Cleveland KGM Operating instructions

Repair Manual
Gas Kettles
Model KGM
Cleveland Range, Inc.
KET-08
UNITED STATES
1333 East 179th St., Cleveland, Ohio 44110 Phone: [phone]•
Telex:98-0546 • FAX: [phone]
CANADA
Garland Commercial Ranges
1177 Kamato Road
Mississaugha, Ontario, Canada L4W1X4
Phone:[phone] • FAX: [phone]

MODEL KGM
OPERATING CONTROLS AND
INDICATORS
For your better understanding and confidence, the following explanation of the control system on
these kettles is offered.
Item No. Description Function
34 On-Off Toggle Switch
(Main Body Dwg.) Controls electric power to kettle.
38 Solid State Temperature Control
Knob (Main Body Dwg.) This control knob allows the operator to select kettle heat increments from Min. to Max.
37 Power Indicator Light (Green)
(Main Body Dwg.) When lit, indicates that there is electrical power to the kettle.
36 Low Water Indicator Light (Red)
(Main Body Dwg.) When lit. indicates that the burners have cut out and the unit requires water. (See jacket filling instructions).
3Vacuum/Pressure Gauge
(Main Body Dwg.) Indicates steam pressure in PSI inside the steam jacket as well
as vacuum.
20 Pressure Relief Valve
(Main Body Dwg.) In the unlikely event that there is an excess steam build-up in
the jacket, this valve opens automatically to relieve this
pressure.
23 Water Level Indicator
(Main Body Dwg.) This sight glass with "HI" and "LOW" (HI and LO) water level
lines shows water level in the steam jacket.
31,33 Gas Control Valve
(Main Body Dwg.) Controls main gas supply to the kettle.
1

