KitchenAid KAC-27 User manual

TECHNICAL EDUCATION
JOB AID 4317318
KAC-27
PROFESSIONAL
GAS COOKTOPS

- ii -
WHIRLPOOL CORPORATION assumes no responsibility for any repair
made on our products by anyone other than Authori ed Factory Service
Technicians.
Copyright 2001, Whirlpool Corporation, Benton Harbor, MI 49022
FORWARD
This Job Aid, Professional Gas Cooktops,” (Part No. 4317318), provides the technician with
information on the operation and service of the Professional Gas Cooktop. It is to be used as a
training Job Aid and Service Manual.
The wiring diagrams and strip circuits used in this Job Aid are typical and should be used for
training purposes only. Always use the wiring diagrams supplied with the product when servicing
the unit.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair the Professional Gas Cooktop.
The objectives of this Job Aid are to:
• Understand and follow proper safety precautions.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the Professional Gas Cooktop to the proper operational status.

- iii -
Table of Contents
SPECIFICATIONS .................................................................................................................. 1-1
INSTALLATION HIGHLIGHTS................................................................................................ 2-1
L.P.Gas Conversion........................................................................................................... 2-1
COMPONENT ACCESS ......................................................................................................... 3-1
Component Locations ........................................................................................................ 3-1
Removing A Sealed Burner & Ignitor ................................................................................. 3-2
Removing The Front Panel ................................................................................................ 3-4
Removing The Ignition Switches & A Gas Valve ............................................................... 3-5
Removing A Spark Module & The Power Supply Cord ..................................................... 3-7
COMPONENT TESTING ........................................................................................................ 4-1
Ignition Switches ................................................................................................................ 4-1
WIRING DIAGRAMS & STRIP CIRCUIT ................................................................................ 5-1
TECH TIPS ............................................................................................................................. 6-1
Requesting Assistance Or Service .................................................................................... 6-1
Cooktop Warranty .............................................................................................................. 6-2
Page

- iv -
MODEL & SERIAL NUMBER DESIGNATIONS
MODEL NUMBER SERIAL NUMBER
MODEL NUMBER K GC P 4 6 7 J S S 0
INTERNATIONAL SALES IND.
or MARKETING CHANNEL
IF PRESENT
K = KITCHENAID BRAND
PRODUCT IDENTIFICATION
EC = ELECTRIC COOKTOP
GC = GAS COOKTOP
MERCHANDISING SCHEME
C = CERAMIC GLASS
D = DOWNDRAFT VENT
E = ELECTRONICS
G = GRILL / GRIDDLE
M = MODULAR / DOWNDRAFT
N = INTERNATIONAL COLLECTION
P = PROFESSIONAL / COMMERCIAL
S = STANDARD PORCELAIN METAL
T = TEMPERED GLASS
X = 208 VOLTS
CAPACITY / SIZE / SERIES / CONFIGURATION
1ST POSITION 2ND POSITION
1 = STANDARD 0 = 30" WIDE
2 = GRILL / GRIDDLE 2 = 42˝ OR 12˝ WIDE
3 = TEMPERED GLASS 3 = 33˝ WIDE
4 = COMMERCIAL 5 = 15˝ WIDE
5 = CERAMIC GLASS 6 = 36˝ WIDE
8 = MODULAR DOWNDRAFT 8 = 48˝ WIDE
0 = 2 BURNER / ELE. SYS.
FEATURES
0 = STANDARD ELEMENTS / BURNERS
1 = RADIANT ELEMENTS
2 = DUAL ELEMENTS
3 =
4 =
5 = SEALED BURNERS / CAST ELEMENTS
6 = 5 BURNERS / ELEMENTS
7 = HALOGEN ELEMENTS / 6 BURNERS
8 = TOUCH CONTROLS
9 = INDUCTION
YEAR OF INTRODUCTION
H = 1999
J = 2000
COLOR CODE
TL = TILE
SS = BRUSHED STAINLESS STEEL
ENGINEERING CHANGE
0 = BASIC RELEASE
1 = FIRST REVISION
2 = SECOND REVISION
SERIAL NUMBER X K 0 5 10052
MANUFACTURING SITE
X = OXFORD
YEAR OF PRODUCTION
K = 2000
WEEK OF PRODUCTION
5th Week
PRODUCT SEQUENCE NUMBER

