Market Forge MT-60 Service Manual
OWNER’S MANUAL
MODULAR TILTING KETTLES
MODELS: □ MT-25
□ MT-40
□ MT-60
INSTALLATION, OPERATION, MAINTENANCE, SERVICE AND PARTS
Form Number: S-2110 Rev: C 06/12
PRINTED IN U.S.A. 35 Garvey Street • Everett • MA • 02149
Tel: (617) 387-47100 • Toll Free: (866) 698-3188 • Fax: (617) 387-4456 • Outside MA Fax: (800) 227-2659
E-Mail: custserv@mi.com • Website: w w w . m f i i . c o m
TABLE OF CONTENTS
INTRODUCTION
DESCRIPTION .......................................................................................................................................................1
25-, 40-, & 60-GALLON TILTING KETTLES ..........................................................................................................1
SERVICE ................................................................................................................................................................1
SERVICE CONNECTIONS ....................................................................................................................................2
OPERATION
OPERATING CONTROLS & INDICATORS ...........................................................................................................3
OPERATING PROCEDURE 25-, 40- & 60-GALLON KETTLES ............................................................................3
CLEANING PROCEDURE .....................................................................................................................................3
CLEANING 25-, 40- & 60-GALLON KETTLES.......................................................................................................3
OPERATING CONTROLS ......................................................................................................................................4
PAN SUPPORT MOUNTING TILTING KETTLES ..................................................................................................5
MAINTENANCE
GENERAL ..............................................................................................................................................................6
PREVENTIVE MAINTENANCE ..............................................................................................................................6
CLEANING .............................................................................................................................................................6
TILTING MECHANISM LUBRICATION ..................................................................................................................6
REPAIR & REPLACEMENT ...................................................................................................................................6
LID COUNTERBALANCE ADJUSTMENT .............................................................................................................6
CABINET EXTERIOR REMOVAL ..........................................................................................................................6
DRAW OFF VALVE REPAIR ..................................................................................................................................7
COMMON LEAK REPAIRS ....................................................................................................................................7
VALVE SEAT LAPPING ..........................................................................................................................................7
TILTING MECHANISM REPAIR .............................................................................................................................7
SAGINAW SCREW ASSEMBLY REMOVAL ..........................................................................................................7
GENERAL INSPECTION & CLEANING .................................................................................................................7
BALL NUT DISASSEMBLY ....................................................................................................................................7
BALL NUT INSPECTION........................................................................................................................................8
BALL NUT REASSEMBLY & BEARING REPLACEMENT .....................................................................................9
CRANK SLEEVE REPLACEMENT ........................................................................................................................9
BRAKE MECHANISM DISASSEMBLY & REPAIR .................................................................................................9
ILLUSTRATED PARTS
GENERAL .............................................................................................................................................................10
ORDERING INFORMATION .................................................................................................................................10
FIG 4 25- & 40-GALLON TILTING KETTLES ........................................................................................................11
FIG 5 TILTING MECHANISM FOR 25- & 40-GALLON KETTLES ........................................................................12
FIG 6 60-GALLON TILTING KETTLES .................................................................................................................13
FIG 7 TILTING MECHANISM FOR 60-GALLON KETTLES ..................................................................................14
FIG 8
HINGE & LID ASSEMBLY ..........................................................................................................................15
FIG
9 STEAM SUPPLY VALVE ............................................................................................................................16
FIG 10 SWING DRAIN ..........................................................................................................................................16
FIG 1
1 DRAW OFF VALVE ....................................................................................................................................17
FIG 12 STEAM TRAP ............................................................................................................................................17
FIG 13
FIG 14
FIG 15 CABINET BASE (NEWER VERSION) ......................................................................................................20
FIG 16 24” CABINET (OLDER VERSION) ............................................................................................................21
FIG 17 36” CABINET (OLDER VERSION) ............................................................................................................22
FIG 18 48” CABINET (OLDER VERSION) ............................................................................................................23
FIG 1
FAUCET & SPOUT ASSEMBLY, 25-, 40- & 60-GALLON KETTLES (NEWER VERSION) .......................18
FAUCET & SPOUT ASSEMBLY, 25-, 40- & 60-GALLON KETTLES (OLDER VERSION) ........................19
9 ACCESSORIES FOR STEAM JACKETED KETTLES ..............................................................................24
INTRODUCTION
This service and parts manual contains general information, operation, and maintenance information
for Market Forge modular kettles. A parts list is included in which each replaceable part is identied and
shown in an accompanying drawing. Accessories for use with the kettles are also described.