MODEL KGM
MAIN BODY
2

MODEL KGM -MAIN BODY
Item No. Part No. Description Qty.
1KE50142 Cover-40 Gal. (see note') 1
KE50143 Cover-60 Gal. (see note*) 1
KE50144 Cover-80 Gal. (see note') 1
KE50145 Cover-100 Gal. (see note*) 1
2KE50151 Handle Knob 1
3KE50429 Pressure Gauge (incl. Item no.4) 1
4SE50001 Pressure Gauge Glass Assy. 1
5KE50556 Water Level Probe 1I
6F105022 Hex Nipple 1
7KE51014
Check Valve.
1/
2"
1
8Fl 00250 Street Elbow 1
9F100151 Plug 1
10
KE00515
Thermistor
1
11-1
7
KE50219 1 1/
2"
Draw-Off Valve Assy, 1
KE50972 2"Draw-Off Valve Assy. 1
KE50973 3"Draw-Off Valve Assy 1
11 N/A
Body
(1
1/2
")
(see note**)
1
N/A Body (2") (see note***
)
1
N/A Body (3") (see note****) 1
12 SE50008 Stem (1 1/2") 1
SE50009 Stem(2") 1
SE50010 Stem(3") 1
13 FA00111 "0"Ring (1 1/2".2") 1
FA00210 "0"Ring (3") 1
14 SE50011
Bonnet
(1
1/2
")
1
SE50012 Bonnet (2") 1
SE50013 Bonnet (3") 1
15 SE50014 Hex Nut 1 1/2") 1
SE50015 Hex Nut (2") 1
SE50016 Hex Nut (3") 1
16 SE50017 Knob(1'/2",2") 1
SE50018 Knob (3") 1
17 SE50019 Wing Nut (1 1/2".2") 1
SE50063 Knob Hex Nut (3") 1
18 F100598 Nipple 1
19 F105024 Coupling 1
20 KE51082 Safety Valve-25 P.S.I. 1
21 KE51087 Blow Down Pipe 1
22 FA00033 "0"Ring, Sight Glass 1
23 KE51053 Sight Glass 1
24 KE50955 Sight Glass Retaining Cover 1
25
KE51114
Pilot Burner
1
26 KE51160 Ignition Electrode 1
27
KE51
111
Pilot Flame Sensor
1
(Thermopile Type)
(Manual Ignition)
KE51159
Pilot Flame Sensor
1
(Mercury Vapor Type)
(Spark Ignition)
Item No. Part No. Description Qty.
28 KE51116 Pilot Orifice Nat. Gas (.020") 1
KE51162 Pilot Orifice LP.(.0145") 1
29 KE51066 Burner 2. 3. 4
30 KE51118 Burner Orifice Nat. Gas 2.3,4
(0-2000 ft. elev. #43 drill)
SE50065 Burner Orifice Nat. Gas 2.3.4
(2000-4000 ft. elev #44 drill)
SE50066 Burner Orifice Nat. Gas 2.3.4
(4000-6000 ft. elev. #45 drill)
KE51119 Burner Orifice L.P. 2. 3.4
(0-2000 ft. elev.#53 drill)
SK50342 Burner Orifice L.P. 2.3.4
(2000-4000 ft. elev. #54 drill)
SE50069 Burner Orifice L.P. 2.3.4
(4000-6000 ft. elev #55 drill)
31
KE51155
Combination Control Valve
1
N.G.-24 VAC (Spark Ignition)
KE51163
Combination Control Valve
1
L.P.-24 VAC (Spark Ignition)
32
KE51159
Pilot Flame Sensor
1
(Mercury Vapor Type)
(Spark Ignition)
33
KE51110
Combination Control Valve
1
N.G.-120VAC
(Manual Ignition)
KE51161
Combination Control Valve
1
•LP-120 VAC
(Manual Ignition)
34 KE50504 Toggle Switch ON/OFF 1
35 KE50988 Potentiometer 1
36 KE50567 LE.D. Red 1
37 KE50568 L.E.D. Green 1
38 KE50569 Knob. Potentiometer 1
39 SK50062 Rubber Boot 1
40 KE51141 Transformer-120 /16V
KE50501 Transformer-240/16V
41 KE50753 Relay.12V DC 1
42
KE00459
Solid State Control Box
1
43 KE51138 Safety Thermostat 1
44 KE51164 Transformer-120/24V 1
KE51165 Transformer-240/24V 1
45 KE51167 Pilot Re-Lite (Spark Ignition) 1
(see note*****)
46 KE51168 Cycling Pilot Safety Timer 1
(Spark Ignition) (L.P. Only)
(see note*****)
47 KE51140 4/10 Amp Fuse (Manual Ignition) 1
KE51169 1 1/2 Amp Fuse (Spark Ignition) 1
48 SK50055 Terminal Block Section 2
49 SK50054 Terminal Block End Section 1
note* Part number is different for full jacketed kettles. Please order by description.
note** Please order KE50219-1 1/2" Draw-Off Valve Assy (incl. Item No. 11-17)
note*** Please order KE50972-2" Draw-Off Valve Assy. (incl. Item No. 11-17)
note****Please order KE50973-3" Draw-Off Valve Assy (incl. Item No. 11-17)
note***** Pilot Re-Lite and Cycling Pilot Safety Timer may be combined as one control cat. No. 50A22-1. Cleveland Part No. KE51405

KETTLE AND SKILLET FAUCET
Item No. Part No. Description Qty.
1SE50020 Hot Water Stem Assy. 1
2SE50021 Cold Water Stem Assy. 1
3SE50022 Yoke Connection Kit 1
4FA00016"O"Ring 1
5FA95022 Retaining Ring 1
6SE50064 Spout Nut 1
7see chart 3/
4"
spout (please see 3/4" 1
spout chart below)
8N/A 3/
4"
spout with Aerator (please 1
order Item No.4, 5. 6. 7)
9KE51401 Single Pantry Control Valve 1
(incl. Item No.2)
Item No. Part No. Description Qty.
10 KE51403 Double Pantry Control Valve 1
(incl, item No.1. 2. 3)
11 N/A Old Style Single Pantry Control 1
Valve (please order Hem No.
4, 5. 6. 7, 9)
N/A Old Style Double Pantry Control
Valve (please order item No.
4. 5. 6. 7. 10)
12 N/A 1"Spout (please order Item No. 1
4. 5. 6. 7. 1 4)
13 FA00115 "O"Ring 2
14 SE50061 Adapter (to adapt new style 1
spout to old style control
valve)
A B Part No.
4" 8" KE50833
10" 9" KE50832
6" 22-KE50831
12 1/2" 14" KE50830
10 3/4 14" KE50829
5" 14" KE50828
24-9" KE50827
20" 9" KE50826
12 1/2" 9" KE50825
Use only replacement parts which are factory supplied as to preserve the certification of Underwriters
Laboratories, American Gas Association. Canadian Standards Association or Canadian Gas Association (as
applicable). The use of other than factory supplied replacement pans will void the warranty.
4

