Vulcan-Hart K20Gl, k20GLT, K40GLT, K40GL, K80GLT User Manual

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SERVICE MANUAL

K Series Gas Kettles 2/3 Jacketed

Stationary and Tilting

K20GL ML-136090

K40GL ML-136091

K60GL ML-136092

K20GLT ML-136094

K40GLT ML-136095

K60GLT ML-136096

K40GL Shown

- NOTICE -

This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified.

This manual is not intended to be all encompassing. If you have not attended a Vulcan Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Vulcan Service Technician.

The reproduction, transfer, sale or other use of this Manual, without the express written consent of Vulcan, is prohibited.

This manual has been provided to you by ITW Food Equipment Group LLC ("ITW FEG") without charge and remains the property of ITW FEG, and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request for such return at any time in the future.

A product of Vulcan-Hart

3600 North Point Blvd Baltimore, MD 21222

 

F45461 Rev. A (0713)

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting

TABLE OF CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MODELS COVERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION, CLEANING AND MAINTAINENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

REMOVAL AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONTROL BOX COVER (TILTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CORNER & REAR PANELS (TILTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SIDE & REAR PANELS (STATIONARY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRICAL PANEL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CONTROL BOX (TILTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 KETTLE CONTROL AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PRESSURE SWITCH (1PAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPARK IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GEAR REDUCER - MANUAL TILTING MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ELECTRICAL PANEL COMPONENTS - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TILT SWITCH (2S) - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DOWN LIMIT SWITCH (3S) - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DC TILT MOTOR - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GEAR REDUCER - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE PROCEDURES AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TEMPERATURE CONTROLLER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 POTENTIOMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 THERMOCOUPLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FILLING THE RESERVOIR JACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

PARTIAL REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 COMPLETE DRAINING AND REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 BLOWER INLET PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 GAS VALVE/BLOWER INLET PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TO ADJUST: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPARK IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FLAME SENSE CURRENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 IGNITION CONTROL MODULE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TILT SWITCH (2S) ADJUSTMENT - MANUAL TILTING MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 KETTLE TILT ADJUSTMENT - MANUAL TILTING MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TILT SWITCH (2S) ADJUSTMENT - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DOWN LIMIT SWITCH (3S) ADJUSTMENT - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . 28 DC TILT MOTOR CONTROLLER TEST - POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 COMPONENT FUNCTION (STATIONARY & TILTING MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 COMPONENT FUNCTION (POWER TILTING OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 COMPONENT LOCATION (STATIONARY & TILTING MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SEQUENCE OF OPERATION (KETTLE CONTROL CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SEQUENCE OF OPERATION (POWER TILTING OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SCHEMATIC DIAGRAM (STATIONARY & TILTING MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SCHEMATIC DIAGRAM (POWER TILTING OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

F45461 Rev. A (0713)

 

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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 STATIONARY & TILTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

© VULCAN 2013

Page 3 of 44

 

F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL

GENERAL

INTRODUCTION

General

The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are of a model K40GLT floor model tilting kettle unless otherwise noted. All information and specifications contained in this manual are based on the latest product information available at the time of printing.

K Series - Tilting Kettles

The tilting kettles models are offered with a manual tilt mechanism as standard and are available with an optional power tilt to automatically lower and raise the kettle. Kettles with the power tilt option can still be operated manually using the crank handle as needed.

K Series - Floor Model Kettles

The 2/3 jacketed gas kettles are self contained. The lower two thirds of the kettle bowl is a double wall stainless steel construction that provides a reservoir for a solution of heat transfer fluid and distilled water for improved heating of the kettle contents. The kettles are used to prepare a variety of liquid or semi-liquid food products such as soups, stews and sauces.

MODELS COVERED

All K Series kettles are mounted to the floor using legs with flanged feet for anchoring.

Model

Type

Gallons

Quarts

K20GL

Stationary

20

80

K40GL

Stationary

40

160

 

 

 

 

K60GL

Stationary

60

240

 

 

 

 

K20GLT

Tilting

20

80

K40GLT

Tilting

40

160

 

 

 

 

K60GLT

Tilting

60

240

 

 

 

 

F45461 Rev. A (0713)

 

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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL

CONTROL PANEL

Dowfrost™ heat transfer fluid Part No. 558038 (5 gallon). Refer to FILLING THE RESERVOIR JACKET for volumes.

