Cleveland KGL-25 Service Manual

SE95052 Rev. 3

Operators Manual

Installation, Operation & Service

Gas 25 Gallon Kettle

MODELS:

KGL-25

KGL-25-T

KGT-25-T

KGT-25

1333 East 179th St., Cleveland, Ohio, U.S.A. 44110

Phone: [phone] Fax: [phone]
Visit our web site at www.clevelandrange.com

d

Enodis

™

Clev elan

FOR THE USER

IMPOR

TANT

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.

KEEP APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE
TECHNICIAN.

RETAIN THIS MANUAL FOR YOUR REFERENCE.

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

DO NOT STORE OR USE

GASOLINE OR ANY OTHER

FLAMMABLE LIQUIDS AND

VAPOURS IN THE VICINITY

OF THIS OR ANY OTHER

APPLIANCE.

IMPORTANT!

PRIOR TO REMOVING ANY FITTINGS ENSURE KETTLE

IS AT ROOM TEMPERATURE AND

PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE.

For your safety

DANGER

Keep clear of pressure
relief discharge.

IMPORTANT

Inspect unit daily for
proper operation.

CAUTION

Surfaces may be
extremely hot! Use
protective equipment.

Keep hands away from
moving parts and pinch points.

Do not fill kettle above
recommended level
marked on outside of kettle.

Wear protective equipment
when discharging hot product.

Do not lean on or place
objects on kettle lip.

SERVICING

Shut off power at main
fuse disconnect prior
to servicing.

GAS APPLIANCES

Do not attempt to operate
this appliance during a
power failure.

Stand clear of product
discharge path when
discharging hot product.

Ensure kettle is at room

0

temperature and pressure
gauge is showing zero or less
prior to removing any fittings.

Keep appliance and area free
and clear of combustibles.

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. 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.

4. Fill out all carrier claims forms and have the
examining carrier sign and date each form.

GENERAL

Installation of the kettle must be accomplished by
qualified installation personnel working to all applicable
local and national codes. Improper installation of
product could cause injury or damage.

This equipment is built to comply with applicable
standards for manufacturers. Included among those
approval agencies are: UL, A.G.A., NSF, ASME/N.Bd.,
CSA, CGA, ETL, and others. Many local codes exist,
and it is the responsibility of the owner/installer to
comply with these codes.

Observe all clearance requirements to provide proper
make-up air flow. Do not obstruct the flow of combustion
and ventilation air. Check rating plate to ensure that
kettle has been equipped to operate with the type of
gas available at the installation.

CLEARANCE REQUIREMENTS

This unit must be installed in accordance with the
clearances shown on the rating label which is adhered
to the unit.

FOR YOUR SAFETY. Keep the appliance area free and
clear of combustible materials.

INSTALLATION

Note: For clearance requirements, suggested

drain location and assembly details refer to
SPECIFICATION DRAWING.

1. Position the unit in it's permanent location, and
level the unit by turning the adjustable feet.

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.

3. Seal joints of flanged feet with a silicone
sealant.

GAS

ENSURE THE GAS SUPPLY MATCHES THE
KETTLE'S REQUIREMENTS AS STATED ON THE
RATING PLATE.

It is recommended that a sediment trap (drip leg) be
installed in the gas supply line. If the gas pressure
exceeds 14” water column, a pressure regulator must
be installed, to provide a maximum of 14” water column
gas pressure to the gas control valve.

Connect the gas line to the manual valve located at the
rear of the control box.

Installation must be in accordance with local codes
and/or the National Fuel Gas Code ANSI Z223.1 Latest
Edition (USA) or the latest Installation Codes for Gas
Burning Appliances and Equipment CAN/ CGA B149.1
and CAN/ CGA B149.2 (Canada). Use a gas pipe joint
compound which is resistant to L.P. gas. Test all pipe
joints for leaks with soap and water solution. Ensure that
the gas pressure regulator is set for the manifold
pressure indicated on the gas rating plate.

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).

INSTALLATION

FLANGED FOOT DETAIL

4 7/8" (124mm)

120 120

7/16"Ø, 3 HOLES

ON 3 1/8" (80mm) B.C.D.

(REAR LEGS ONLY)

ELECTRICAL

ENSURE THE ELECTRICAL SUPPLY MATCHES THE
KETTLE'S REQUIREMENTS AS STATED ON THE
RATING LABEL.

A cord and plug are supplied with the unit. Simply plug
the unit into any grounded outlet rated for a minimum of
10 amps.

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. 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 kettle when installed, must be electrically
installed and grounded in accordance with local codes,
or in the absence of local codes, with National Electrical
Code, ANSI/NFPA 70-1990 (USA) or the Canadian
Electrical Code, CSA C22.2, Part 1 (Canada).

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.

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, the taps require 1/2" copper tubing as
supply lines.

INSTALLATION CHECKS

Although the kettle has been thoroughly tested before
leaving the factory, the installer is responsible for
ensuring the proper operation of kettle once installed.

DO NOT ATTEMPT TO OPERATE THIS APPLIANCE
DURING A POWER FAILURE.

KEEP APPLIANCE AND AREA FREE AND CLEAR OF
COMBUSTIBLES.

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. Supply power to the kettle by placing the fused
disconnect switch to the "ON" position.

3. Unit has been thoroughly checked for gas leaks at
the factory however the installer should check all
connections using soap bubble or gas detector for
any leaks which may have resulted from shipping or
installation.