DESCRIPTION
Market Forge tilting steam jacketed kettles of three
capacities, each mounted in a modular stainless
steel cabinet.
Double wall construction around the lower half of the
kettle forms a surrounding chamber into which steam
is introduced as a source of heat for cooking.
Steam input plumbing is equipped with a manual control valve. Condensate is removed through a steam
trap connecting with the kettle drain plumbing assembly. A swivel spout, hot-cold combination faucet
provides a source of water for addition to the kettle
for cooking and cleaning.
An optional 12” spacer unit with faucet and sink may
be used instead of the standard built-in faucet.
25-, 40-, & 60-Gallon Tilting Kettles
Large capacity kettles are tted with heavy duty tilting mechanisms operated by removable hand crank.
Each model is equipped with a pan support which
maintains continuous alignment of serving pans under the pouring spout at all levels of kettle elevation.
SERVICE
Modular kettles are exceptionally reliable and durable
cooking equipment requiring a minimum of service
other than routine cleaning and preventive methods
explained in the maintenance section. Should repairs
be required, a network of authorized service agencies is available to assist with prompt service.
A current Directory of Authorized Service Agencies
may be obtained by contacting:
Customer Service Department, Market Forge
35 Garvey Street, Everett, Massachusetts 0214
Telephone: (617) 387-41 00, (866) 698-3188
custserv@mi.com, www.mi.com
The model and serial numbers must be referenced
when corresponding with Market Forge.
The data plate containing model and serial numbers
pertaining to the equipment is located inside the cabinet door on the right vertical frame member.
9
Counterbalanced hinged lids cover the kettles in the
lowered position. All are plumbed for direct connection to a remote steam source. An optional cold water
circuit to the steam jacket is available for use with all
models for quick cooling of foods after cooking.
Applicable model designation include:
MT-25 A 25-gallon (94 liter) capacity tilting
kettle mounted in a 36” (914mm) wide
cabinet base.
MT-40 A 40-gallon (152 liter) capacity tilting
kettle mounted in a 36” (914mm) wide
cabinet base.
MT-60 A 60-gallon (228 liter) capacity tilting
kettle mounted in a 48” (1219mm) wide
cabinet base.
1
INTRODUCTION
SERVICE CONNECTIONS
Direct Connected
S Steam Supply - 3/4” (19mm) NPT, 15 P.
S.I (1.0 kg/cm2) minimum; 30 P.S.I (2.1
kg/cm2) maximum.
HW Hot Water - 3/8” (10mm) OD tubing to
hot water for kettle ll faucet.
CW Cold Water - 3/8” (10mm) OD tubing to
cold water for kettle ll faucet.
D Drain - Pipe full 2”
oor drain. Do not make solid connection to drain.
MT-25
MT-40
CR* Condensate Return - 1/2”
connection for condensate return from
kettle when specied.
EC* Electrical Controls - 115 volts AC, 60 Hz,
40 watts, 1/2” (13mm) conduit connection or equivalent. Use wire suitable for
at least
with power lift.
* Optional
90OC. Draws less than 1 Amp
NPT (51mm) to ush
I.P.S. (13mm)
NOTES:
Pressure-reducing valve is required if incoming pressure exceeds 30 PSI (2.1 kg/cm
Recess area for kettle draw-off (dotted line) must be
kept free of all piping and connections.
PVC and CPVC pipe are not acceptable materials for
drains.
2
).
MT-60
Separate height for 25-, 40-, and 60-gallon kettles.
2
OPERATION
OPERATING CONTROLS & INDICATORS
All of the controls required to operate the kettles are
listed in table on page 4, together with an explanation
of location and a short functional description.
OPERATING PROCEDURE 25- 40- & 60-GALLON
KETTLES
All kettles must be supplied with steam from a generator which is remotely located. Consult steam generator information or instruction plate and complete
all start-up instructions. Proceed with kettle operating
procedure as follows:
Check pressure gauge of steam supply source to
1.
insure steam input is at 15 PSI (1.0 kg/cm2). For
direct connected steam, turn on external steam
supply valve.
Check that Draw-Off Valve is tightly closed.
2.
Lift kettle lid and place either a Solid or Perforated
3.
