10" (Max.) and allow
the kettle to preheat. The green light should remain on
until the set temperature is reached. Then the green light
will cycle ON and OFF, indicating the burner is cycling
ON and OFF to maintain temperature.
9. Check carbon monoxide is less than 0.08 percent in an
air-free sample of the flue gases. See FREE AIR
CALCULATION procedure in “Maintenance Procedures &
Parts Lists” manual.
ELECTRICAL
ENSURE THE ELECTRICAL SUPPLY MATCHES THE
KETTLE'S REQUIREMENTS AS STATED ON THE RATING
WARNING: Electrical Grounding Instructions.
This unit is equipped with a three-prong (grounding)
plug for your protection against shock hazard and
should be plugged directly into a properly grounded
three-prong receptacle. Do not cut or remove the
grounding prong from this plug.
LABEL.
For 110-120 volt units a cord and plug are supplied with the
unit. Simply plug the unit into any grounded outlet rated for a
minimum of 10 amps.
The kettle must be electrically installed and grounded in
accordance with local codes, or in the absence of local
codes, with National Electrical Code, ANSI/NFPA 70 (USA) or
the Canadian Electrical Code, CSA C22.2, (Canada).
Standard supply voltage is 115 volts A.C., however, optional
A.C. voltages can be supplied on special order. A separate
fused disconnect switch must be supplied and installed in the
high voltage electrical supply line.
The wiring diagram is located under the cover of electrical
box inside the back console.
For 200-240 volt units a terminal block is provided.
1. Remvove the consol cover. A wiring diagram is affixed to
the underside of the cover.
CLEANING
After installation the kettle must be thoroughly cleaned and
sanitized prior to cooking.
5.
!
WARNING
If for any reason this unit is not
functioning correctly DO NOT
OPERATE. Contact your
authorized service agent.
OPERATING INSTRUCTIONS
OPERATING THE KETTLE
1.
Perform daily startup inspection.
Temperature
Control
Setting
OPERATING CONTROLS AND
INDICATORS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
4
5
7
6
1
Approximate
Product Temperature
°F
°C
120
135
150
165
180
195
210
225
245
265
49
57
66
74
82
91
99
107
118
130
2
9
NOTE: Certain combinations of ingredients will
result in temperature variations
3
8
2.
Preheat the kettle by turning the ON/OFF Temperature
Control to the desired temperature setting. The Heat
Indicator Light (Green) will remain lit, indicating the
burner is on, until the temperature setting is reached.
When the green light goes off, the burners are off, and
preheating is complete.
NOTE: When cooking egg and milk products, the kettle should not
be preheated, as products of this nature adhere to hot cooking
surfaces.
1 LOW WATER INDICATOR LIGHT (RED)
When lit, indicates that the kettle is low on water and will not operate in
this condition. This will also light when the kettle is in the tilted position.
3.
Place food product into the kettle. The green Heat
Indicator Light will cycle on and off indicating the burners
are cycling on and off to maintain the set temperature.
4.
When cooking is completed turn Temperature Control to
the "OFF' position.
5.
Pour the contents of the kettle into an appropriate
container by tilting the kettle forward or using discharge
valve.
2 ON-OFF TEMPERATURE CONTROL
Turns kettle ON/OFF and allows the operator to adjust the kettle
temperature.
3 HEAT INDICATOR LIGHT (GREEN)
When lit, indicates that the kettle's burner is on. Cycles ON-OFF with
burner.
4 VACUUM/PRESSURE GAUGE
Indicate steam pressure in PSI inside steam jacket and vacuum in inches of
mercury.
5 PRESSURE RELIEF VALVE (NOT SHOWN)
This valve is used to vent the kettle and in the unlikely event there is an
excess steam build-up in the jacket.
6 WATER LEVEL SIGHT GLASS
Displays water level in steam jacket.
7 TILT WHEEL
Used for tilting the kettle on hand tilt models.
NOTE: Cleaning should be completed immediately after cooked
foods are removed.
8 LOW WATER INDICATOR LIGHT (RED)
When lit, indicates a low water condition.
NOTE: A five minute complete shut-of period is required
before relighting.
9 TANGENT DRAW-OFF VALVE
Used for draining product or wash water from kettle.
6.
CLEANING INSTRUCTIONS
CLEANING INSTRUCTIONS
CARE AND CLEANING
Cooking equipment must be cleaned
regularly to maintain its fast, efficient
cooking performance and to ensure its
continued safe, reliable operation. The
best time to clean is shortly after each
use (allow unit to cool to a safe
temperature).
1.
Turn unit off.
2.
Remove drain screen (if applicable). Thoroughly wash and rinse the screen
either in a sink or a dishwasher.
3.
Prepare a warm water and mild detergent solution in the unit.
4.
Remove food soil using a nylon brush.
5.
Loosen food which is stuck by allowing it to soak at a low temperature setting.
6.
Drain unit.
7.
Rinse interior thoroughly.
8.
If the unit is equipped with a Tangent Draw-Off Valve, clean as follows:
a)
WARNINGS
Do not use
detergents or
cleansers that are
chloride based or
contain quaternary
salt.
Chloride Cleaners
Do not use a metal
bristle brush or
scraper.
Wire Brush &
Scrapers
Steel wool should
never be used for
cleaning the stainless
steel.
b)
c)
d)
e)
9.
Disassemble the draw-off valve first by turning the valve knob counterclockwise, then turning the large hex nut counter-clockwise until the valve
stem is free of the valve body.
In a sink, wash and rinse the inside of the valve body using a nylon brush.
Use a nylon brush to clean tangent draw-off tube.
Rinse with fresh water.