4. Turn on main gas supply to unit. Open the kettle's
shut-off valve (located at back of console).

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.

CLEANING

After installation the kettle must be thoroughly cleaned
and sanitized prior to cooking.

OPERATING INSTRUCTIONS

ITEM # DESCRIPTION FUNCTION

1. Tilt Wheel (tilting models only) Used for tilting the kettle.

2. Vacuum/Pressure Gauge Indicate steam pressure in PSI inside steam jacket as well as

vacuum in inches of mercury.

3. Pressure Relief Valve This valve is used to vent the kettle and in the unlikely event there is
an excess steam build-up in the jacket, this valve opens
automatically to relieve this pressure.

4. 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 tilted.

5. On-Off Switch/ Turns kettle ON/OFF and allows the operator to adjust the kettle

Solid State Temperature temperature in increments from 1 (Min.) to 10 (Max.).
Control

6. Heat Indicator Light (Green) When lit, indicates that the kettle's burner is on.
Cycles ON-OFF with burner.

7. Water Level Sight Glass Displays water level in steam jacket.

8. Ignition Failure Indicator Light Indicates failure of heating system to ignite.

(Amber)

9. Tangent Draw-Off Valve Used for draining product or wash water from kettle. It is supplied as
standard equipment on stationary kettles and is optional on tilting kettles

.

General Parts Drawing

2

3

1

7

4

5

6

8

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.

1. Before turning kettle on, read the Vacuum/Pressure

Gauge (2). The gauges needle should be in the
green zone. If the needle is in the "VENT AIR"
zone, refer to the Kettle Venting Instructions. Any
air that may be present will increase cooking times.
Once heated, the kettle's normal maximum
operating pressure is approximately 10-12 psi while
cooking a water base product.

2. Ensure that the electrical service to the kettle is

turned on at the fused disconnect switch.

Temperature Range Chart

3. Preheat the kettle by turning the

ON/OFF

Switch/Solid State Temperature Control

(5) to the
desired temperature setting (see above,
TEMPERATURE RANGE CHART). The Heat
Indicator Light (Green) (6) 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. These types of food should be placed in
the kettle before heating is begun.

4. Place food product into the kettle. The Heat
Indicator Light (Green) (6) will cycle on and off
indicating the burners are cycling on and off to
maintain the set temperature.

NOTE: Do not fill kettle above
recommended level marked on outside
of kettle.

NOTE: The Low Water Indicator Light (Red) (4) should not
be lit when kettle is in upright postion during kettle operation.
This light indicates that the burners have been automatically
shut off by the kettle's safety circuit. It is, however, normal for
the red light to come on when the kettle is in a tilted position.

5. When cooking is completed turn

ON/OFF

Switch/Solid State Temperature Control

(5) to the

"OFF' position.

NOTE: A five minute complete shut-of period is
required before relighting.

6. Pour the contents of the kettle into an appropriate
container by tilting the kettle forward. Care should
be taken to pour slowly enough to avoid splashing
off the product.

NOTE: As with cleaning food soil from any cookware, an
important part of kettle cleaning is to prevent food from
drying on. For this reason, cleaning should be completed
immediately after cooked foods are removed.

APPROXIMATE BOILING TIMES

The accompanying chart shows approximate times
required for electric kettles of various capacities to boil
water. The

ON/OFF Switch/Solid State Temperature

Control

(5) must be set at “10” (Max.) throughout the
heat-up period. Water will boil about 1/3 faster if the
kettle is filled only to the outer steam jacket’s welded
seam resulting in a kettle filled to 2/3 capacity.

Approximate Boiling Times

Kettle Capacity Minutes

25 gallon 37

Temperature Approximate

Control Product Temperature
Setting °F °C

MIN. 120 49

1. 130 54

2. 145 63

3. 160 71

4. 170 77

5. 185 85

6. 195 91

7. 210 99

8. 230 110

9. 245 118

MAX. 265 130

NOTE: Certain combinations of ingredients will

result in temperature variations

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

➩ Do not use detergents or

cleansers that are chloride
based or contain quaternary
salt.

➩ Do not use a metal bristle

brush or scraper.

➩ Steel wool should never be

used for cleaning the stainless
steel.

➩ Unit should never be cleaned

with a high pressure spray
hose.

➩

Do not leave water sitting in unit
when not in use.

CLEANING INSTRUCTIONS

CAUTION

SURFACES MAY

BE EXTREMELY HOT!

CLEANING INSTRUCTIONS

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

TTaannggeenntt DDrraaww--OOffff

VVaallvvee

, clean as follows:

a) Disassemble the draw-off valve first by turning

the valve knob counter-clockwise, then turning
the large hex nut counter-clockwise until the
valve stem is free of the valve body.

b) In a sink, wash and rinse the inside of the valve

body using a nylon brush.

c)

Use a nylon brush to clean tangent draw-off tube.

d) Rinse with fresh water.

e) Reassemble the draw-off valve by reversing the

procedure for disassembly. The valve's hex nut
should be hand tight only.

9. If the unit is equipped with a

BBuutttteerrffllyy VVaallvvee

, clean

as follows:

a) Place valve in open position.

b) Wash using a warm water and mild detergent

solution.

c) Remove food deposits using a nylon brush.

d) Rinse with fresh water.

e) Leave valve open when unit is not in use.

10 . Using mild soapy water and a damp sponge, wash

the exterior, rinse, and dry.