Drain Disc over the drain inside kettle. Use solid
disc to retain liquids; perforated to strain liquids
from food.
Load kettle with foods to be cooked.
4.
Add water for cooking by swinging spout over
5.
kettle and using Combination Faucet.
Turn Steam Control Valve to full counter-clock-
6.
wise position to heat kettle content to an initial
rapid boil.
Adjust subsequent cooking temperature by turn-
7.
ing Steam Control Valve. Turn clockwise to reduce heat and counter-clockwise to increase.
Close Steam Control Valve (full clockwise posi-
8.
tion) when cooking is complete.
CAUTION: FOOD MUST EIThER BE RE-
MOVED FROM ThE KETTLE IMMEDIATELy
OR COOLED By A KETTLE jACKET COOLING
SySTEM TO PREVENT OVER COOKING.
3427) can be used to support pan during lling.
12.
Remove food from tilting kettles. With Pan Support mounted (see section pan support mounting
tilting kettles, on page 5), food pan in support, and
Crank installed in front of cabinet, turn crank clockwise to elevate kettle for pouring. (Tilting mecha-
nism is innitely adjustable and non-coasting in
kettle elevation and lowering). Liquid foods may
also be removed by use of the Draw-Off Valve as
explained in step 11 for stationary kettles.
13.
Complete cleaning procedures (See section be-
low, cleaning 25-, 40- & 60-gallon kettles).
CLEANING PROCEDURE
As with cleaning food soil from any cookware, an important part of kettle cleaning is to prevent foods from
drying on. For this reason cleaning should be completed immediately after cooked foods are removed.
If time can not be allotted for immediate complete
cleaning the kettle should be soaked by lling it with
warm detergent water solution.
2.4.2 CLEANING
Wash the kettle with a long handled nylon bristle
1.
kettle brush (Part No. 10-5308).
Empty wash water by opening Draw-Off Valve
2.
over Swing Drain.
Remove Drain Disc (solid or perforated) from in-
3.
side kettle and clean.
Rinse kettle by ushing with hot water from the
4.
Swivel Spout.
Loosen hex nut on Draw-Off Valve and carefully
5.
remove all parts. Clean and reassemble. (See g-
ure 11, on page 17).
Rotate Swing Drain to left and push up off drain
6.
assembly. Clean drain and screen. Reassemble
on kettle.
25-, 40- & 60-GALLON KETTLES
For Chill Kettles use an external water source
9.
to ood kettle interior with cold water until all hot
cooking water ow over kettle rim into sink.
For kettles equipped with optional cold water
10.
source water jacket cooling system open the
Jacket Cold Water Valve (full counter-clockwise
position) and leave open until food temperature is
sufciently lowered.
Remove food from stationary kettles. For liquids
11.
rotate the Swing Drain to the side and ll food
containers from the Draw-Off Valve. For solids
which will not pass through the valve, use a ladle.
An optional stationary pan holder (Part No. 90-
3
OPERATION
OPERATING CONTROLS
NAME LOCATION FUNCTION
Kettle Handle Kettle Rim Grasped to tilt kettle for pouring.
Steam Control Valve Top, Left Side Controls steam ow to kettle jacket.
Combination Faucet Top, Right Side Controls hot and cold water to swivel spout.
Swivel Spout Top, Beside Kettle Direct water into kettle. Turns away for kettle
tilting.
Sink with Splash Shield Top, Front Accepts kettle drainage. Shield forward pro-
tects operator from splashing, reverses for
storage.
Lid Handle On Lid Grasped to open and close kettle lid.
Perforated Drain Disc Inside Kettle on Drain Covers drain to strain liquids when draw-off
is open.
Solid Drain Disc (Optional) Inside Kettle on Drain Covers drain to block it off.
Crank (Tilting Kettles) Front, Right Side Raises and lowers tilting kettles for pouring.
Stow on back of cabinet door when not in
use.
Steam Control Valve Top, Right Side Controls steam ow to kettle jacket.
Draw-Off Valve Inside Cabinet, Left Controls drainage of kettle.
Swing Drain with Strainer Inside Cabinet, Left Accepts drainage from draw-off valve.
Swings to side to allow serving containers to
be placed under draw-off valve.
Combination Faucet with Swivel
Spout
Cold Water Valve (Chill Kettles
and Others with Optional Jacket
Cooling Systems)
Basin Waste Drain (Chill Kettles
Only)
Pan Support (Tilting Kettles Only) Front, Top Holds serving pan in alignment with kettles
Top, Right Side Control hot and cold water to kettle interior.