Reassemble the draw-off valve by reversing the procedure for disassembly.
The valve's hex nut should be hand tight only.
If the unit is equipped with a Butterfly Valve, clean as follows:
a)
b)
c)
d)
e)
Place valve in open position.
Wash using a warm water and mild detergent solution.
Remove food deposits using a nylon brush.
Rinse with fresh water.
Leave valve open when unit is not in use.
10. If the unit is equipped with an Air Valve, clean as follows:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Open product valve.
Disconnect air hoses.
Remove air cylinder.
Remove valve tee.
Remove all O-rings.
Clean air cylinder, do not submerge in water. Wipe clean and sanitize.
Clean and sanitize tee and O-rings.
Grease and reinstall O-rings.
Reinstall valve tee to kettle outlet.
Reinstall air cylinder to bottom of tee.
Reconnect air hoses.
Close valve and check for alignment.
11. Using mild soapy water and a damp sponge, wash the exterior, rinse, and dry.
Steel Pads
NOTES
Unit should never be
cleaned with a high
pressure spray hose.
High Pressure
Spray Hose
DISPOSAL INSTRUCTIONS
Do not leave water
sitting in unit when
not in use.
Stagnant
Water
➩ For more difficult cleaning applications one of the following can be used: alcohol,
baking soda, vinegar, or a solution of ammonia in water.
➩ Leave the cover off when the kettle is not in use.
➩ For more detailed instructions refer to Stainless Steel Equipment Care and
Cleaning (www.nafem.org/resources/stainlesssteelfinal.doc) on Nafem’s website
(www.nafem.org).
This unit is recyclable. Do not dispose in landfill.
The unit may contain rust inhibitor and or antifreeze within the
jacket. Drain unit and dispose following Federal, State and local
regulations.
The majority of the unit is composed of stainless steel. Other alloys and electrical
components make up a small percentage of the total. Follow Federal, state and
local regulations for disposal.
7.
PREVENTATIVE MAINTENANCE
FOR MAINTENANCE AND REPAIRS CONTACT YOUR AUTHORIZED MANITOWOC SERVICE AGENCY
AND HAVE A QUALIFIED SERVICE TECHNICIAN MAINTAIN YOUR EQUIPMENT.
WARNING:
!
0
If for any reason this unit is not
functioning correctly DO NOT
OPERATE. Contact your
authorized service agent.
DAILY
PRE-STARTUP
INSPECTION
1. Flue is not obstructed.
2. Draw-Off Valve is installed and handle is in place.
3. Cover lifts up and down freely and is held in place when fully open.
4. Pressure Gauge is in the green when unit is cold.
5. Green Light comes on when unit is energized.
6. Red Light comes on when unit is tilted (tilting models only).
SIX MONTH SERVICE INSPECTION
1.
2.
3.
4.
5.
6.
7.
Perform daily startup inspection.
Tilt hand wheel is tight (tilting model).
Grease bearings on both trunnions (tilting model).
Check for play in gears (adjust if required) (tilting model).
Fasteners securing panels are in place and tight.
Perform pressure relief valve periodic test (see Pressure Relief Valve Testing).
Adequate exhaust and makeup air is supplied to working area.
YEARLY SERVICE INSPECTION
1.
2.
3.
4.
Perform six month service inspection.
Check kettle maximum temperature setting (see Calibrating Procedure).
Perform free air calculation (see FREE AIR CALCULATION).
Follow “SAFETY INSPECTION CHECKLIST”.
8.
SAFETY INSPECTION CHECKLIST
NOTE: The following instructions are intended for use by qualified service personnel.
The following steps should be completed IN SEQUENCE.
A/ KETTLE PREPARATION
1. Disconnect main power at fused disconnect switch.
2. Kettle should be cold. If necessary add water to kettle pot to cool unit.
3. The pressure gauge should now show a vacuum and have no indication of leakage.
If gauge gauge looks damaged replace gauge.
4. Gauge must be showing a vacuum prior to proceeding. If not check for leaks, and repair
kettle prior to proceeding. Refer to REFERENCE SECTION (KETTLE VENTING INSTRUCTIONS).
Pressure Gauge in Vacuum.
B/ MECHANICAL CHECKS
1. Inspect controls, replace damaged seals, switches, LED's etc..
2. Remove the console cover and check that the seal is not cracked or split.
Replace seal, screws, missing or worn nylon anchor nuts. Leave cover off.
3. Remove the kettle bottom cover and check that the seal is not cracked or split.
Leave cover off.
4A. For units with tilt handleA. Check handle for tightness. If loose apply lock tight and reinstall. Check handle
knob is on end of handle and firmly tightened. If missing replace, if loose apply
lock tight and reinstall.
B. Check that kettle tilts smoothly and there is no excessive wear in the trunnion bearings.
Add grease to nipples as required.
4B. For units with tilt crankA. Check that the kettle tilts smoothly. If there is excess play adjust the worm to gear
clearance with Locking Nuts or Adjusting Screw as required.
B. Check that there is no excessive wear in the trunnion bearings.
C. Apply grease to gear teeth and bearings.
4A. Grease Nipples.
Adjusting
Screw
Locking
Nuts
Worm
Screw and
Tilt
Gear
Cross
Bar
4B. Illustration inverted for clarity.
C/ MARINE LOCK TEST
1. Check that lock mechanism is not bent or damaged.
2. Check that lock clears stop pin on side box without rubbing when kettle is tilted.
3. Check side to side play. Lock should remain fully over stop pin when pushed to it's maximum side to side play.
D/ LOW WATER LEVEL PROBE:
Functional Test:
Installation Check:
1. Turn main power on at fused disconnect
switch.
