Cleveland KGL-40 Installation, Operation, Maintenance And Parts Manual

Gas floor kettles

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Operator's manual (58 pages)

Specifications (2 pages)

Operator's manual (42 pages)

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Gas Floor Model Kettles

Installation, Operation, Maintenance, Parts & Service

This manual is updated as new information and models are released. Visit our website for the latest manual.

MODELS:

KGL-40, KGL-60, KGL-80, KGL-100

KGL-40-T, KGL-60-T, KGL-80-T

KGL-40-SH, KGL-60-SH,

KGL-40-TSH

KGL-40-T

Read the manual thoroughly.

Improper installation, operation or

maintenance can cause property

damage, injury or death.

Statement of Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Trouble Shooting & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Part # - KE004002-2 B August 2019

For your future reference.

Model # ______________________________________

Serial # ___________ ____________________________

Model # &

Serial #.

KGL-40SH

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Summary of Contents for Cleveland KGL-40

Page 1: Table Of Contents
Installation, Operation, Maintenance, Parts & Service This manual is updated as new information and models are released. Visit our website for the latest manual. MODELS: For your future reference. KGL-40, KGL-60, KGL-80, KGL-100 KGL-40-T, KGL-60-T, KGL-80-T Model # ______________________________________ KGL-40-SH, KGL-60-SH,...
Page 2: Statement Of Responsibilities
Cleveland Range, LLC s’est efforcé à Cleveland Range, LLC se ha esforzado en unintentional errors and omissions. fournir des renseignements précis dans ce suministrar información precisa en este The information in this document may...
Page 3: For Your Safety
FOR YOUR SAFETY / POUR VOTRE SÉCURITÉ / PARA SU SEGURIDAD FOR YOUR SAFETY POUR VOTRE SÉCURITÉ PARA SU SEGURIDAD Do not store or use Ne pas entreposer ou No guarde ni use gasolina gasoline or any other utiliser d'essence ou o cualesquiera otros flammable liquids and d'autres liquides ou...
Page 4 WARNING / AVERTISSEMENT / ADVERTENCIA Improper installation, operation, adjustment, alteration, Heavy / Lourd / Pesado service or maintenance can cause property damage, Team or mechanical lift. / Équipe ou remontée injury or death. Read the installation and operating mécanique. / Equipo o elevador mecánico. instructions thoroughly before installing, operating or servicing this equipment.
Page 5: Installation
4. Fill out all carrier claims forms and have the examining APPROXIMATE WEIGHTS shown on the rating label which is adhered to the unit. carrier sign and date each form. Unit with KGL-40-T 520 lbs. 555 lbs. RIGHT LEFT REAR...
Page 6 rear or bottom of the console, and fasten to the terminal ENSURE THE GAS SUPPLY MATCHES THE KETTLE'S block. Be sure to connect the ground wire to the separate REQUIREMENTS AS STATED ON THE RATING PLATE. ground terminal connector (ground lug). NOTE: Units are tested on a in-house ground fault system.
Page 7: Operating Instructions
WARNING OPERATING INSTRUCTIONS If for any reason this unit is not functioning correctly DO NOT OPERATE. Contact your authorized service agent. OPERATING THE KETTLE Perform daily startup inspection. Temperature Approximate Control Product Temperature Setting ° F ° C OPERATING CONTROLS AND INDICATORS NOTE: Certain combinations of ingredients will result in temperature variations...
Page 8: Cleaning Instructions