Fig. 1

TOOLS

Standard

Standard set of hand tools.

Pipe thread sealant (must be resistant to the action of propane gases).

VOM with an AC current tester (meter sensitivity should be at least 20,000 ohms per volt).

Temperature meter (thermocouple type) for checking kettle temperature.

Manometer capable of reading at least 16" W.C. of gas pressure.

Container that is capable of holding at least 8 gallons of drained reservoir jacket fluid.

Special

Torque wrench capable of tightening combustion chamber mountings nuts to 30 ft-lbs.

36mm socket to remove sight glass for jacket fluid draining.

Requires U-inclined (Grainger P/N 3T294) or digital (Grainger P/N 1XFW2) manometer for measuring gas pressures and blower air pressures.

Distilled water only for re-filling of the jacket (purchase locally). Refer to FILLING THE RESERVOIR JACKET for volumes.

SPECIFICATIONS

Electric

120VAC / 60HZ / 1 phase

5 amp rating.

Supplied with 6 foot power cord and 3-prong grounding plug (proper ground required).

NOTE: Machines with electronic ignition systems should be connected to a standard 120VAC electrical outlet rather than a ground fault circuit interrupter (GFCI) if possible. Machines connected to certain GFCI circuits may repeatedly nuisance trip the GFCI. If the machine must be connected to a GFCI, use Part No. 913053 (Pass and Seymour) approved by engineering for use with electronic ignition systems.

Gas Supply

NOTICE The gas supply pressure must not exceed 14” WC (½ PSI). Pressures higher than 14” WC will damage the equipment’s gas controls and is not covered under warranty. If the supply pressure exceeds 14” WC an additional supply line regulator rated for the supply line pressure (inches WC), nominal pressure (OUT), and gas flow for the kettle BTU rating must be installed.

Span gas technology enables "field adjustable manifold pressure" from natural to propane gas or propane to natural. All kettles shipped for natural gas at sea level atmospheric pressure. Requires a U- Inclined or digital manometer. See TOOLS.

Refer to F35461 Installation & Operation Manual for specific instructions on GAS CONNECTIONS and GAS AND ALTITUDE ADJUSTMENTS. A combustion anaylizer is required for gas type conversions and altitude adjustments as outlined in these procedures.

Page 5 of 44

 

F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL

GAS SUPPLY PRESSURES

GAS TYPE

Manifold (in W.C.)

NOMINAL (in W.C.)

MIN (in W.C.)

MAX (in W.C.)

Natural

Low Speed * - 0.27 to 0.30

7

5

14

High Speed - 1.91 to 1.98

 

 

 

 

Propane

Low Speed * - 0.27 to 0.30

11

11

13

High Speed - 1.91 to 1.98

 

 

 

 

 

 

 

 

 

* Low Speed – Blower operates at low speed during trial for ignition (approximately 7 seconds). Ignition is successful and burner lights. Blower switches to high speed for normal operation approximately 8 seconds later (total time delay of 15 sec. to high speed) and runs until set point temperature is satisfied. Cycle repeats upon call for heat.

Kettle Rating

All models listed on front cover have an input BTU rating of 100,000 BTU/HR.

OPERATION, CLEANING AND MAINTAINENCE

Refer to F35461 Installation & Operation Manual for specific instructions. The manual includes:

A page from the Stainless Steel Care and Cleaning Guide for proper care and cleaning of stainless steel.

Draw-Off Valve and Plug Valve dissassembly & cleaning instructions.

F45461 Rev. A (0713)

 

Page 6 of 44

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

CONTROL BOX COVER (TILTING)

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: Remove screws from cover where indicated.

NOTE: On kettles with manual tilt or power tilt option, the control box height is now taller (as shown) to acomodate additional tilt components. The cover is held in place using the same number of screws.

K20GLT Manual Tilt Shown

SIDE & REAR PANELS (STATIONARY)

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: Remove screws from panel where indicated.