2. Turn kettle on and set temperature to maximum.
3. Green light will come on and contactors close.
4. Tilt kettle over. After approximately a fivesecond delay the red light will come on, green
light go off and the contactors will disengage.
5. Turn kettle upright. Green light will come back
on and contactors reengage.
6. Turn kettle off
7. If unit does not function as above, make
required repairs.
8. Disconnect main power at fused disconnect
switch.
(A)
✔
Probe properly
attached
✘
Probe
bypassed
by running (A) an
additional wire
✘
Probe
bypassed by
(B) grounding the
connecting wire
9.
E/ SAFETY THERMOSTAT
Installation Check:
Correct
Installation
1
2
3
Incorrect Installations
✔
1. Safety thermostat probe
Probe
fully
inserted
in tube
Wiring is properly
connected
is not completely
inserted into tubing
(except KET-3-T that
has a small loop).
2. Safety thermostat probe
✘
✘
Probe
removed
partially
is removed from tubing.
✘
Probe
removed
completely
3. Safety thermostat
Thermostat
electrically
bypassed
electrical connection is
bypassed.
F/ SAFETY VALVE
Installation Check:
Physical Checks
3
1
✔
Correct
Installation
✘
✔
4"
maximum
length
The above illustrations show the
variations of factory installed Safety
Valves. Any modifications are
unacceptable.
✘
Tube
diameter
reduced
2
Plug
to drain
✘ Plumbed
or water line
Incorrect Installation
Pressure Relief Valve Periodic Testing Procedure
1. With the kettle empty, set On-Off 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.
3. Stand to the side of the pressure relief valve discharge tube and pull
valve 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.
If valve appears to be sticking replace pressure relief valve.
If foreign material is discharged then drain kettle and replace pressure
relief valve.
10.
1. Check that the PSI rating
on the valve matches
MAWP (maximum
allowable working
pressure) on the plate
welded to the kettle.
2. Check that the Safety
Valve has a "UV" stamp.
3. Check that the valve is
not damaged in any way.
If any of the above criteria
is not met, replace valve.
G/ CALIBRATING PROCEDURE
1. Kettle must be empty when this procedure is executed.
265º
2. Insure the unit has a vacuum before you begin calibrating procedures. If unit
requires venting see REFERENCE SECTION (KETTLE VENTING
INSTRUCTIONS).
✔
260º - 265º
MAXIMUM
KETTLE
TEMPERATURE
3. Turn kettle ON and set temperature dial to 10 (Max.).
4. Allow the unit to cycle twice (the green light must go on and off).
5. Check temperature of the inner kettle surface with a digital surface thermometer.
For accurate readings move probe around bottom of kettle to locate the hottest
location.
6. Temperature should be between 260° F and 265° F. Pressure gauge should read
between 20 - 28 PSI.
Take reading
from hottest
spot in bottom
of kettle.
7. Using a screw driver adjust temperature by turning the potentiometer on the
black box. Turn very little. Turn clockwise to INCREASES and counter-clockwise
to DECREASE temperature.
8. Allow the unit to cycle twice.
9. Re-check temperature.
10. Repeat steps 7 - 9 until unit is calibrated.
OPERATING SEQUENCES
1.
Turn On-Off / Temperature Dial*
-
14 volt transformer is energized and powers solid state control system.
Temperature knob is turned up and control box calls for heat.
Relay (RY-1) closes and powers 24 volt transformer.
Ignition control box is powered.
3.
Ignitor Sparks*
- Gas valve is energized.
- Ignitor sparks and ignition occurs.
4.
Temperature Reached*
-
Solid state controls senses temperature reached.
Relay (RY-1) opens and 24 volt transformer loses power.
Ignition control box is turned off.
Gas valve closes.
5.
Maintaining Temperature*
-
Solid state controls senses temperature drop.
Relay (RY-1) closes and powers 24 volt transformer.
Ignitor control box is powered.
Steps three and four are repeated.
SOLID STATE CONTROL SEQUENCE
Our solid state controls consist of the following components.
On-Off / Temperature* Provides or interrupts electrical power to the control system.
Dial (Potentiometer) Rotate to change resistance from 0 to 50,000 ohms. This resistance is compared to the resistance on the thermistor using a voltage
comparator circuit inside the control box.
If the resistance is lower than the thermistor resistance then the control box will provide 14v dc to pin #8. The green indicator light
illuminates and the control relay (RY-1) is energized closed to provide power to the heating system.
Control Box*
Analyzes inputs from water level probe, tilt switch, potentiometer, thermistor. Energizes control relay (RY-1)
Water Level Probe*
Senses water in jacket.
Tilt Switch
When kettle is in upright position tilt switch is closed to complete circuit between pin #8, the relay (RY-1) and green indicator light.*
Thermistor*
The thermistor resistance decreases as temperature increases. When the thermistor resistance equals the potentiometer then 14v dc
is removed from pin #8. The control relay (RY-1) returns to the normally open position.
Green LED Light
Indicates that the control box is calling for heat. Pin #8 powered.
Red LED Light
Indicates that the water level probe is not immersed in water. Not enough water in the jacket or kettle tilted.
Relay (RY-1)
When energized allows the heating circuit to function. Electric elements or gas burner system.
NOTES:
* A ground loop circuit must be established between kettle body, water in jacket, water level probe and control box. If this loop is present, it
indicates that there is sufficient water in the kettle for safe operation.
* If there is not sufficient water in the jacket then the loop is broken and the control box will prevent 14v DC from being supplied to pin #8.
The control relay (RY-1) will remain (or return) to the normally open position and the unit cannot heat. The red LED light will be illuminated.
11.