NOTES

➩ 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 the Nafem

Stainless Steel Equipment Care and Cleaning manual
(supplied with unit).

Chloride Cleaners

Wire Brush &

Steel Pads

High Pressure

Spray Hose

Stagnant

Water

STAINLESS STEEL EQUIPMENT CARE AND CLEANING

(Suppied courtesy of Nafem. For more information visit their web site at www.nafem.org)

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. Such metals are called “active”
because they actively corrode in a natural environment when their atoms
combine with oxygen to form rust.

Stainless steels are passive metals because they contain other metals, like
chromium, nickel and manganese that stabilize the atoms. 400 series
stainless steels are called ferritic, contain chromium, and are magnetic;
300 series stainless steels are called austenitic, contain chromium and
nickel; and 200 series stainless, also austenitic, contains manganese,
nitrogen and carbon. Austenitic types of stainless are not magnetic, and
generally provide greater resistance to corrosion than ferritic types.

With 12-30 percent chromium, an invisible passive film covers the steel’s
surface acting as a shield against corrosion. As long as the film is intact
and not broken or contaminated, the metal is passive and stain-less. If the
passive film of stainless steel has been broken, equipment starts to
corrode. At its end, it rusts.

Enemies of Stainless Steel

There are three basic things which can break down stainless steel’s
passivity layer and allow corrosion to occur.

1. Mechanical abrasion

2. Deposits and water

3. Chlorides

Mechanical abrasion means those things that will scratch a steel surface.
Steel pads, wire brushes and scrapers are prime examples.

Water comes out of the faucet in varying degrees of hardness. Depending
on what part of the country you live in, you may have hard or soft water.
Hard water may leave spots, and when heated leave deposits behind that
if left to sit, will break down the passive layer and rust stainless steel. Other
deposits from food preparation and service must be properly removed.

Chlorides are found nearly everywhere. They are in water, food and table
salt. One of the worst chloride perpetrators can come from household and
industrial cleaners.

So what does all this mean? Don’t Despair!

Here are a few steps that can help prevent stainless steel rust.

1.

Use the pr

oper tools.

When cleaning stainless steel products, use non-abrasive tools. Soft
cloths and plastic scouring pads will not harm steel’s passive layer.
Stainless steel pads also can be used but the scrubbing motion must
be in the direction of the manufacturers’ polishing marks.

2.

Clean with the polish lines.

Some stainless steel comes with visible polishing lines or “grain.”
When visible lines are present, always scrub in a motion parallel to the
lines. When the grain cannot be seen, play it safe and use a soft cloth
or plastic scouring pad.

3.

Use alkaline, alkaline chlorinated or non-chloride containing cleaners.

While many traditional cleaners are loaded with chlorides, the industry
is providing an ever-increasing choice of non-chloride cleaners. If you
are not sure of chloride content in the cleaner used, contact your cleaner
supplier. If your present cleaner contains chlorides, ask your supplier if
they have an alternative. Avoid cleaners containing quaternary salts; it
also can attack stainless steel and cause pitting and rusting.

4.

Treat your water

.

Though this is not always practical, softening hard water can do much
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.

5.

Keep your food equipment clean.

Use alkaline, alkaline chlorinated or non-chloride cleaners at
recommended strength. Clean frequently to avoid build-up of hard,
stubborn stains. If you boil water in stainless steel equipment,
remember the single most likely cause of damage is chlorides in the
water. Heating cleaners that contain chlorides have a similar effect.

6.

Rinse, rinse, rinse.

If chlorinated cleaners are used, rinse and wipe equipment and
supplies dry immediately. The sooner you wipe off standing water,
especially when it contains cleaning agents, the better. After wiping
equipment down, allow it to air dry; oxygen helps maintain the
stainless steel’s passivity film.

7.

Never use hydrochloric acid (muriatic acid) on stainless steel.

8.

Regularly restore/passivate stainless steel.

Recommended cleaners for specific situations

Job Cleaning Agent Comments

Routine cleaning Soap, ammonia, Apply with cloth or sponge

detergent, Medallion

Fingerprints & smears Arcal 20, Lac-O-Nu Provides barrier film

Ecoshine

Stubborn stains & Cameo, Talc, Zud, Rub in direction of polish lines
discoloration First Impression

Grease & fatty acids, Easy-off, De-Grease Excellent removal on all finishes
blood, burnt-on-foods It Oven Aid

Grease & oil Any good Apply with sponge or cloth

commercial detergent

Restoration/Passivation Benefit, Super Sheen

Review

1. Stainless steels rust when passivity (film-shield) breaks down as a
result of scrapes, scratches, deposits and chlorides.

2. Stainless steel rust starts with pits and cracks.

3. Use the proper tools. Do not use steel pads, wire brushes or scrapers

to clean stainless steel.

4. Use non-chlorinated cleaners at recommended concentrations. Use
only chloride- free cleaners.

5. Soften your water. Use filters and softeners whenever possible.

6. Wipe off cleaning agent(s) and standing water as soon as possible.

Prolonged contact causes eventual problems.

To learn more about chloride-stress corrosion and how to prevent it,
contact the equipment manufacturer or cleaning materials supplier.

Developed by Packer Engineering, Naperville, Ill., an independent testing
laboratory.

FAUCET ASSEMBLY

(optional)

ITEM PART DESCRIPTION QTY.
NO. NO.

1.