K20GLT Manual Tilt Shown

CORNER & REAR PANELS (TILTING)

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: Remove screws from panel where indicated.

K20GL Shown

Page 7 of 44

 

F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

BOTTOM COVER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: Remove screws from cover where indicated.

Tilting models - tilt kettle to empty contents and gain access to bottom components.

Stationary models - use draw off valve to empty contents.

Raise the kettle for easier access to the bottom components as necessary. Support the kettle in some manner (2x4 blocks etc.) while work is being performed.

K20GLT Manual Tilt Shown

ELECTRICAL PANEL

COMPONENTS

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: Pictures show the electrical panel components for a tilting kettle (control box & kettle control area). On a stationary kettle, all the electrical

panel components are mounted in the kettle control area.

CONTROL BOX (TILTING)

1.Remove CONTROL BOX COVER (TILTING).

2.Disconnect lead wires from component being replaced.

3.Remove screws securing the component to panel.

4.Reverse procedure to install and check for proper operation.

NOTE: Ensure J1 jumper is installed on temperature controller.

Control Box - K Series Tilting Kettle

KETTLE CONTROL AREA

1.Remove CORNER PANEL (TILTING) or SIDE PANEL (STATIONARY).

2.Disconnect lead wires from component being replaced.

3.Remove fastener securing the component to panel.

A.If installing blower speed control, ensure switches SW1, SW2 & SW4 are properly set as shown in Blower Speed Control - Switch Settings picture in this procedure.

4.Reverse procedure to install and check for proper operation.

F45461 Rev. A (0713)

 

Page 8 of 44

 

Vulcan-Hart K20Gl, k20GLT, K40GLT, K40GL, K80GLT User Manual

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

Kettle Control Area - K Series Tilting Kettles

Blower Speed Control - Switch Settings

PRESSURE SWITCH (1PAS)

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

5.Remove air from reservoir jacket as outlined under VENTING procedure.

6.Check for proper operation.

NOTE: Pressure switch setting is fixed and should not be adjusted.

Fig. 9

GAS VALVE

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit.

All gas joints disturbed during

servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame.

1.Remove CORNER & REAR PANELS (TILTING) or SIDE & REAR PANELS (STATIONARY).

1.Open pressure relief valve until reservoir jacket is completely vented.

2.Remove CORNER PANEL (TILTING) or SIDE PANEL (STATIONARY).

3.Remove pressure switch from tubing.

4.Reverse procedure to install.

2.Remove electrical connector from gas valve.

3.Disconnect gas line from gas valve.

4.Remove gas valve from blower.

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F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

Fig. 10

5.Remove piping from gas valve inlet and install on replacement valve. Ensure the factory tags that are wired to the piping remain installed.

NOTE: Replacement gas valve contains valve plate, orifice and o-ring already assembled. The gas valve/ blower design allows natural and propane gas kettles to use the same orifice size. Labels for gas type are also included.

Clean pipe threads and apply thread sealant that is suitable for use with propane gas.

6.Reverse procedure to install.

7.Affix the appropriate gas label (natural or propane) on top of gas valve.

8.Perform GAS VALVE/BLOWER INLET PRESSURE CHECK.

BLOWER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1.Remove GAS VALVE from blower.

2.Remove BOTTOM COVER.

3.Separate burner manifold compression fitting on gas supply tube (feeding burner).

Fig. 11

4.Remove electrical connectors (2) from blower.

5.Remove blower from kettle at burner manifold.

Fig. 12

A.Remove blower from burner manifold (4 screws).

B.Remove swirl plate (3 screws) and blower plate (2 screws) from blower intake.

F45461 Rev. A (0713)

 

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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

Fig. 13

6.Reverse procedure to install replacement blower and check for proper operation.

NOTE: Install replacement blower gasket as necessary.

BURNER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit.

All gas joints disturbed during

servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame.

1.Remove BOTTOM COVER.

2.Remove clips securing insulation to bottom of kettle.

A.Gently remove insulation and save for reuse.

3.Disconnect spark ignitor lead wires at the ignition module.

4.Separate compression nuts on gas supply tube.