TROUBLESHOOTING GUIDE
PROBLEM:
KGL-25
Kettle Won't
Heat
Replace
the on/off
switch (toggle
or rotary).
Yes
Does red light
come on when unit
is first turned on?
Yes
Does red light go
off shortly after
unit is turned on?
No
Replace the
wire harness in
the trunion
Add water to
jacket of Kettle.
No
Is 16 VAC at the
secondary side of
the transformer?
No
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
With a jumper
across pins 5 and
7 on the controller,
is there 12 VDC
across the coil of
the DC relay?
No
Yes
No
Replace the
relay.
Replace the
transformer.
Yes
No
Is there 115 VAC
to the primary of
the transformer?
No
Yes
Does the relay pull
in?
Does the
potentiomer have
a resistance of
50,000 ohms on
low and 0 ohms at
No
high?
Yes
Replace the
high limit.
No
Supply115
VAC to the
kettle.
Is there 115 VAC
to the primary of
the ignition
transformer?
No
Does the probe
have a resistance
of 100,000 ohms +
Yes
10% at room
temperature?
Is there 24 VAC to
the ignition
Module?
No
Replace Probe
Yes
Is there 24 VAC to
the Gas valve for 4
Seconds?
No
Yes
Replace
the Ignition
module.
Is there Gas to the
burner?
Yes
Is there Spark to
the ignitor for 4
seconds.
No
Yes
If there
is spark and gas to
the burner assmbly
there should be
flame. Check
alighnment.
12.
Yes
Add water
Replace the
potentiometer
Yes
Yes
Replace the
ignition
transformer
With the jumper
removed and the
probe wire
grounded at the
probe, is 12 VDC
measured across
the coil of the DC
relay?
No
Replace the
gas valve
Replace the
controller
PROBLEM:
KGL-25
Kettle Not
Hot Enough
Does the kettle
heat at all?
No
See Problem:
kettle won't heat.
Yes
With kettle pot
empty and
temperature knob
set at 10, is the
temperature of the
surface of the pot
260 degrees?
Yes
No
Vent
the kettle per
instructions in
the manual.
No
Unit is
operating
properly
Yes
Replace the
igniton
transformer
When unit is cold
(room temp) is the
pressure gauge in
the green?
No
Is there 24 VAC to
the ignition
module?
Yes
Yes
When the unit is
calling for heat
(the green light is
on), is there flame
at the burner?
No
Is there 115 VAC
to the primary of
the ignition
module?
No
Replace the
thermister.
No
Replace the
potentiometer.
Yes
Is the resistance of
the thermister
100,000 ohms
+10% at room
temperature?
Yes
Replace
controller.
Yes
Is the
potentiometer
resistance 50,000
ohms at low and 0
ohms at high?
13.
No
Replace the
high limit
PROBLEM:
KGL-25
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 115 vac to
the primary of the
ignition
transformer?
Is the resistance of
the potentiometer
50,000 ohms at
the low setting and
0 ohms at high?
Yes
Yes
Is there 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?
14.
Yes
Replace the
controller.
No
Replace the
thermister.
No
Replace the
potentiometer
SERVICE PROCEDURES
FOR MAINTENANCE AND REPAIRS CONTACT YOUR AUTHORIZED MANITOWOC SERVICE AGENCY
AND HAVE A QUALIFIED SERVICE TECHNICIAN MAINTAIN YOUR EQUIPMENT.
0
KETTLE VENTING INSTRUCTIONS
150
200
100
250
20
50
150
200
100
20
50
30
10
0
50
60
psi
Pressure
Relief
Valve
350
400
kPa
50
60
psi
300
40
IR
NT A
VE
0
Pressure
Gauge
250
300
40
0
IR
NT A
VE
0
30
10
350
400
kPa
3. 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.
REPAIRING LEAKS IN STEAM
JACKETED KETTLE FITTINGS
The following procedure should be followed when the
Vacuum/Pressure Gauge needle is in the "VENT AIR" zone:
NOTE: Check for and eliminate leaks prior to venting (See
Repairing Leaks in Steam Jacketed Kettle Fittings.
Pressure
Gauge
DANGER: PRESSURE RELIEF
VALVE WILL EXHAUST HIGH
TEMPERATURE STEAM. CONTACT
WITH SKIN COULD RESULT IN
SERIOUS BURNS. KEEP FACE,
HANDS AND BODY CLEAR OF
DISCHARGE.
6
5
7
4
8
Pressure
Relief Valve
Sight
Glass
1. Turn kettle ON and set dial to
10 (Max.), heat the empty
kettle until unit cycles off.
3
If unit will not hold a vacuum the most likely cause is a
leak at one of the components threaded fittings, or within
the component itself.
9
2
1
Water Level
Probe
10
There are two methods available for preventing leaks. The
advantage of the “Preferred Method” is that you eliminate
all potential leaks.
OFF
2. Vent kettle by pulling safety
valve ring 8-10 times in short
2-3 second blasts with a 5
second interval between pulls.
Preferred Method: Replace (using teflon tape)
Pressure Relief Valve, Pressure Guage, Water Level Probe
and Sight Glass.
NOTE: If unit cycles ON, stop
venting and wait for kettle to
cycle OFF before continuing.
Second Method: Remove and reinstall (using teflon
tape) all of the above four components. If unit continues
to lose vacuum replace components as per “Preferred
Method”.
15.
CALIBRATING PROCEDURE
1.
Insure the unit has a vacuum before you begin
calibrating procedures. If unit requires venting refer
to Kettle Venting Instructions.
2.
Turn dial 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 black 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.
RESERVOIR FILL PROCEDURES
C. Fill unit via 1/2” Street Elbow
A.*
Remove Pressure
Relief Valve
B.