HINGE ASSEMBLY FOR GAS KETTLES
Item No. Part No. Description Qty.
1-9KE00598 Hinge Assy. (40 gal. and under) 1
KE00677 Hinge Assy. (60 gal. and over) 1
1KE51218 Body Spring Assist Hinge 1
2KE50824 Hinge Bearing 1
3KE50823 Pin (Hinge) 1
4KE50820 Insert Brass Adjust 1
5KE50819 End Piece 1
6FA11507 Screws Ad just 2
7FA11284 Bolts End Block 2
8KE50122 Spring(40 gal. and under) 1
KE50121 Spring(60 gal. and over) 1
9KE50821 Cylinder (40 gal. and under) 1
KE00653 Cylinder (60 gal. and over) 1
10 KE50151 Knob Ball Type 1
11 Cover Handle (Specify Model) 1
12 KE00095 Lid Holder 1
13 FA30500 Washer Lid Holder 1
14 FA11223 Bolt Lid Holder 1
Use only replacement parts which are factory supplied as to preserve the certification of Underwriters Laboratories.
American Gas Association. Canadian Standards Association or Canadian Gas Association (as applicable). The use of other than
factory supplied replacement parts will void the warranty.
5

GAS KETTLE SERVICING
GUIDE
This section contains servicing information intended for use by Authorized Service Personnel.
Note:If Fault Isolation Procedure is needed, be sure to start at step # 1.
A/ PROBLEM: Kettle is not heating at all. (Burners fail to ignite) (Kettle must be on and
temperature control set).
Possible Causes
1. No power — either gas or electric.
2. Low water condition.
3. Defective on/off switch.
4. Defective 24 VAC transformer.
5. Defective 16 VAC transformer.
6. Defective safety thermostat.
7. Defective 12 VDC relay.
8. Defective low water probe.
9. Defective thermistor.
10. Defective potentiometer.
11. Defective or incorrectly adjusted control box.
12. Defective pilot flame sensor.
13. Defective pilot re-light.
14. Defective cycling pilot safety timer.
15. Defective or incorrectly adjusted gas control valve.
16. Blown 4/10 or 1 1/2 amp fuse.
17. Poor ground.
18. Incorrect spark gap.
19. Faulty wiring.
Fault Isolation Procedure
Step
1. Test Are both gas and electrical supplies on? (120
VAC at terminal block)
Result
Yes Remedy Go to step # 2
No Correct external power
supply.
2. Is red LED illuminated? Yes Follow kettle filling
procedure.
No Go to step #3.
3. Is green LED illuminated? Yes Go to step # 4.
No Go to step # 8.
4. Is 24 VAC present at output of 24 V transformer? Yes Go to step # 14.
Or if manual ignition, is 120 VAC present at gas control
valve? No Go to step #5.
5. Is there 12-16 VDC at circuit path #8? Yes Go to step #6.
SEE NOTE* SEE NOTE**No Go to step #8.
6