5.Loosen gas manifold mounting nuts and remove gas supply tube from the fittings.

Fig. 14

6.Remove combustion chamber cover from bottom of kettle.

Fig. 15

7.Note alignment of pipe elbow connected to burner. Remove elbow from burner.

8.Remove burner from combustion chamber cover.

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F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

Fig. 16

9.Reverse procedure to install replacement burner and check for proper operation.

Apply pipe thread sealant to burner threads that is suitable for use with propane gas.

NOTE: Torque mounting nuts for combustion chamber cover to 30 ft-lb.

Fig. 17

6.Ensure spark gap between ignitor electrode and ground rod is approximately 1/8". If necessary, adjust as outline under SPARK IGNITION TEST Step 8C.

7.Reverse procedure to install and check for proper operation.

 

SPARK IGNITOR

 

 

Disconnect the

 

 

electrical power to the machine and

 

 

follow lockout / tagout procedures.

 

1.

Remove CONTROL BOX COVER (TILTING) or

 

 

CORNER PANEL (STATIONARY).

 

2.

Disconnect spark ignitor lead wires at ignition

 

 

module.

 

3.

Remove BOTTOM COVER.

 

4.

Remove clips holding insulation against

 

 

combustion chamber cover.

 

5.

Remove spark ignitor from combustion chamber

Fig. 18

 

cover.

 

 

F45461 Rev. A (0713)

 

Page 12 of 44

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit.

All gas joints disturbed during

servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame.

1.Remove CONTROL BOX COVER (TILTING).

2.Disconnect lead wires for gas shut-off valve (1SOL) at terminal strip in control box.

3.Remove piping from inlet side of valve.

4.Remove threaded plug (NPT) from the ½” swivel fitting secured to end of pivot shaft.

GEAR REDUCER - MANUAL

TILTING MODELS

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Shut off the gas before servicing the unit.

All gas joints disturbed during

servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame.

1.Place kettle in the fully upright position and remove crank handle.

2.Support kettle from the bottom in some manner (2x4 etc). Raise it slightly to take the kettle arm weight off gear reducer.

3.Remove GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY.

4.Remove tilt switch (2S) from bracket leaving the lead wires connected.

5.Remove bolts securing gear reducer and control box to kettle frame.

K20GLT Manual Tilt Shown

5.Remove gas shut-off valve from control box.

6.Remove piping from outlet side of valve.

7.Reverse procedure to install replacement gas shut-off valve and check for proper operation.

Clean pipe threads and apply thread sealant that is suitable for use with propane gases.

Fig. 20

6.Pull gear reducer away from kettle by working it off the kettle arm until free. Note that the kettle arm is keyed.

NOTE: Control box can be moved as necessary for ease of gear reducer removal.

7.Remove reducer shaft extension from gear reducer shaft.

Page 13 of 44

 

F45461 Rev. A (0713)

 

K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS

2. Disconnect lead wires from component being replaced.

3. Remove screws securing the component to panel.

4. Reverse procedure to install and check for proper operation.

Fig. 21

8.Remove positive stop plate from gear reducer. Note that the positive stop shaft is keyed.

Fig. 22

9.Reverse procedure to install replacement gear reducer.

10.Perform KETTLE TILT ADJUSTMENT - MANUAL TILTING MODELS to check for proper operation.

Fig. 23

TILT SWITCH (2S) - POWER TILTING OPTION ONLY

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1.Place kettle in the fully upright position.

2.Remove CONTROL BOX COVER (TILTING).

3.Note lead wire locations and disconnect from tilt switch (2S).

4.Remove adjustment screws (2) securring switch bracket to mounting plate.

ELECTRICAL PANEL

COMPONENTS - POWER TILTING

OPTION ONLY

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

5.Remove mounting nuts and screws (2) securring tilt switch (2S) to bracket.

6.Reverse procedure to install tilt switch (2S).

7.Perform TILT SWITCH (2S) ADJUSTMENT - POWER TILTING OPTION ONLY.

1.Remove CONTROL BOX COVER (TILTING).

F45461 Rev. A (0713)

 

Page 14 of 44

 

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