Operators Manual Installation, Operation & Service Gas Floor Model Kettles MODELS: Stationary - KGL-40, KGL-60, KGL-80, KGL-100 Tilting - KGL-40-T, KGL-60-T, KGL-80-T Short Series - KGL-40-SH, KGL-60-SH, KGL-40-TSH KGL-40 KGL-40SH KGL-40-T ™ Cleveland Enodis 1333 East 179th St., Cleveland, Ohio, U.S.A. 44110 Phone: (216) 481-4900 Fax: (216) 481-3782 Visit our web site at www.clevelandrange.com SE95003-1 Rev.
FOR THE USER IMPORTANT! PRIOR TO REMOVING ANY FITTINGS ENSURE KETTLE IS AT ROOM TEMPERATURE AND PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE. FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS AND VAPOURS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation and operating instructions thoroughly before installing or servicing this equipment.
For your safety DANGER Keep clear of pressure relief discharge. Keep hands away from moving parts and pinch points. IMPORTANT Do not fill kettle above recommended level marked on outside of kettle. Inspect unit daily for proper operation. CAUTION Surfaces may be extremely hot! Use protective equipment. Wear protective equipment when discharging hot product. Do not lean on or place objects on kettle lip. Stand clear of product discharge path when discharging hot product.
INSTALLATION 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. SHIPPING DAMAGE INSTRUCTIONS If shipping damage to the unit is discovered or suspected, observe the following guidelines in preparing a shipping damage claim. 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.
ELECTRICAL INSTALLATION CHECKS ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING LABEL. Although the kettle has been thoroughly tested before leaving the factory, the installer is responsible for ensuring the proper operation of kettle once installed. 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 wiring diagram is located under the cover of electrical box inside the back console.
OPERATING INSTRUCTIONS 8 5 1 2 3 9 4 4 6 7 Operating Controls & Indicators ITEM # DESCRIPTION FUNCTION 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. 2. On-Off Switch/ Solid State Temperature Control Turns kettle ON/OFF and allows the operator to adjust the kettle temperature in increments from 1 (Min.) to 10 (Max.). (see the TEMPERATURE RANGE CHART).
OPERATING THE KETTLE DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE. ! KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES. DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE LIP. SERIOUS INJURY COULD RESULT IF KETTLE TIPPED OVER, SPILLING HOT CONTENTS. IF YOU ARE COOKING AN EGG OR MILK PRODUCT, DO NOT PRE-HEAT KETTLE. Before turning kettle on, read the Vacuum/Pressure Gauge (5). The gauges needle should be in the green zone.
CLEANING INSTRUCTIONS CLEANING INSTRUCTIONS CAUTION SURFACES MAY BE EXTREMELY HOT! 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). WARNINGS ➩ 2. Remove drain screen (if applicable). Thoroughly wash and rinse the screen either in a sink or a dishwasher. 3.
STAINLESS STEEL EQUIPMENT CARE AND CLEANING (Supplied courtesy of Nafem. For more information visit their web site at www.nafem.org) to reduce deposits. There are certain filters that can be installed to remove distasteful and corrosive elements. To insure proper water treatment, call a treatment specialist. Contrary to popular belief, stainless steels ARE susceptible to rusting. Corrosion on metals is everywhere. It is recognized quickly on iron and steel as unsightly yellow/orange rust.
SERVICE PARTS CONSOLE CONTROLS 6 9 11 3 7 9 5 4 1 10 0 50 15 AI R 0 VE 2 0 10 20 0 NT 8 9 20 0 30 USED PRIOR TO JANUARY 2000 25 0 40 30 0 50 ps60 i 35 0 kP 40 a 0 10 ITEM NO. PART NO. DESCRIPTION 1. 2. 3. KE50504 SK50062 SE00114 KE50988-2 KE51005 KE50569-1 SE003013-1 SE003013-2 SE003013-3 SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . .1 RUBBER BOOT (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL COMPONENT BOX 6 13 4 3 2 1 ITEM ON. 5 10 9 PART NO. DESCRIPTION 9. 13. KE01422 KE53439 KE53440 KE53599-1 KE53838-27 KE53444 KE54833-3 KE02372 KE53469-4 KE00458 KE50303 KE50753-7 KE50753-8 KE55069-6 FI05050 KE02400 KE55453-1 KE53838-20 KE53582 ELECTRICAL CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 COVER, COMPONENT BOX . . . . . . . . . . . . .