6. Is 120 VAC present across 12 VDC relay contacts? Yes Replace defective 12 VDC relay.
No Go to step #7.
7. Is 120 VAC present across safety thermostat? Yes Replace defective safety thermostat.
No Replace defective 24 V transformer.
8. Remove on/off switch wiring. Is there proper continuity
when switch is activated? Yes
No Go to step #9. Replace defective on/off
switch.
9. Is there 16 VAC present across the output of the 16V
transformer? Yes Go to step #10.
No Replace defective 16 V transformer.
10. Is there ground to circuit path #7 Yes Go to step #11.
SEE NOTE* No Correct poor ground connection
11. Is there continuity between ground and circuit path # 5?Yes Go to step # 12.
SEE NOTE* No Replace defective low water cut-off
probe.
12. Measure continuity across the potentiometer. Does
resistance change while turning the potentiometer knob? Yes
No Go to step #13. Replace defective
potentiometer.
13. While kettle is cold, remove edge connector from control
box. Test resistance on edge connector between pins #2
and #7. Is there approx. 100,000 ohms?
Yes
No Replace defective control box. Replace defective thermistor.
14. It is assumed that there is proper incoming gas pressure of
minimum 7" W.C. tor natural gas and 12" W.C. for LP gas.
For manual ignition go to step # 15.
For spark ignition natural gas go to step #19.
For spark ignition LP. gas go to step # 25.
15. Is there 120 VAC across the 4/10 amp fuse? Yes Replace blown 4/10 amp -fuse.
No Go to step #16.
7

16. Can a pilot be achieved? Yes Go to step #17.
No Refer to pilot adjustment
procedure. If adjustment of pilot is
unsuccessful, replace defective
gas control valve.
17. Do burners fail to ignite? Yes Go to step #18.
No Refer to "kettle heats too slowly"
servicing guide.
18. Does the pilot flame sensor (thermopile) generate
450-750 mV? Yes Replace defective gas control valve.
No Replace defective pilot flame
sensor (thermopile).
19. Can a pilot be achieved? Yes Go to step #24.
No Go to step #20.
20. Is the pilot re-light generating a spark? Yes Go to step #23.
No Go to step #21.
21. Is there 24 VAC across the 1 1/2amp fuse? Yes Replace blown 1 1/2amp fuse.
No Go to step #22.
22. Is the spark gap1/8"± 1/32"? Yes Replace defective pilot re-light.
No Adjust spark gap.
23. Measure continuity across pilot flame sensor's pins
#3 and #4. Is it a closed circuit? Yes Replace defective gas control valve.
No Replace defective pilot flame
sensor.
24. After pilot has been lit for 5 minutes, pull pilot flame
sensor's connection off and quickly measure
continuity between pins#2 and #4. Is it a closed
circuit at first and after pilot flame sensor cools down
the circuit opens?
Yes No Replace defective gas
control valve.
Replace defective pilot
flame sensor.
25. Can a pilot be achieved? Yes Go to step #31.
No Go to step #26.
26. Is the pilot re-light generating a spark? Yes Go to step #29.
No Go to step #27.
8

27. Is there 24 VAC across the 1 1/2amp fuse? Yes Replace blown 1 1/2amp fuse.
No Go to step #28.
28. Is the spark gap 1/8" ± 1/32'' Yes Go to step #29.
No Adjust spark gap.
29. Turn power on/off switch to "off" for 5 minutes. This
will zero
cycling pilot safety timer. Then turn unit back
on. Is a pilot now achieved?
Yes If burners now do not ignite, go to
step #31.
No Go to step #30.
30. Measure continuity across pilot flame sensor's pins
#3 and #4.Is it a closed circuit? Yes Replace either defective pilot re-
light
or defective gas control valve.
No Replace defective pilot flame sensor.
31. After pilot has been lit for 5 minutes, pull pilot flame
sensor's connection off and quickly measure
continuity between pins #2 and #4. is ita closed
circuit at first and after pilot flame sensor cools down
the circuit opens?
Yes No Replace defective gas
control valve.
Replace defective pilot
flame sensor.
NOTE* Slightly pull off edge connector from control box. Edge connector must still contact with circuit paths.
Pin numbers are marked on edge connector.
NOTE** Measure DC to ground.
B/ PROBLEM:Kettle heats too slowly or not hot enough (Note: Operating pressure is 10-12 psi).
Possible Causes
1. Loss of vacuum.
2. Low incoming gas pressure.
3. Defective safety thermostat.
4. Defective potentiometer.
5. Defective thermistor.
6. Defective control box.
7. Defective gas control valve.
Fault Isolation Procedure
Step Test Result Remedy
1. In a cold state, does the pressure guage read "
vent
air"? Yes Follow kettle venting procedure.
No Go to step #2.
2. Do the burners shut off too early? Yes Go to step #3.
No Go to step #6.
9