Attach Street
Elbow
*ImportantPull ring on Pressure Relief Valve
prior to removal to
insure vessel is not pressurized.
9. Repeat steps 4. through 8. until unit is calibrated.
DISTILLED WATER REQUIREMENTS
Kettle
Capacity
PRESSURE RELIEF VALVE WILL EXHAUST
HIGH TEMPERATURE STEAM. CONTACT
WITH SKIN COULD RESULT IN SERIOUS
BURNS. KEEP FACE, HANDS AND
BODY CLEAR OF DISCHARGE.
2.
Turn dial to "0" (Off).
3.
Stand to the side of the pressure relief valve discharge
tube and pull valve 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.
70 ounces
12 gallon
120 ounces
2. Remove electrical plug from
power source.
150
200
100
250
20
50
0
30
10
300
40
0
50
60
psi
350
400
kPa
Shut off gas supply to kettle.
3. Pull Pressure Relief Valve (A) open to insure vessel
is not pressurized.
4. Remove Pressure Relief Valve (A).
WARNING: Kettle surface will be hot and steam will be
released during testing. Take necessary precautions
including the use of gloves and eye protection to
prevent personal injury.
With the kettle empty, turn dail to "10" (Max.). Allow the
kettle to heat until the unit cycles off.
6 gallon
1. Ensure kettle is at room temperature
and pressure gauge showing zero
or less pressure.
DANGER:
1.
When red “Low Water Light” comes on,
add distilled or botttled water.
IR
NT A
VE
PRESSURE
RELIEF
VALVE
PERIODIC
TESTING
PROCEDURE
5. Replace Pressure Relief Valve (A) with 1/2” Street
Elbow (B).
6. Add distilled or bottled water (C)
through the Street Elbow (B),
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
Pressure Relief Valve's (A) thread and replace.
8. Reconnect gas and electrical supplies.
9. The kettle must now be vented. (Refer to the
KETTLE VENTING INSTRUCTIONS).
If valve appears to be sticking replace pressure relief valve.
If foreign material is discharged then drain kettle and
replace pressure relief valve.
If Low Water Light comes on after this procedure, you need
to add water to the jacket (see RESERVOIR FILL
PROCEDURE).
16.
Sight
Glass
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.
Remove
Pressure
Relief
Valve
Attach
Street
Elbow
Fill unit via Street Elbow
ImportantPull pressure relief valve
ring open to insure vessel
is not pressurized.
RUST INHIBITOR
10. Tilt kettle upright, apply a thread sealant (i.e. Teflon
tape) to the sight glass threads and replace.
Use a “radiator rust inhibitor” that can be purchased at
your local automotive centre. It should not contain any
anti-freeze and preferably no lubricant.
11. Refer to chart below to determine the required
volume of water.
To ensure satisfactory mixing follow the manufacturer’s
instructions.
Kettle Size
DISPOSAL - Follow all Federal, State and local codes
when disposing of product.
6 U.S. Gal.
12 U.S. Gal.
PROCEDURE
150
200
100
250
20
50
50
60
psi
12. In a separate container mix water with the required
rust inhibitor.
1. Ensure kettle is at room temperature and
pressure gauge showing zero or less pressure.
13. Fill jacket via the street elbow with the mixture.
2. Shut off and disconnect gas supply.
14. Remove street elbow.
3. Remove electrical plug from power source.
15. Apply a thread sealant (i.e. Teflon tape) to the pressure
relief valve and replace.
300
40
0
IR
NT A
VE
0
30
10
350
400
kPa
Volume of Mixture
U.S. Gal.
Liters
1.6
5.8
2.2
8.3
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.
20. Replace bolts holding kettle to tabletop.
9.
Tilt kettle on its side (sight glass opening facing
downwards) and allow to drain. Flush out with water.
21. Reconnect gas and electrical supplies.
✔
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.
22. Turn kettle on and vent kettle.
SAFETY
THERMOSTAT
CONNECTION
LOW WATER
LEVEL PROBE
CONNECTION
Probe
fully
inserted
in tube
✔
Wiring is properly
connected
17.
Probe properly
attached
Atmospheric Burner Gas Kettles
FIELD CONVERSION
INSTRUCTIONS -
KGL-25, KGL-25-T
Natural Gas to Propane Gas
BTU's per
Hour
90000
90000
Gas
Type
NAT
LP
Water
Column
4.2
10
# of
Orifices
2
2
TO MAIN GAS
SUPPLY
! CAUTION
The gas supply shall be shut off prior to disconnecting
the electrical power, before proceeding with the
conversion.
PIPE
NIPPLE
GAS
SHUT-OFF
VALVE
REGULATOR
GAS
IDENTIFICATION
STICKER
TH
IS
H CO
COAS BNETRO
NV EN L
TOERTE
LP D
GAS
COMBINATION
VALVE
BURNER
MAIN
ORIFICE
GASKET
MAIN
ORIFICE
FITTING
PRESSURE
REGULATOR
UNIT
!
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.
Conversion Kit
(KE003716-3)
Part No.
Description
Quantity
KE53406-18
Orifice
1
KE55240-4
Valve Conversion Kit
1
KE603910-2
Instruction Sheet
1
KE603911-3
Rating Label
1
3.
Remove GAS SHUT-OFF VALVE from kettle supply pipe
and install REGULATOR (pre-set to 10 " W.C. pressure)
supplied in field conversion kit.
4.
Re-install SHUT-OFF VALVE using PIPE NIPPLE supplied
in kit.
5.
Remove side cover from control console.
6.