33//44"" SSPPOOUUTT

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

(DOUBLE PANTRY ONLY)

6. SE50021 COLD WATER STEM ASSEMBLY . . . . . . . .1

7. KE51401 SINGLE PANTRY BODY . . . . . . . . . . . . . . .1

(C/W ITEM NO. 6)

8. KE50335 ADAPTER WASHER . . . . . . . . . . . . . . . . . .1

(SINGLE PANTRY ONLY)

9. KE51403 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

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.

1

2

1

2

3

4

8

10

11

12

13

3

4

5

6

6

10

7

11

12

13

9

14

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

FOR 120V OPTION

7. KE53838-20 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE53838-27 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FOR 240V OPTION

7. KE53838-18 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE53838-21 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

* FOR TILTING MODELS SEE “GENERAL ASSEMBLY - TILTING MODELS”

COMPONENT MOUNTING PLATES

STATIONARY MODELS

TILTING MODELS

43 5 1110 12

10 13

2

5

9

1 7 8

1

8 7 4

3 5 10

2 6 9

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE54897-1 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

BURNER ASSEMBLY

711

8

10

2151617 3

1 4 5 6

1412

13

9

TANGENT DRAW-OFF VALVE

ITEM NO. PART NO. DESCRIPTION QTY.

1. - 7. KE50973 2” DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50972-B 3” DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1. FA95049 WING NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21050 ACCORN NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21501-1 ACCORN NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE52755 KNOB, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50018 KNOB, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. FI05180-1 HEX NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FI05180-2 HEX NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE52753 RETAINER, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50013 RETAINER, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE52752 PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50010 PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. FA05002-24 "O" RING, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA05002-38 "O" RING, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE50972-B VALVE BODY, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50973 VALVE BODY, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

5

4

3

2

1

7

GENERAL ASSEMBLY

- STATIONARY MODELS (pg. 1 of 2)

34

11

13

531

7 8 10

21

A

6

7 9

14 15 16

10 L1

VIEW "A"

COMPONENT MOUNTING BOX

WITH LID REMOVED

L3

25

27

26

28 29 28 30

4

19 20

VIEW "B"

MANIFOLD & BURNER

TUBE PIPING DETAIL

322 3

L2

22

1

17242325 18

L4

B

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE00099 ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

11.

PPRREESSSSUURREE GGAAUUGGEE

KE000714-4 FOR UNITS BUILT PRIOR TO FEBRUARY 2005 . . . . . . . . . . . . . . . . . . . . . . . . .1

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

LABELS

L1. KE90424 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L2. KE95555-5 OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L3. KE95552 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L4. KE95551 LABEL SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL ASSEMBLY

- STATIONARY MODELS (pg. 2 of 2)

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE00099 ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE51723-1 SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.

PPRREESSSSUURREE GGAAUUGGEE

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

GENERAL ASSEMBLY

- TILTING MODELS (pg. 1 of 3)

See Trunnion Assembly Page

62

3

2

VIEW "G"

MANIFOLD & BURNER TUBE PIPING DETAIL

55

56

57

8

5

60 L5

10

13

12 11 12 14

L2 L3

6

9

L4

7

L1

161

G

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

:

KE54618-1 PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54618-2 PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21. F105226-12 NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL ASSEMBLY

- TILTING MODELS (pg. 2 of 3)

KE517112 LH BEARING
KE51712 GREASE NIPPLE

KE51711 RH BEARING

Gear box same as
KGL-40 to 100-T

26

25

28

27

30

29

BB

23

24

CC

16 172221 18 19 20

15

3837 39 40 41 36 42 43 45 43 42

44

46 47 48 49 50

58

53

59

31

32

33

34

35

516052 53 54

22. FI00040 ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23. FA19177 HEX SOCKET SET SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24. FA20047 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25. KE50294-1 MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26. KE54456-1 MERCURY SWITCH BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27. KE50295-1 CLIP FOR MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28. FA11396 HEX HEAD BOLT (3/8-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29. FA31031 SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30. FA15018-7 SCREW 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31. KE52833 WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32. FA10772 SOCKET HEAD CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

33. FA20030 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

34. FA95007-4 RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35. FA95055-1 SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36. KE50315 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

37. KE51730 TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

38. FA31010 SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

39. FA20030 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

40. KE503752 TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

41. FA95005 TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

42. KE52193 THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

43. KE52191 ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

44. KE52192 THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

45. FA30088 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

46. FA95008 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

47. KE53469-2 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54308-4 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

48. FA10245 SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

49. FA20004 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

50. FA32005 TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

51. KE53390 GAS VALVE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

52. FA10367 BINDING HEAD SCREW (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

53. FA32006 TOOTH LOCKWASHER (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

54. FA20007 MACHINE SCREW NUT (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

55. KE55069-6 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

56. KE00515 THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

57. KE50556-1 LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

58. KE01928-1 COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .1

(see COMPONENT MOUNTING PLATES)

59. FA20006 MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

60. FA11145 SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

61. KE54833-2 SNAP-IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

62. KE54468 WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LABELS

L1. KE95555-5 OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L2. KE95552 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L3. KE95551 GAS KETTLE LABEL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L4. KE95040 DIRECTION OF TILT LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L5. KE90424 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL ASSEMBLY

- TILTING MODELS (pg. 3 of 3)

TRUNNION ASSEMBLY

ITEM PART DESCRIPTION QTY.
NO. NO.