CLEANING INSTRUCTIONS CLEANING INSTRUCTIONS Turn unit off. Remove drain screen (if applicable). Thoroughly wash and rinse the screen either in a sink or a dishwasher. Prepare a warm water and mild detergent solution in the unit. CARE AND CLEANING Remove food soil using a nylon brush. Cooking equipment must be cleaned Loosen food which is stuck by allowing it to soak at a low temperature setting.
Page 9: Preventative Maintenance
PREVENTATIVE MAINTENANCE FOR MAINTENANCE AND REPAIRS CONTACT YOUR AUTHORIZED MANITOWOC SERVICE AGENCY AND HAVE A QUALIFIED SERVICE TECHNICIAN MAINTAIN YOUR EQUIPMENT. WARNING: If for any reason this unit is not functioning correctly DO NOT OPERATE. Contact your authorized service agent. DAILY PRE-STARTUP INSPECTION...
Page 10: Trouble Shooting & Maintenance
TROUBLESHOOTING AND MAINTENANCE PROCEDURES The following trouble shooting guide and maintenance procedures are meant to be used by Qualified Service Technician ANY REPAIRS TO THE PRESSURE VESSEL MUST BE DONE BY A CERTIFIED PRESSURE VESSEL REPAIR SHOP AND ALL REPAIR METHODS AND MATERIALS MUST BE APPROVED BY THE MANUFACTURER.
Page 11 TROUBLESHOOTING GUIDES (Legend) 1. Green Light 2. Red Light 3. ON/OFF Switch KE95555-10A 6. Pressure Gauge 4. Potentiometer 5. Kettle Jacket Water Sight Glass 16. High Limit Tube 9. Water Level Probe 10.Thermistor 11. Ignitor 7. Gas Valve 8. Blower (showing hose for pressure tap) 1.
Page 12 TROUBLESHOOTING GUIDES (continued) PROBLEM: Problem: Does red light (2) Add water Does red light (2) Kettle Won't Kettle come on when unit go off shortly after to jacket of is first turned on? unit is turned on? Kettle. Heat won’t heat. With the Replace Is 16 VAC...
Page 13 TROUBLESHOOTING GUIDES (continued) PROBLEM: Problem: With kettle pot See Problem: empty and Does the kettle Kettle Not Kettle won't temperature knob Unit is Kettle not heat at all? heat. set at 10, is the operating Hot Enough hot enough. temperature of the properly surface of the pot 260 degrees?
Page 14 TROUBLESHOOTING GUIDES (continued) PROBLEM: Problem: Kettle With the kettle Kettle gets empty and the Gets Too temperature set at too hot. kettle is working 10, is the surface properly. temp 260-265 degrees? Does the kettle Is the resistance of continue to call for the thermister (10).
Page 15 KETTLE SAFETY INSPECTION AND TESTING SAFETY VALVE LOW WATER INSTALLATION: LEVEL PROBE: Probe properly The above illustrations show attached the three variations of factory installed Safety Valves. Modifications are unacceptable. SAFETY THERMOSTAT: Correct Probe Installation fully inserted in tube Probe bypassed by Probe bypassed by running (A) an (B) grounding the...
Page 16 CALIBRATING PROCEDURE FREE AIR CALCULATION Insert drager pump tube 4" down the center Solid State Temperature Adjustment of the flue and take one sample each of Control Box ______________ ______________ Carbon Dioxide (CO2) and Carbon % CO % CO2 (PPM) Monoxide (CO) and record results.
Page 17 KETTLE VENTING INSTRUCTIONS RESERVOIR FILL PROCEDURES WARNING: Improper refilling of kettle jacket will result in irreversible damage to unit. Pressure Relief Valve 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"...
Page 18 KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES The following procedure should be preformed at least once every three years to prevent possible corrosion and ensure the optimum life of the kettle. DANGER: Rust inhibitor can be dangerous. RUST INHIBITOR Read label and follow safety instructions.
Page 19 Gas Orifice Spring Plug Console Cover BTU's per Water # of Kettles Hour Type Column Orifices KGL-40, KGL-40-T, 140000 Natural Gas KGL-60 to 100, 140000 Propane KGL-60-T to 80-T, KGL-40-TSH, 190000 Natural Gas KGL-40-F to 60-F, 190000 Propane KGL-40-SH to 60-SH,...