Remove PRESSURE REGULATOR UNIT from GAS
COMBINATION VALVE inside console, and replace with
blocked PRESSURE REGULATOR UNIT from kit. Make
sure GASKET is correctly seated in recess in GAS
COMBINATION VALVE during installation.
7.
Tilt kettle. Remove kettle side box cover. Remove screw
securing end of BURNER. Remove BURNER. Support
MAIN ORIFICE FITTING and remove MAIN ORIFICE.
Install new orifice from kit.
8.
Replace BURNER. Check MAIN ORIFICE/BURNER
alignment insuring MAIN ORIFICE points straight into the
center of the BURNER.
9.
Reconnect to gas supply. Turn on propane gas. Tilt kettle to
upright position, turn on power and check all gas
connections for leaks.
10. Check inlet pressure is between 12-14 inches W.C.
11. On the underside of the console cover with indelible marker
place the following information: Company, Name, Address
& Date of Conversion.
NOTE: Use thread sealant compatible with propane gas on all
threaded piping connections.
12. Turn off power and main gas supply, and replace all covers.
Attach GAS IDENTIFICATION STICKER to nameplate.
1.
Disconnect electrical connection.
13. Place gas conversion label next to rating label.
2.
Shut off main gas supply and disconnect kettle from supply line.
14. Reconnect electrical and gas supplies.
KE603910-2
18.
REPAIRING LEAKS IN STEAM
JACKETED KETTLE FITTINGS
Water Level Probe
Pressure Gauge
Pressure
Relief Valve
5.
6.
Remove wire from ground lug.
Remove thermistor from tube.
7.
Add new “eye” connector to one of the thermistor
leads and fasten to ground lug.
8.
Connect orange wire to the other thermistor lead and
fasten with pigtail connector.
9.
Insert thermistor as far as possible into tube and
hold in place. While holding add silicon to secure
thermistor into tube. Insure silicon completely
surrounds tube and thermistor.
If unit will not hold a vacuum the most likely cause is a leak
at one of the fittings. Often, the easiest way to eliminate a
leak is reseal the suspect areas.
1. Water Level Probe
Remove, clean threads, apply
teflon thread sealant and reinstall.
2. Pressure Relief Valve
A/ Inspect for signs of leaks.
Replace if required.
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/ Remove, clean threads, apply
teflon thread sealant and reinstall.
If leek persist replace all these components at the same
time.
THERMISTOR REPLACEMENT
1.
2.
3.
4.
Disconnect main power at fused disconnect switch.
Remove bottom cover.
Locate thermistor.
Cut pigtail connection off.
10. Replace covers, reconnect power and test operation.
19.
Cross
Bar
TEST #1 GREEN
RED
Probe senses water
No water sensed
TEST #2 GREEN Thermistor is sensed
ORANGE Thermistor is shorted
RED
Thermistor is open circuit
SWITCH
POTENTIOMETER
LOW WATER
HEATER OUTPUT
1. If required remove board from holding bracket for better
access.
Apply grease to gear teeth.
Check for excessive play and
adjust with adjusting screw
located on top of cross bar.
KETTLE TRUNNIONS
Rapid flashing during normal operation
TEST #1 = 1 flash/sec Water level test
TEST #2 = 2 flash/sec Thermistor test
TEST #3 = 3 flash/sec Heater Ouput test
TEST #3 GREEN voltage output
to relay for 20 seconds.
Normal operation LED matches
Front heater (greeen) LED
These parts are accessed
through the top cover of the
console.
Worm
Screw and
Tilt
Gear
SWITCH - Push for 5 seconds to enter TEST #1
Press again for TEST #2 and again for TEST #3
CPU -
THIS CONTROL BOX MUST BE
CALIBRATED WHEN REPLACED
(see back for test and
calibration instructions)
TRUNNION HOUSING,
WORM SCREW AND
TILT GEAR
Adjusting
Screw
SSK Solid State Control (part number KE00458-1)
CPU
Lubricate the following parts every three months to insure
smooth operation and reduce wear.
DIAGNOSTIC
LED
SSK SOLID
STATE
CONTROL
TEST
INSTRUCTIONS
LUBRICATION PROCEDURE
2. Turn unit on and set to 10 (maximum).
3. Push and hold the SWITCH button for approximately 5
seconds until the CPU starts to flash 1 flash/second. You
are now in TEST #1. Output to 12v relay is disabled. With
kettle upright the DIAGNOSTIC LED should be green, with
kettle tilted it should be red.
Trunnion Housing
Grease Nipple
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.
4. Push SWITCH button. The CPU starts to flash 2 flash/
second. You are now in TEST #2. Check the DIAGNOSTIC
LED for indication of the temperature probe status.
5. Push SWITCH button. The CPU starts to flash 3
flash/second. You are now in TEST #3. The HEATER
OUTPUT LED should light for 20 seconds and power to
the relay should energize the 12v relay for the heat source.
After 20 seconds test mode is exited and unit reverts to
normal operation.
HINGE ADJUSTMENT
INSTRUCTIONS
FREE AIR CALCULATION
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.
3/8" Allen wrench
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.
1.
Insert 3/8" Allen wrench.
2.
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.
Dilution Factor X CO (PPM) = _____________________________
10,000
% Carbon Monoxide
Result must not exceed 0.08% carbon monoxide.
Carbon Dioxide Factor
in Sample Propane
(percent)
Gas
4.0
3.50
4.2
3.33
4.4
3.18
4.6
3.04
4.8
2.92
5.0
2.80
5.2
2.69
5.4
2.59
5.6
2.50
5.8
2.41
6.0
2.33
6.2
2.26
6.4
2.19
6.6
2.12
6.8
2.06
20.