1. KE00354 TRUNNION BEARING ASSEMBLY . . . . . .1

(INCLUDES PART # 3 & 6)

2. KE00351 TRUNNION BEARING ASSEMBLY . . . . . .1

(INCLUDES PART # 3 & 6)

3. 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 . . . . . . . . . . . . . . . . . . . .2

7. FA95027 MODIFIED BOLT, 5/16-18 X 1 1/2" . . . . .4/2

TANGENT DRAW-OFF VALVE

ITEM NO. PART NO. DESCRIPTION QTY.

Complete KE50972-B 2” DRAW-OFF ASSEMBLY (TD-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Valve KE50973 3” DRAW-OFF ASSEMBLY (TD-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE02044-2 2” DRAW-OFF ASSEMBLY (TD-2A with ACME THREAD) . . . . . . . . . . . . . . . . .1

KE02044-4 3” DRAW-OFF ASSEMBLY (TD-3A with ACME THREAD) . . . . . . . . . . . . . . . . .1

1. FA95049 WING NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21050 ACCORN NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21501-1 ACCORN NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE52755 KNOB, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50018 KNOB, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. FI05180-1 HEX NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FI05180-2 HEX NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE52753 RETAINER, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50013 RETAINER, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE52752 PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50010 PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. FA05002-24 "O" RING, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA05002-38 "O" RING, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

For tilting units
with covers

1

3

2

1

For tilting units
without covers

6

3

4

5

6

5

4

2

7

CONSOLE
CONTROLS

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

2

3

76

5 7

1

4 7

8

HINGE ASSEMBLY

1

5

32

1312

6

4

7

11

8

10

9

9

ITEM NO. PART NO. DESCRIPTION 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50597-5 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 KE50597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50121-1 Hinge Spring Heavy - for KE50597-1, KE50597-3, KE50597-4, KE50597-5, . .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, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

11. SK50418 Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. KE50151-2 Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MAINTENANCE

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.

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 check 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.

ITEM CHECK

HAND WHEEL

(tilting models only) Check hand wheel for tightness. If loose tighten allen screw.

LUBRICATION (tilting models only) Check that kettle tilts smoothly. Grease trunnion housings and

gear/worm assembly every three months as
recommended in LUBRICATION PROCEDURE.

GEAR/WORM Inspect for play. Tighten Allen screws if required.

PRESSURE GAUGE Check that the gauge does not have moisture on its inside face.

Replace if moisture is present.

Check that the gauge shows a vacuum (needle is well into the Green
zone) when cold and shows between 25-40 psi when unit is hot. If not
follow VACUUM LEAK TEST.

PRESSURE RELIEF VALVE Check pressure relief valve as described in PRESSURE RELIEF VALVE

TESTING PROCEDURE.

TEMPERATURE CHECK Following the CALIBRATING PROCEDURE, check the inner kettle

surface temperature with a digital surface thermometer and adjust if
required.

ON/OFF SWITCH/ Check for damage. Replace if necessary.

TEMPERATURE CONTROL

SPRING ASSIST COVER Check cover is tightly secured to handle and insure spring is holding

cover up - adjust if required. Refer to HINGE ADJUSTMENT
INSTRUCTIONS.

IMPORTANT!

ENSURE KETTLE IS AT ROOM TEMPERATURE AND

PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE

PRIOR TO REMOVING ANY FITTINGS.

SAFETY INSPECTION CHECKLIST

-

TILTING MODELS (pg. 1 of 2)

Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of
equipment. Inspections must include testing of the pressure relief valve and checks of the operating
system to insure that it has not been altered.

No safety features designed into the equipment should ever be tampered with.
Tampering with or bypassing controls is a very dangerous practice and unfortunately we have seen several
cases of this. Following is a short list of the most common and the most dangerous alterations performed
on kettles.

✘

Plug

✘

Tube
diameter
reduced

✘

Frozen,
stuck, or
plugged

✘

Plumbed to
drain or
water line

1

2

3

4

✔

Incorrect Installations

1

Safety valve has plug threaded into the
discharge opening preventing any steam from
escaping.

2

Safety valve’s tube diameter has been
reduced.

3

Safety valve is sticking, frozen shut or plugged.
To test, refer to PRESSURE RELIEF VALVE
PERIODIC TESTING PROCEDURE.

4

Safety valve is plumbed to a drain or water
line creating back pressure and reducing flow.

SAFETY VALVE

:

This illustrations show the correct configuration
of a factory installed Safety Valves.

Any modifications are unacceptable.

This illustrations show the correct configuration of a factory installed Safety Valves.

Any modifications are unacceptable.

SAFETY THERMOST

AT:

Incorrect
Installations

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.

Low W

ater Level Probe:

Probe bypassed by
running (A) an
additional wire

Probe properly
attached

260º - 270º
MAXIMUM
KETTLE
TEMPERATURE

265º

✔

If maximum temperature is not
in this range (on empty kettle),
refer to the CALIBRATING
PROCEDURE.

Operating
Thermostat:

✔

✘

Probe bypassed by
(B) grounding the
connecting wire

✘

(A)

(B)

SAFETY INSPECTION CHECKLIST

-

TILTING MODELS (pg. 2 of 2)

✔

Probe
fully
inserted
in tube

Wiring is properly

connected

123

✘

Probe

removed

partially

✘

Probe

removed

completely

✘

Thermostat

electrically

bypassed

LUBRICATION PROCEDURE

Lubricate the following parts every three months to
insure smooth operation and reduce wear.