GAS CONTROL ASSEMBLY Air Blower Primary Air Orifice 1 Stationary Models 21 25 22 2 23 24 3 Secondary Air Orifice 26 4 27 22 16 28 Gas Orifice 29 Ignitor 17 19 18 7 20 5 6 4 Burner 37 Gas Valve 8 11 34 28 12 Shut-Off Valve 30 9 13 14 40 41 15 38 42 25 31 39 32 33 34 Tilting Models 30 29 (for units built prior to March 2005) 35 10
GAS CONTROL ASSEMBLY ITEM ON. PART NO. DESCRIPTION 1. KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53441-1 BLOWER, 220V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE54420 AIR INTAKE WASHER (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAS CONTROL ASSEMBLY (for units built after February 2005) 9 10 6 1 5 2 3 4 7 Tilting Models 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. FI00040-1 FI05226 FI05231 FI05222 FI05223 KE55240R F015 KE000960 FA30505-1 FA11256 8 ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 NIPPLE, 1/2" NPT, 8" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 ADAPTOR . . . .
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. KE52836-2 KE50315 FA95005 KE52193 KE52192 KE52191 FA30088 FA95008 KE55057-4 FA95062 KE00508 FA19501 KE51730 FA19177 FA20047 KE003209-11 TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TENSION PIN . . . . . . . . . . . . . . . . . . . .
PNEUMATIC BOX ASSEMBLY (FOR OPTIONAL FLUSH PISTON VALVE) (USED AFTER 2003)
PNEUMATIC BOX ASSEMBLY (FOR OPTIONAL FLUSH PISTON VALVE) (USED AFTER 2003) ITEM NO. PART NO. DESCRIPTION 1. 2. 3. 4. 5. KE003050 KE602957 KE54846-9 FA95074 KE01812-1 KE003209-9 KE601601 KE602960 KE52697 KE601602 FA32500 KE600814-1 FI00351 FI05317-2 FI05220-1 KE601603 KE02292-1 KE02369 FI05318 KE532176 KE50555-3 KE51238-1 KE50473 KE55004-3 FA21006 WC101655 FA21002 FA32004 FA11091 KE55242 KE95481-5 KE602071 N0440B4 KE55232 PNEUMATIC BOX WLD'T; KGL/T . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONAL FLUSH PISTON VALVE 12 (USED AFTER 2003) 13 4 12 AIR VALVE ASSEMBLY FPVA-3 1 5 2 6 3 7 8 9 10 8 11 ITEM ON. PART NO. DESCRIPTION QTY. 1. KE55210 WELD RING, KETTLE BOTTOM OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. FI05144-3 SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. KE52154-4 GASKET, SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRUNNION ASSEMBLY For tilting units with covers 1 ITEM PART NO. NO. DESCRIPTION 1. TRUNNION BEARING ASSEMBLY . . . . . .1 (INCLUDES PART # 3 & 6) 2. 3. KE00354 KE00351 QTY. TRUNNION BEARING ASSEMBLY . . . . . .1 (INCLUDES PART # 3 & 6) KE51711 ROLLER BEARING . . . . . . . . . . . . . . . . . 2 4. KE51571-1 SPHERICAL WASHER . . . . . . . . . . . . . . . .1 5. FA95081-3 BOLT, 5/16-18 X 1/2" . . . . . . . . . . . . . . . . .1 6. KE51886 GREASE NIPPLE . . . . . . . . . . . . . . . . . . . .
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. FA05049 MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE 1 3. FI00151 STREET ELBOW, 90°, 1/2", BRASS 2 4. FI00178 TEE, 1/2" FPT, BRASS 1 5. KE54941-5 KE54941-31 SAFETY VALVE, 50 PSI, 1/2", (EUROPE) 1 6. KE54223 BLOW DOWN TUBE 1 7. KE54864 ACCESS PANEL 1 8.
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 KE50597-1 25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE50597-2 60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE50597-3 100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .1 KE50597-4 KDM-60, KDM-60-T, Cook Tank . . . . . . . . . .
WRAP COVERS BACK TOP LEFT SIDE RIGHT SIDE FRONT TRANSFORMER COVER & GASKET RIGHT SIDE BACK WRAP COVER GASKET TRANSFORMER TRANSFORMER COVER COVER GASKET KETTLE TOP FRONT LEFT SIDE KGL-40 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 KE53871-1 RB01851 (1ft.) KGL-80 KE01479-2 KE53483-6 KE54253-2 KE01432-2 KE02186-3 KE54419-3 KE53871-1 RB01851 (1ft.
MAINTENANCE INSPECTION AND MAINTENANCE CHECKLIST Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guideline for inspection and maintenance to keep your unit functioning at 100%. INSPECTION AND MAINTENANCE CHECKLIST The following checks should be completed every six months or more frequently if unit is in a high volume facility. WARNING: It is imperative that damaged seals be repaired immediately to prevent equipment failure and/or damage.