Factor
Natural
Gas
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
Carbon Dioxide Factor
in Sample Propane
(percent)
Gas
7.0
2.00
7.2
1.94
7.4
1.89
7.6
1.84
7.8
1.79
8.0
1.75
8.2
1.71
8.4
1.67
8.6
1.63
8.8
1.59
9.0
1.56
9.2
1.52
9.4
1.49
9.6
1.46
9.8
1.43
10.0
1.40
Factor
Natural
Gas
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
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 factorysupplied replacement parts should be used. The use of other than factory supplied replacement parts will
void warranty.
FAUCET ASSEMBLY (optional)
1
2
1
ITEM PART
NO. NO.
DESCRIPTION
QTY.
3
4
2
5
3
6
4
3/4" SPOUT
1.
KE50825-7
FOR STATIONARY KETTLES . . . . . . . . . . .1
KE50825-2
FOR TILTING KETTLES . . . . . . . . . . . . . . .1
2.
FA95022
RETAINING RING . . . . . . . . . . . . . . . . . . . .1
3.
FA05002-19
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE51736
LONG FAUCET NUT . . . . . . . . . . . . . . . . .1
5.
SE50020
HOT WATER STEM ASSEMBLY . . . . . . . . .1
6
10
6.
SE50021
COLD WATER STEM ASSEMBLY . . . . . . . .1
7.
KE51401
SINGLE PANTRY BODY . . . . . . . . . . . . . . .1
ADAPTER WASHER . . . . . . . . . . . . . . . . . .1
(SINGLE PANTRY ONLY)
9.
KE51403
9
12
13
11
12
13
(C/W ITEM NO. 6)
KE50335
11
8
10
(DOUBLE PANTRY ONLY)
8.
7
DOUBLE PANTRY BODY . . . . . . . . . . . . . .1
(C/W ITEM NO. 5&6)
10.
SK00395-1
FAUCET MOUNTING BRACKET . . . . . . . .1
11.
FA11258
HEX CAP SCREW . . . . . . . . . . . . . . . . . . .2
12.
FA30505-1
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . .2
13.
FA21008
HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . .2
14.
SE50447
WASHER HORSESHOE . . . . . . . . . . . . . . .1
21.
14
COMPONENT MOUNTING PLATES
TILTING MODELS
STATIONARY MODELS
3
4
5 10
10 11 12 13
8
7
4
2
5
9
3
1
7
8
1
2
6
5 10
9
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE01927-1
COMPONENT MOUNTING PLATE (STATIONARY MODELS) . . . . . . . . . . . . . . .1
KE01927
COMPONENT MOUNTING PLATE (TILTING MODELS) . . . . . . . . . . . . . . . . . . .1
2.
KE50753-7
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE00458
SSK CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE50303
ELECTRONIC BOX HOLDER (STATIONARY MODELS) . . . . . . . . . . . . . . . . . . .1
KE52548
ELECTRONIC BOX HOLDER (TILTING MODELS) . . . . . . . . . . . . . . . . . . . . . . .1
5.
FA11089
SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
6.
FA11052
SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
9.
FA32004
TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
10.
FA32005
TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
11.*
KE53469-2
IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54308-3
HIGH VOLTAGE LEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.*
FA10245
SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
13.*
FA20004
HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
7.
KE53838-20
TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE53838-27
TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FOR 120V OPTION
FOR 240V OPTION
7.
KE53838-18
TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE53838-21
TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* FOR TILTING MODELS SEE “GENERAL ASSEMBLY - TILTING MODELS”
22.
BURNER ASSEMBLY
11
7
8
10
17 16 15
2
3
1
4
5
6
12 14 13
9
ITEM NO.
PART NO.
DESCRIPTION
1.
KE54897-1
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
QTY.
2.
KE54890-1
IGNITION GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
FA11144
SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
4.
KE54881-1
BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE54894-1
HOLDER, BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE54895-3
INSULATION ON TOP OF COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE01500-2
BURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE01500-4
BURNER WITHOUT IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
KE02195-1
BURNER PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
KE54895-2
INSULATION BETWEEN BOTTOM COVER & BURNER ASSEMBLY . . . . . . . . .2
11.
KE54895-4
INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE53406-21
GAS ORIFICE, NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
KE53406-18
GAS ORIFICE, LP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
13.
FI05134-1
COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
14.
FI00565-6
NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15.
KE53437-1
IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16.
FA11145
SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
17.
KE54775
IGNITOR POSITION HOLDING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
23.
TANGENT DRAW-OFF VALVE
7
6
5
4
3
2
1
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1. - 7.
KE50973
KE50972-B
2” DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3” DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
FA95049
FA21050
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
7.
KE50972-B
KE50973
VALVE BODY, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
VALVE BODY, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
24.
GENERAL ASSEMBLY - STATIONARY MODELS (pg. 1 of 2)
34
31
5
7
8 10
VIEW "B"
L3
MANIFOLD & BURNER
TUBE PIPING DETAIL
21
A
25
6
7
9 10 L1
27
14 15 16
26
28
29
28
30
VIEW "A"
COMPONENT MOUNTING BOX
WITH LID REMOVED
11
2
3
4
32
13
19 20
23
24
25
17 18
L4
L2
B
22
1
25.
GENERAL ASSEMBLY - STATIONARY MODELS (pg. 2 of 2)
ITEM NO.
PART NO.
DESCRIPTION
1.
KE00099
ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
QTY.
2.
KE01928-2
COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .1
(see COMPONENT MOUNTING PLATES)
3.
FA20006
MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
FA32006
TOOTH LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE54991-1
LID (COMPONENT BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE54991-2
LID (SIDE BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
FA95074
ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8.