TRUNNION
HOUSING,
WORM SCREW
AND TILT GEAR

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.

KETTLE
TRUNNIONS

On the left hand side of
the kettle there are two
grease nipples on the
top back portion of the
trunnion housing. On the
right hand side of the
kettle you must remove
the console cover to
access the grease
nipple.

HINGE ADJUSTMENT
INSTRUCTIONS

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

counter-clockwise 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.

3/8" Allen wrench

Adjusting

Screw

Worm
Screw and
Tilt
Gear

Cross

Bar

Trunnion Housing

Grease Nipple

CALIBRATING PROCEDURE

1. Insure the unit has a vacuum before you begin

calibrating procedures. If unit requires venting refer
to Kettle Venting Instructions.

2.

Set On-Off Switch/Temperature Control to "10" (Max.).

3. Allow the unit to cycle twice.

4. Check temperature of the inner kettle surface with

a digital surface thermometer.

5. Temperature should be between 260° F and 265° F.

6. Using a screw driver adjust temperature by turning

the potentiometer on the black box. Turn very little.
Turn clockwise to INCREASES and counter­clockwise to DECREASE temperature.

7. Allow the unit to cycle twice.

8. Check temperature of the inner kettle surface with

a digital surface thermometer.

9. Repeat steps 4. through 8. until unit is calibrated.

PRESSURE RELIEF VALVE
PERIODIC TESTING
PROCEDURE

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.

NOTE: The following instruction is intended for use by
qualified service personnel.

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.

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 (see
KETTLE JACKET CLEANOUT & PASSIVATION
PROCEDURES) and replace pressure relief valve.

See RESERVOIR FILL PROCEDURE for full instructions
on the correct method for refilling kettle jacket.

WARNING: Improper refilling of kettle jacket will result
in irreversible damage to unit.

NOTE: Rust inhibitor is purchased locally. Read
directions and do not exceed manufacturer's
recommendation (excessive rust inhibitor can also
cause solidification).

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.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

RESERVOIR FILL
PROCEDURES

The kettle's water level must be maintained at the
proper level. Under normal operating conditions, the
sealed water reservoir should never require the addition
of water.

If the red "low water" light comes on during use (while
the kettle is in an upright position), the water level has
reached a critically low level. The low water protection
control has automatically shut off the gas burner. The
following procedure must be completed before further
use:

NOTE: Have a qualified service technician repair the
leakage problem and add water to the unit. Ensure that
the red "low water" light is on when the kettle is upright.
On tilting kettles, it is normal for the red light to come on
when the kettle is in a tilted position.

DISTILLED WATER REQUIREMENTS

When red “Low
Kettle Water Light” comes
Capacity on, add distilled water

25 gallon Approximately 1 gal.

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.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

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.

3. Pull Pressure Relief Valve (A) open to insure vessel
is not pressurized.

4. Remove Pressure Relief Valve (A).

5. Replace Pressure Relief Valve (A) with Street

Elbow (B).

6. Add distilled 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.

Restore power to unit at the fused disconnect
switch.

9.

The kettle must now be vented. (Refer to the
KETTLE VENTING INSTRUCTIONS).

Sight
Glass

50

0

100

150

200

250

300

350

400

40

50

60

0

10

20

30

psi

kPa

V

E

N

T

A

I

R

Pressure Relief Valve/Gauge Assembly Drawing

C. Fill unit via Street Elbow

B.

Attach Street

Elbow

A.*

Remove

Pressure

Relief

Valve

*Important-

Pull ring on Pressure Relief Valve

prior to removal to insure vessel is not pressurized.

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.

DESCRIPTION - Molyfilm 315 inhibits corrosion in
stainless steel and copper. A pH buffer is present to
assist in maintaining the appropriate pH to assist in
corrosion inhibition.

DISPOSAL - Follow all Federal, State and local codes
when disposing of product.

SHELF LIFE - Molyfilm 315’s effectiveness will
diminish after three years.

REFILL QUANTITIES (ORDERING INFO: 1 Liter
Molyfilm 315 Rust Inhibitor - Part# KE600340-1)

IIMMPPOORRTTAANNTT

: To ensure satisfactory mixing follow the

MIXING / FILLING PROCEDURE described below.

Kettle Size Volume of Water Volume of Molyfilm 315

U.S. Gal. Liters oz. cc (ml.)

25 U.S. Gal. 4.4 16.6 6 176

MIXING / FILLING PROCEDURE

1. Refer to chart to determine the required volumes of

water and Molyfilm 315.

2. In a separate container mix 1/2 gallon of the required
volume of water with the total required volume of
Molyfilm 315.

3. Pour mixture into kettle.

4.

Pour the remaining required volume of water into kettle.

WARNING:

IMPROPER REFILLING OF KETTLE JACKET WILL

RESULT IN IRREVERSIBLE DAMAGE TO UNIT

.

DANGER:

MOLYFILM 315 IS CORROSIVE, AVOID

CONTACT WITH SKIN AND EYES.

DANGER:

AVOID INHALATION - VAPORS FROM

MOLYFILM 315 MAY BE HARMFUL OR FATAL.

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.

DANGER:

WORKING ON MACHINES WITH

POWER COULD RESULT IN SEVERE

ELECTRICAL SHOCK.

DANGER:

EXTREMELY HOT SURFACES.

WORK ONLY ON COLD

KETTLE.