Kettle Safety Inspection Checklist Just recently a competitor’s steam jacketed kettle exploded causing serious personal injury and damage to a kitchen. In most cases these accidents are caused by poor maintenance and/or incorrect installation. We at Cleveland would like to restate that regular inspection and maintenance of units is essential to obtain trouble free and safe operation of equipment.
SAFETY THERMOSTAT: 1 ✔ Probe fully inserted in tube Wiring is properly connected ✘ Probe removed partially Incorrect Installations 2 ✘ Probe removed completely 3 ✘ Thermostat electrically bypassed 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.
LUBRICATION PROCEDURE Lubricate the following parts every three months to insure smooth operation and reduce wear. 3/8" Allen wrench TRUNNION HOUSING, WORM SCREW AND TILT GEAR Adjusting Screw Worm Screw and Tilt Gear Cross Bar These parts are accessed through the top cover of the console. Apply grease to gear teeth. Check for excessive play and adjust with adjusting screw located on top of cross bar.
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.
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.
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.
KETTLE VENTING INSTRUCTIONS 150 0 250 20 A. Water Level Probe. 30 10 300 40 0 50 IR NT A VE VACUUM LEAK TEST PROCEDURE If the kettle will not hold vacuum, test for leaks at: 200 100 50 Pressure Relief Valve 350 60 Valve Ring 400 psi kPa Access Panel B. Pressure Relief Valve/Pressure Gauge and connecting plumbing. C. Boiler Drain Cap. D. Sight Glass.
RESERVOIR FILL PROCEDURES 150 30 10 300 40 0 50 IR NT A VE 0 250 20 50 WARNING: IMPROPER REFILLING OF 200 100 60 KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT. 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. The kettle's water level must be maintained at the proper level.
PRESSURE RELIEF VALVE PERIODIC TESTING Pressure Relief Valve Valve Ring Access Panel Most insurance agencies require periodic testing of pressure relief valves used on pressure vessels. This procedure will allow you to safely and quickly test your kettle's pressure relief valve. We recommend this test be performed twice a year. 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.
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: WARNING: WORKING ON MACHINES WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK. IMPROPER REFILLING OF KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT. DANGER: DANGER: MOLYFILM 315 IS CORROSIVE, AVOID CONTACT WITH SKIN AND EYES. EXTREMELY HOT SURFACES. WORK ONLY ON COLD KETTLE.
GAS KETTLE ORIFICE REPLACEMENT 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 main kettle CONSOLE COVER. Remove Cover 4. 1. Remove PLUG Console and SPRING. 5. 6. Remove GAS ORIFICE and “O” RING. 2. Remove Plug and Spring Replace first with new “O” RING and then GAS ORIFICE. 3. Remove Orifice 7. 8. Replace SPRING and PLUG. 4.
FIELD CONVERSION INSTRUCTIONS Natural Gas to Propane Gas Power Burner Gas Kettles KGL-40, KGL-40-T, MKGL-40-T, KGL-60 to 100, KGL-60-T to 80-T, KGL-40-TSH, KGL-40-F to 60-F, KGL-40-SH to 60-SH, HA-MKGL-60 to 100, HA-MKGL-60 to 100-T BTU's per Hour Gas Type Water Column # of Orifices 140000 140000 NAT LP 3.5 3.5 1 1 “O” RING GAS ORIFICE 190000 190000 NAT LP 3.5 3.5 1 1 SPRING PLUG TOP COVER NOTE: Use thread sealant compatible with propane gas on all threaded piping connections. 1.
WIRING DIAGRAMS (after Sept.
WIRING DIAGRAMS (after Sept. 2004) Diagram #1 (continued) Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz (NORTH AMERICA) ITEM NO. PART NO. DESCRIPTION QTY. 1 KE55069-6 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS (after Sept. 2004) Diagram #2 (see diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz (NORTH AMERICA) ITEM NO. PART NO. DESCRIPTION QTY. 21 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 22 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS (after Sept.
WIRING DIAGRAMS (after Sept.
WIRING DIAGRAMS (after Sept.
WIRING DIAGRAMS (prior to Sept.
WIRING DIAGRAMS (prior to Sept. 2004) Diagram #1 (continued) Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz ITEM NO. PART NO. DESCRIPTION QTY. 1 KE55069-6 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS (prior to Sept. 2004) Diagram #2 (see diagram #1 for common parts) Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz ITEM NO. PART NO. DESCRIPTION QTY. 21 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 22 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS (prior to Sept. 2004) Diagram #3 (see diagram #1 for common parts) Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 50Hz ITEM NO. PART NO. DESCRIPTION QTY. 23 KE53441-1 BLOWER, 220V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 24 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 25 KE50753-8 RELAY, 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE50753-7 RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