KE54846-4
GASKET (COMPONENT BOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
KE54846-5
GASKET (SIDEBOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
FA95031
PAN HEAD PHILLIPS DRIVE SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
KE000714-4
FOR UNITS BUILT PRIOR TO FEBRUARY 2005 . . . . . . . . . . . . . . . . . . . . . . . .1
PRESSURE GAUGE
11.
KE50429-5
FOR UNITS BUILT AFTER JANUARY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
KE54941-6
SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
KE55069-6
SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15.
KE00515
THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16.
KE50556-1
LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17.
KE02053
GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18.
FA10360
SCREW PAN HEAD PHILLIPS (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
19.
F01518-1
GAS SHUT OFF VALVE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS OPTIONS:
KE54618-1
PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54618-2
PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20.
FI00607
CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
21.
KE54821-8
SUPPLY CORD (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
22.
KE54833-2
SNAP IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
23.
FA00152
STREET ELBOW (3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
24.
FI00355
BUSHING (3/4 X 3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
25.
FI00565-3
NIPPLE (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
26.
FI05198-5
COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
27.
FI00265
COUPLING (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
28.
FI05134-1
COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
29.
KE54667-4
BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
30.
FI00565-6
NIPPLE (3/8 NPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
31.
KE51238
CORD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
32.
CHS-25
SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
34.
KE54468
WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L1.
KE90424
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L2.
KE95555-5
OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L3.
KE95552
RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L4.
KE95551
LABEL SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABELS
26.
GENERAL ASSEMBLY - TILTING MODELS (pg. 1 of 3)
62
3
2
VIEW "G"
MANIFOLD & BURNER TUBE PIPING DETAIL
55
56
57
10
8
13
12
11
12
14
L2
5
L3
60 L5
6
9
L4
G
7
L1
61
1
ITEM NO.
PART NO.
DESCRIPTION
1.
KE00099
ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
QTY.
2.
KE51723-1
SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PRESSURE GAUGE
3.
KE000714-4
FOR UNITS BUILT PRIOR TO FEBRUARY 2005 . . . . . . . . . . . . . . . . . . . . . . . .1
KE50429-5
FOR UNITS BUILT AFTER JANUARY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE529773
LID FOR GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE00508
HANDWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE54821-8
SUPPLY CORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
CHS-KGL-25-T
SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
KE00351
TRUNNION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
FI05321-1
NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
KE54667-3
BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
27.
GENERAL ASSEMBLY - TILTING MODELS (pg. 2 of 3)
25 26
27 28
29 30
23
B
24
B
C
C
21 22
15 16
17
18
19
20
37 38 39 40 41 36 42 43 45 43 42 46
47 48 49 50
58
53
59
31
44
32
33
34
35
60
51 52 53 54
12.
FI05134-1
COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
13.
FI05198-5
COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
FI00565-6
NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15.
FI05222
SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16.
FI05231
FLUSH BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17.
FI05223
SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18.
KE02053
GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
19.
FI00607
CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20.
F01518-1
GAS SHUT OFF VALVE
GAS OPTIONS:
21.
KE54618-1
PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54618-2
PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
F105226-12
NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
28.
GENERAL ASSEMBLY - TILTING MODELS (pg. 3 of 3)
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
FI00040
FA19177
FA20047
KE50294-1
KE54456-1
KE50295-1
FA11396
FA31031
FA15018-7
KE52833
FA10772
FA20030
FA95007-4
FA95055-1
KE50315
ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX SOCKET SET SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MERCURY SWITCH BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CLIP FOR MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEX HEAD BOLT (3/8-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SCREW 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SOCKET HEAD CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
KE51730
FA31010
FA20030
KE503752
FA95005
KE52193
KE52191
KE52192
FA30088
FA95008
KE53469-2
KE54308-4
FA10245
TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
49.
50.
FA20004
FA32005
HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
51.
52.
53.
54.
55.
56.
57.
KE53390
FA10367
FA32006
FA20007
KE55069-6
KE00515
KE50556-1
GAS VALVE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BINDING HEAD SCREW (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOTH LOCKWASHER (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MACHINE SCREW NUT (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
58.
KE01928-1
59.
60.
61.
62.
LABELS
L1.
L2.
L3.
L4.
L5.
FA20006
FA11145
KE54833-2
KE54468
COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .1
(see COMPONENT MOUNTING PLATES)
MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SNAP-IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE95555-5
KE95552
KE95551
KE95040
KE90424
OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS KETTLE LABEL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DIRECTION OF TILT LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
29.
CONSOLE
CONTROLS
4 7
8
1
5 7
3
2
6 7
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
SE00114
POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #2 . . . . . . . . . . . . . . . . .1
2.
KE51005
RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE50569-1
KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
SE003013-1
L.E.D., RED, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . . . . .1
5.
SE003013-2
L.E.D., GREEN, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . . .1
6.
SE003013-3
L.E.D., AMBER, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . .1
7.
FA05002-18
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
30.
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
25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-2
60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-3
100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-4
KDM-60, KDM-60-T, Cook Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00597-5
KDL-200, KDL-250, KDL-150-F, KDL-250-F . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
KE50822
Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE51217
Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE50121-2
Hinge Spring Light - for KE00597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50121-1
Hinge Spring Heavy - for KE00597-1, KE00597-3, KE00597-4, KE00597-5, . .1
4.
KE50823-1
Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE50824
Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE50819-1
Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE50820
Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE50819
Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FA11284
Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
10.
FA11507
Cutting Screw,
11.
SK50418
Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE50151-2
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
31.
32.
+1-800.338-2204 WWW.CLEVELANDRANGE.COM
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your operaonal needs from one restaurant to mulple locaons
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