- v -
MODEL & SERIAL NUMBER LABEL LOCATION
The Model / Serial Number label is located in one of two positions, as shown below.
Model & Serial
Number Label Location
Prior To July, 2000
Model & Serial
Number Label Location
Beginning July, 2000

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IMPORTANT SAFETY INFORMATION
Your safety and the safety of others is very important.
Important safety messages have been provided in this Job Aid. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to hazards that can kill or hurt you and others.
All safety messages will be preceded by the safety alert symbol and the word
WARNING.”
All safety messages will identify the hazard, tell you how to reduce the chance of injury, and tell
you what can happen if the instructions are not followed.

1-1
SPECIFICATIONS
Model Number KGCP467JTL KGCP467JSS KGCP487JSS
Model Description Sealed Cooktop Sealed Cooktop Sealed Cooktop
Size-Configuration 36" Dec. Tile Frames 36" 48"
Feature Level/Series Professional Professional Professional
Dimensions/Specifications
Exterior Dimensions
Overall Height (in) 7 1/2" 7 1/2" 7 1/2"
Overall Width (in) 35 7/8" 35 7/8" 47 7/8"
Overall Depth (in) 26 1/4" 26 1/4" 26 1/4"
Cutout Dimensions
Cutout Height (in) (Measure Or Min/Max) 7 1/4" 7 1/4" 7 1/4"
Cutout Width (in) (Measure Or Min/Max) 36" (F); 35 1/4" (B) 36" (F); 35 1/4" (B) 48" (F); 47 1/4" (B)
Cutout Depth (in) (Measure Or Min/Max) 1 1/4" (B); 22" (N) 1 1/4" (B); 22" (N) 1 1/4" (B); 22" (N)
Weight
Net Weight (lbs) 140 140 T B D
Shipping Weight (lbs) 160 160 T B D
Ratings
Electric Voltage/Phase/Frequency (Hz) 120 V/Single Phase/60 Hz 120 V/Single Phase/60 Hz 120 V/Single Phase/60 Hz
Circuit Amps 15 Amp 15 Amp 15 Amp
Exterior
Cooktop Controls Push-to-Turn Push-to-Turn Push-to-Turn
Cooktop Control Type Infinite Infinite Infinite
Cooktop Control Location Front Front Front
Cooktop Control # 66 8
Control Area Yes Yes Yes
Burner Grate Cast Iron Cast Iron Cast Iron
Griddle Yes-Opt Yes-Opt Yes-Opt
Gas Cooktop Burners Yes Yes Yes
Gas Burner Type Sealed Sealed Sealed
Gas R Front Output (BTU)(Nat/LP) 6000 BTU/5000 BTU 6000 BTU/5000 BTU 6000 BTU/5000 BTU
Gas L Front Output (BTU)(Nat/LP) 6000 BTU/5000 BTU 6000 BTU/5000 BTU 6000 BTU/5000 BTU
Gas R Rear Output (BTU)(Nat/LP) 15000 BTU/12000 BTU 15000 BTU/12000 BTU 15000 BTU/12000 BTU
Gas L Rear Output (BTU)(Nat/LP) 15000 BTU/12000 BTU 15000 BTU/12000 BTU 15000 BTU/12000 BTU
Gas Center Rear Output (BTU)(Nat/LP) 15000 BTU/12000 BTU 15000 BTU/12000 BTU 15000 BTU/12000 BTU
Gas Center Front Output (BTU)(Nat/LP) 15000 BTU/12000 BTU 15000 BTU/12000 BTU 15000 BTU/12000 BTU
Gas Center Right Front (BTU)(Nat/LP) 15000 BTU/12000 BTU
Gas Center Left Front (BTU)(Nat/LP) 15000 BTU/12000 BTU
Gas Ignition Electronic Electronic Electronic
LP Conversion Kit Included Kit Included Kit Included
Accessories
Backsplash Included Included Included
Backsplash Part/Comment Standard 9" Standard 9" Standard 9"
Island Trim Included Included Included
Island Trim Part/Comment Standard Standard Standard
Other Accessory Yes Yes Yes
Comment
Simmer Plate - Factory
Packed
Simmer Plate - Factory
Packed
Simmer Plate - Factory
Packed
Miscellaneous
Product Literature
Installation Instructions Part# 8284670 8284670 8284670
Service Manual Part# 4317318 4317318 4317318
Use & Care Guide Part# 8284642 8284642 8284642
Wiring Diagram Part# 3192100 3192100
Agency Approvals AGA,CGA AGA,CGA AGA,CGA
Approved to Install Over BI Oven No No No
Power Cord Length & # Wires 3 1/2 Foot/3 Wire 3 1/2 Foot/3 Wire 3 1/2 Foot/3 Wire
Warranty Yes Yes Yes
Full 12 Mo 12 Mo 12 Mo
Gas Burners 60 Mo 60 Mo 60 Mo