Flushing Procedure

1. Ensure kettle is at room temperature and

pressure gauge showing zero or less
pressure.

2. Shut off and disconnect gas supply.

3.

Remove electrical plug from power source.

4. Remove bolts holding kettle to tabletop/floor.

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.

8. Remove sight glass.

9. Tilt kettle on its side (sight glass down) and allow to

drain. Flush out as much debris as possible with water.

10. Tilt kettle upright, apply a thread sealant (i.e. Teflon
tape) to the sight glass threads and replace.

11. Fill jacket via the street elbow with a mixture of water
and Molyfilm 315 (see REFILL QUANTITIES).

12. Remove street elbow.

13. Apply a thread sealant (i.e. Teflon tape) to the pressure

relief valve and replace.

14. Reconnect gas and electrical supplies.

15. Turn kettle on, vent and heat to high for 1/2 hour.

16. Cool and drain kettle as per above procedure.

Refilling Unit

1. Apply a thread sealant (i.e. Teflon tape) to the sight

glass threads and replace.

2. Fill kettle jacket with a mixture of water and Molyfilm
315 (see REFILL QUANTITIES charts).

3. Apply a thread sealant (i.e. Teflon tape) to the filler
plug threads and replace.

4. Turn kettle on and check for leaks at sight glass and
filler plug. See Vacuum Leak Test.

5. Vent kettle. See Kettle Venting Instructions for proper
procedure.

p

Sight

Glass

Remove
Pressure
Relief
Valve

Attach
Street
Elbow

Important-

Pull pressure relief valve

ring open to insure vessel

is not

Fill unit via Street Elbow

ressurized.

150

200

100

20

30

50

10

0

0

R

I

A

T

N

E

V

psi

250

300

40

50

350

60

400

kPa

KETTLE VENTING
INSTRUCTIONS

1. Turn kettle ON and set

Temperature Control to 10
(Max.), heat the empty kettle
until unit cycles 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.

NOTE: If unit cycles ON, stop
venting and wait for kettle to
cycle OFF before continuing.

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.

50

0

100

150

200

250

300

350

400

40

50

60

0

10

20

30

psi

kPa

V

E

N

T

A

I

R

50

0

100

150

200

250

300

350

400

40

50

60

0

10

20

30

psi

kPa

V

E

N

T

A

I

R

The following venting 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.

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.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.

VACUUM LEAK TEST
PROCEDURE

If the kettle will not hold vacuum, test for leaks at:

A. Water Level Probe.

B. Pressure Relief Valve.

C. Pressure Gauge.

LEAK TEST PROCEDURE:

1. Heat kettle until unit cycles off.

2. Shut off power to the kettle at the fused disconnect

switch.

3. Spread Bubble Type Leak Detector over suspected
areas and watch closely for bubbles.

4. Repair areas as required.

REPAIRING LEAKS IN STEAM
JACKETED KETTLE FITTINGS

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.

Pressure

Gauge

Pressure

Relief

Valve

Pressure
Gauge

Pressure
Relief Valve

Water Level
Probe

6

5

4

3

2

1

10

OFF

7

8

9

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 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. Turn off power and main gas supply, and replace all
covers. Attach GAS IDENTIFICATION STICKER to
nameplate.

11. Place gas conversion label next to rating label.

NOTE:

Place GAS IDENTIFICATION STICKER on

face of GAS COMBINATION VALVE.

Atmospheric Burner Gas Kettles

BTU's per Gas Water # of
Hour Type Column Orifices

KGT-6-T 34000 NAT 4.2 1

34000 LP 10 1

KGT-12-T 53000 NAT 4.2 1

53000 LP 10 1

KGL-25, KGL-25-T 90000 NAT 4.2 2

90000 LP 10 2

Conversion Parts Required

Part No. Description Quantity

KE95549 Conversion Label 1

SE50438 Field Conversion Kit, 6 gallon 1

SE50438-1 Field Conversion Kit, 12 gallon 1

FIELD CONVERSION
INSTRUCTIONS -

Natural Gas to Propane Gas

IDENTIFICATION

STICKER

COMBINATION

VALVE

T

H

IS

GAS

C

O

H

N

A

T

S

C

R

B

O

O

E

N

L

E

V

N

E

R

T

T

O

E

L

D

P

GAS

GASKET

PRESSURE

REGULATOR

UNIT

BURNER

ORIFICE

MAIN

ORIFICE

FITTING

MAIN

PIPE

NIPPLE

REGULATOR

TO MAIN GAS

SUPPLY

GAS
SHUT-OFF
VALVE

WIRING DIAGRAM

TABLE-TOP GAS KETTLE, 120-240 VOLTS KE90424-F

SEQUENCE OF OPERATIONS

1. To turn the unit on, turn the switch to the on

position.

■ Power is sent to primary side of the
120vac/16vac transformer.

■ Power is sent to the normally closed high limit.

■ From the high limit power is sent to the normally

open contacts of the 12VDC relay.

2. From the secondary of the transformer 16VAC is
sent to the controller.

■ Power is sent to the red LED (low water indicator
light) from terminal 4 of the controller.

■ If the water probe is grounded through water the
LED will go off.

■ If the water probe is not grounded the LED will
remain on and the unit will not heat.

■ If the resistance of the thermistor is higher than
the setting of the potentiometer( the unit is calling
for heat) then 16VDC is sent to the coil of the relay
and the green LED (heat indicator light)

■ The 12VDC relay will close until the unit reaches
temperature

3. With the contacts of the relay closed, power is sent
to the 24 VAC transformer.

■ The transformer sends 24 VAC to the ignition
module.