Page 20 WIRING DIAGRAM - 110-120V, 60 HZ. Consult factory for alternate voltages. For Australian wiring diagram see separate addendum.
Page 21: Service Parts
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 factory-supplied replacement parts should be used.
Page 22 HINGE ASSEMBLY ITEM PART # DESCRIPTION QTY QTY QTY QTY KE00597-6 KE00597-4 KE00597-2 KE00597-1 HINGE BASE; CHS KE50822 KE51217 HINGE CYLINDER HINGE SPRING; HEAVY (0.187DIA/12 COILS) KE50121-1 HINGE SPRING; LIGHT (0.162DIA/16 COILS) KE50121-2 KE50823-1 HINGE PIN; LIGHT SPRING HINGE PIN MODIFD; HEAVY SPRING KE50823-2 HINGE BEARING;...
Page 23 Page 1 of 2 FAUCETS 3/8” COPPER TUBE 1/2” Common Parts ITEM # PART # DESCRIPTION QTY. SPK ____ SINGLE PANTRY FAUCET KIT, (includes items 1-10) see page 2 for ordering information DPK ____ DOUBLE PANTRY FAUCET, (includes items 1-8 & 11) see page 2 for ordering information KE50825- ___ SPOUT, see page 2 for ordering information ____________...
Page 24 Page 2 of 2 FAUCETS Models FAUCET BRACKET SPOUT KDT12/20 ON SD TABLE SPK1 KE50825-1 DPK1 KDL60/80/100T SPK2 KE54159 KE50825-2 KEL40/60/80/100T DPK2 KE02071-1 (CP) KET20 KGT,MKET, KDP60-100/T KDL25/40T SPK3 KE54159 KE50825-3 KEL25T,KDP25/40T DPK3 KDM60/T SPK-KDM60 KE50825-2 DPK-KDM60 KDM25/40/T SPK6 KE50825-6 DPK6 KDL40/60/80TSH SPK7...
Page 25 CONSOLE CONTROLS 1 0 2 0 ITEM NO. PART NO. DESCRIPTION QTY. KE50569-1 KNOB, POTENTIOMETER ......... .1 KE51005 RUBBER BOOT .
Page 26 PRESSURE RELIEF ASSEMBLY ITEM NO. PART NO. DESCRIPTION QTY. PRESSURE RELIEF VALVE ASSEMBLIES KE01450 FOR ASME KETTLES (INCLUDES #2-6) KE01450-1 FOR CE KETTLES (INCLUDES #2-6) FI05049 MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE KE600812-1 STREET ELBOW, 90°, 1/2", BRASS KE600814-1 TEE, 1/2"...
Page 27 GAS CONTROL ASSEMBLY Stationary Models 23 24 40 41 Tilting Models (for units built prior to March 2005)
Page 28 GAS CONTROL ASSEMBLY ITEM ON. PART NO. DESCRIPTION QTY. KE53441 BLOWER, 115V, 60 HZ ..............1 KE53441-1 BLOWER, 220V, 50 HZ .
Page 29 GAS CONTROL ASSEMBLY Tilting Models FI00040-1 ELBOW, 1/2" ..............1 NIPPLE, 1/2"...
Page 30 ELECTRICAL COMPONENT BOX - 115 VOLT UNITS Q T Y . IT E M P A R T # D E S C R IP T IO N C O M P O N E N T B O X W E L D M E N T ; K G L/-T K E 003654 IG N IT IO N C O N T R O L ;...
Page 31 GEARBOX ASSEMBLY 26 27 28 16 19 20...
Page 32 GEARBOX ASSEMBLY ITEM NO. PART NO. DESCRIPTION QTY. KE54644 TILT SHAFT, MANUAL TILT ........1 KE52836-2 TILT SHAFT, POWER TILT .
Page 33 PRIOR TO NOVEMBER, 2014 - TANGENT DRAW-OFF VALVES (1.5, 2” & 3”) ITEM NO. PART NO. DESCRIPTION QTY. 1. - 7. KE50219 1.5” DRAW-OFF ASSEMBLY ........1 KE50972-B 2”...
Page 34 FRONT SERVICE WRAP TRANSFORMER LEFT RIGHT COVER TRANSFORMER COVER KETTLE (c/w gasket) FRONT SIDE SIDE BACK GASKET COVER GASKET KGL-40 KE01479-X KE53483-4 KE54253-X KE01432-X KE02186-1 KE54419-1 KE53871 RB01851 (1ft.) KGL-60 KE01479-1 KE53483-5 KE54253-1 KE01432-1 KE02186-2 KE54419-2 KE53871 RB01851 (1ft.) KGL-80...
Page 35 SPARE PARTS LIST The following is a spare parts listing of parts that wear during normal us or are apt to be misplaced during normal operation. These parts should be kept on hand to prevent loss time due to a minor problem. PART NUMBER DESCRIPTION QUANTITY...
Page 36 +1-800.338-2204 WWW.CLEVELANDRANGE.COM Every new piece of Welbilt Foodservice equipment comes with KitchenCare® and you choose the level of service that meets your opera onal needs from one restaurant to mul ple loca ons StarCare – Warranty & life me service, cer ﬁed OEM parts, global parts inventory, performance audited ExtraCare —...

This manual is also suitable for:

Kgl-60 Kgl-80 Kgl-100 Kgl-40-t Kgl-60-t Kgl-80-t ... Show all