1-2
— NOTES —

2-1
INSTALLATION HIGHLIGHTS
WARNING
To convert the cooktop for use with L.P. gas,
perform the following steps.
1. Turn off the gas supply to the cooktop.
2. Disconnect power to the cooktop.
3. Use a screw river an remove the access
cap on the gas pressure regulator.
L.P. GAS CONVERSION
Explosion Hazard
Securely igh en all gas connec ions.
If connec ed o L.P. gas, have a qualified
person make sure gas pressure does no
exceed 14˝ wa er column.
Examples of a qualified person include
licensed hea ing personnel, au horized
gas company personnel, and au horized
service personnel.
Failure o do so can resul in dea h, explo-
sion, or fire.
This conversion ki shall be ins alled by a
qualified service agency in accordance
wi h he manufac urer’s ins ruc ions and
all applicable codes and requiremen s of
he au hori y having jurisdic ion. If he
informa ion in hese ins ruc ions is no
followed exac ly, a fire, explosion or pro-
duc ion of carbon monoxide may resul
causing proper y damage, personal in-
jury or loss of life. The qualified service
agency is responsible for he proper in-
s alla ion of his ki . The ins alla ion is no
proper and comple e un il he opera ion
of he conver ed appliance is checked as
specified in he manufac urer’s ins ruc-
ions supplied wi h his ki .
The following parts are provi e with Conver-
sion Kit Par #8284673:
WARNING
Conversion Instructions - Par #8284674
Conversion Label
Par #8284675
Access Cap
Gas Pressure
Regulator
4. Turn the access cap so that the letters L.P.
are facing up an then reinstall the cap on
the regulator.
NAT Position L.P. Position
Orifice/Spu Package
Par #8284663

2-2
5. Remove the grates from the cooktop an
the burner caps from the burner bases.
IMPORTANT NOTE: The 5,000 B.T.U. orifices
(re , 0.70 mm) MUST be use in the small left
an right front corner burners only. The 12,000
B.T.U. orifices (blue, 1.10 mm) MUST be use
in all the other burners.
7. Install the L.P. orifices in the burner loca-
tions shown below. NOTE: The 48˝/8-
burner mo els also have the two 2,300
B.T.U. burners at the outer front left an
right locations.
8. Replace the burner caps an grates.
6. Use a 7 mm nut river an remove the
orifices from each of the burners. NOTE:
Place a small piece of masking tape along
the insi e e ge of the nut river to help
keep the orifice in the river.
Rating Color Size
5,000 B.T.U. Re 0.70 mm
12,000 B.T.U. Blue 1.10 mm
Burner Orifice
5,000 B.T.U.
(Re /0.70 mm)
5,000 B.T.U.
(Re /0.70 mm)
(4) 12,000 B.T.U.
(Blue / 1.10 mm)
36˝ / 6-Burner Model Shown