■ Ignition module sends 24 VAC to the Amber LED

■ The ignition module will send spark to the igniter

and 24 VAC to the gas valve.

■ With 24VAC to the gas valve the valve opens
and gas is sent to the burner.

■ Spark and gas together cause ignition.

■ When this happens and the module reads at

least 0.7 micro amps DC within 4 seconds, the
Amber light will go out and the 24 VAC will remain
on the gas valve.

■ The unit will heat causing the water to boil and
steam to be generated.

■ If the module does not see the 0.7 micro-amps in
4 seconds, the module will try again in 15 seconds.
It will try 3 times then lock out.

4. The kettle will heat (build pressure) until the
controller is satisfied by the thermistor at the
setting of the potentiometer.

■ The controller will then turn off the heat circuit
until the temperature of the kettle is below the
setting.

■ When the temperature drops below the setting
the controller will send 12 VDC to the relay and the
heat circuit will be energized again.

5. To turn the unit off, place the switch in the off
position.

■ Power will be removed from the controller and
the heat circuit will de-energize.

PROBLEM:
KGL-25
Kettle Won't
Heat

Replace

the on/off

switch (toggle

or rotary).

Replace the

transformer.

Yes

Yes

Is 16 VAC at the

secondary side of

the transformer?

No

Is there 115 VAC

to the primary of
the transformer?

No

Supply115

VAC to the

kettle.

Does red light

come on when unit

is first turned on?

Is 16 VAC

measured across

No

Pins 9 and 10 on

the controller?

Replace the

Replace the

high limit.

Replace the

transformer

No

relay.

ignition

Does red light go

Yes

off shortly after

unit is turned on?

potentiometer set

at 10, is 12 VDC at

Yes

the coil of the

Does the relay pull

No

Is there 115 VAC

to the primary of

No

transformer?

Is there 24 VAC to

No

Yes

With the

relay?

Yes

in?

Yes

the ignition

Yes

the ignition

Module?

Yes

Add water to

No

jacket of Kettle.

With a jumper

across pins 5 and

7 on the controller,

No

is there 12 VDC

across the coil of

the DC relay?

Does the

potentiomer have

a resistance of

50,000 ohms on

low and 0 ohms at

Does the probe

have a resistance

of 100,000 ohms +

10% at room

temperature?

Replace Probe

Yes

high?

Yes

No

removed and the

No

probe, is 12 VDC
measured across
the coil of the DC

No

Yes

Replace the

wire harness in

the trunion

No

With the jumper

probe wire

grounded at the

relay?

Yes

Add water

Replace the

potentiometer

Replace the

controller

No

Replace

the Ignition

module.

No

Is there 24 VAC to

the Gas valve for 4

Seconds?

Yes

Is there Gas to the

burner?

Yes

Is there Spark to

the ignitor for 4

seconds.

Yes

If there

is spark and gas to

the burner assmbly

there should be

flame. Check

alighnment.

No

Replace the

gas valve

PROBLEM:
KGL-25
Kettle Not
Hot Enough

Does the kettle

heat at all?

Yes

With kettle pot

empty and

temperature knob

set at 10, is the

temperature of the

surface of the pot

260 degrees?

No

Yes

See Problem:

kettle won't heat.

Unit is

operating

properly

Yes

Vent
the kettle per
instructions in

the manual.

When unit is cold

(room temp) is the

No

pressure gauge in

the green?

When the unit is

calling for heat

(the green light is

on), is there flame

at the burner?

Is the resistance of

the thermister

100,000 ohms

+10% at room

temperature?

No

Yes

Yes

Is there 24 VAC to

Is there 115 VAC

to the primary of

No

No

Replace the

igniton

transformer

No

the ignition

module?

Yes

the ignition

module?

Replace the

thermister.

No

Replace the

high limit

Replace

controller.

Yes

ohms at low and 0

Yes

Is the

potentiometer

resistance 50,000

ohms at high?

No

Replace the

potentiometer.

PROBLEM:
KGL-25
Kettle Gets
Too Hot

The

kettle is working

properly.

temperature set at

Yes

continue to call for

the kettle reaches
260-265 degrees?

With the kettle
empty and the

10, is the surface

temp 260-265

degrees?

No

Does the kettle

heat (green light

stays on) when

No

Is the resistance of

Yes

100,000 ohms +

;the thermister

10% at room
temperature?

Yes

No

Replace the

thermister.

Is there 115 vac to

Replace the

gas valve.

Replace the

Relay

No

No

the primary of the

ignition

transformer?

Yes

Is there DC

voltage to the coil

of the relay?

Yes

Replace the

controller

PROBLEM: Red Add Water LED Stays On

Add the proper

amount of distilled

water and rust

inhibitor.

Does Red LED stay on

after adding the proper

No

amount of distilled

water and rust inhibitor?

Is the resistance of

the potentiometer

50,000 ohms at

the low setting and

0 ohms at high?

Yes

Replace the

controller

No

Replace the

potentiometer

Clean or

replace water

probe.

Replace the

wire harness in

the trunion.

No

No

Yes

Is the red LED on

with probe

grounded?

Yes

Does the red LED

stay on with a

jumper between

pins 5 and 7 on

the controller?

Yes

Replace the

controller.