Turns away for kettle tilting and access.
Right, Front Controls ow of water to steam jacket for
rapid cooling after cooking.
Left, Top Accepts kettle overow in chill kettle sink.
for pouring (see section pan support mount-
ing tilting kettles, on page 5)
4
OPERATION
PAN SUPPORT MOUNTING TILTING KETTLES
For convenience during cooking, the pan support
need not be installed until needed for removing food
from the kettles. To Insure correct operation and to
prevent spills the support must be securely installed
as shown in Figure 1 below and as explained below:
Hold the pan support in front of the upright as
1.
shown at A.
Place the stud of the left-hand support upright
2.
into the hole in the left side of the pan support.
Then push the right side of the support in until it
engages the spring loaded pin of the right-hand
support upright, shown at B.
Rotate the pan support upward (C) and engage
3.
the slotted ends of the support links in the studs
at the base of each support upright as in D.
The removal procedure is the reverse of installation with the exception that in step 2 support upright
springs must be pushed out to release the support
from studs.
Figure 1 Mounting Pan Support
5
MAINTENANCE
WARNING:
DO NOT hOSE DOWN UNIT AS IT
CONTAINS ELECTRICAL COMPONENTS.
GENERAL
This section contains both preventive and corrective
maintenance information. Preventive maintenance
may be performed by maintenance personnel at the
establishment in which the kettle is installed.
It is recommended that user personnel never attempt
to make repairs or replacements to the equipment
without the assistance of authorized service. Assistance in service methods or, a current Directory of
Authorized Service Agencies may be obtained from
Market Forge. (See service section on page 1).
PREVENTIVE MAINTENANCE
The most important preventive maintenance operation on the steam jacketed kettle is the cleaning procedure after each use described on page 3. Additional preventive maintenance operations are presented
in this section.
CLEANING
A policy should be faithfully observed of completing,
by the end of each day’s operation, all kettle cleaning
procedures explained in cleaning procedure section
on page 3.
tle itself or the steam supply which heats the kettle.
While mechanical problems are obvious faults of the
kettle, any deciencies in volume and pressure of
steam should be traced to the steam generator and
the cause determined.
Steam input requirements are listed in Appendix A,
Modular Kettle Steam Requirements. Additional information may be found in separate service publications
for steam generators.
LID COUNTERBALANCE ADjUSTMENT
The kettle lid is equipped with a torsion spring counterbalance device to assist in lid lifting and to prevent
slamming. The device is shown assembled in the
Figure 2 below and exploded in Figure 8, on page 15.
If lid slams closed when handle is released, spring
tension should be increased. If lid lifts up or refuses
to remain down on kettle, tension should be reduced.
To adjust spring tension proceed as follows:
Loosen 1/4” jam nut.
1.
Adjust spring tension by turning 1/4” hex head
2.
cap screw. Tighten to increase tension; loosen to
reduce tension.
Operate lid several times, repeating, step 2 until
3.
desired operation is obtained.
Hold hex head screw rmly in position and tighten
4.
jam nut to lock adjustment.
In addition, cabinet doors, top, xtures, kettle lid, etc.,
should be washed and rinsed to remove all food spills.
For Chill Kettles, extra care must be given to cleaning
the sink surrounding the kettle. Pan support should
be removed as described in pan support mounting
tilting kettles on page 5.
TILTING MEChANISM LUBRICATION
Lubrication of the tilting mechanism of 25-, 40- and
60-gallon tilting kettles is the only required preventive
maintenance other than daily cleaning. Inspect the
screw of the tilting mechanism annually for adequate
lubrication.
Should screw appear “dry” apply a good grade of
ball bearing grease directly on the threads so that
the threads appear to be barely damp. If mechanism
fails to run smoothly (see tilting mechanism repair on
page 7).
REPAIR & REPLACEMENT
In the event that the kettle fails to operate correctly,
the difculty should rst be isolated to either the ket-
Figure 2 Lid Counterbalance Adjustment
CABINET ExTERIOR REMOVAL
Side and rear panels of all cabinets in which kettles
are mounted are easily removed without the use of
tools. Each panel is grasped at the bottom edge and
pulled out sharply to release it from the panel mounting brackets Shown in Figure 8, on page 15.
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