3-1
COMPONENT LOCATIONS
This section instructs you on how to service each component inside the cooktop. The components
and their locations are shown below.
COMPONENT ACCESS
Gas Valve &
Ignition Switch
Powe
Supply Co d
Spa k Modules
Sealed Bu ne
& Ignito
36˝ Model

3-2
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the cooktop.
Check all gas line connections and replace
all panels before operating the cooktop.
Failure to do so could result in explosion, fire,
or other in ury.
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the
cooktop.
Replace all panels before operating cooktop.
Failure to do so can result in death or electri-
cal shock.
REMOVING A SEALED BURNER & IGNITOR
1. Turn off the gas and electrical power going
to the cooktop.
2. Remove the grates and burner caps from
the cooktop.
CAUTION: When you work on the cooktop, be
careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
WARNING
3. Use a T20 torx screwdriver and remove
the two screws from each burner head,
then lift the heads off the cooktop.
4. Lift the front of the cooktop and remove it.
Bu ne Head IgnitoSealed Bu ne
G ate Bu ne Cap
Lift Lift
Sealed Bu ne s & Ignito s
Cooktop

3-3
5. To emove an ignito f om a sealed
bu ne :
a) Disconnect the ignitor wire from the
terminal.
b) Remove the screw from the ignitor
bracket.
Sealed Bu ne
Ignito
c) Remove the two hex-head screws from
the burner bracket and remove the
sealed burner.
d) Remove the screw from the ignitor
bracket and remove the ignitor from the
sealed burner.
6. To emove a sealed bu ne :
a) Disconnect the ignitor wire from the
ignitor terminal (see step 5).
b) Use a 1/2˝ open-end or an ad ustable
wrench and remove the gas line fitting
from the sealed burner you are replac-
ing.
1/2˝ Gas Line Fitting
B acket
Ignito
Sc ew Bu ne
Head
Hex-Head Sc ews
Sealed Bu ne
Ignito
Wi e
Ignito Sc ew

3-4
REMOVING THE FRONT PANEL
CAUTION: When you work on the cooktop, be
careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
1. Turn off the gas and electrical power going
to the cooktop.
2. Remove all of the knobs from the front
panel by pulling them off the control shafts.
4. Slide the front panel down so that the five
tabs are out of their slots and remove the
panel.
F ont Panel Sc ew
(1 of 2)
5 F ont Panel Tabs
3. Remove the two lower screws from the
ends of the front panel.
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the cooktop.
Check all gas line connections and replace
all panels before operating the cooktop.
Failure to do so could result in explosion, fire,
or other in ury.
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the
cooktop.
Replace all panels before operating cooktop.
Failure to do so can result in death or electri-
cal shock.
WARNING

3-5
b) Pull the ignition switches off the gas
valve stems.
Rubbe
Shield
Gas Valve
Stem
Ignition
Switch
REMOVING THE IGNITION SWITCHES & A GAS VALVE
CAUTION: When you work on the cooktop, be
careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
1. Turn off the gas and electrical power going
to the cooktop.
2. Remove the front panel (see page 3-4 for
the procedure).
3. To emove the ignition switches:
NOTE: The ignition switches must be replaced
as an assembly. They cannot be changed indi-
vidually.
Ignition Switches
a) Remove the rubber shields from the
gas valve stems.
Gas Valve
Stem
c) Disconnect the black ignition switch
wire from the harness connector and
the white wire from the indicated spark
module terminal.
d) Loosen the wire tie and pull the ignition
switch wire connectors through it.
Black Wi e
Connecto
Wi e Tie
Continued on the next page.
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the cooktop.
Check all gas line connections and replace
all panels before operating the cooktop.
Failure to do so could result in explosion, fire,
or other in ury.
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the
cooktop.
Replace all panels before operating cooktop.
Failure to do so can result in death or electri-
cal shock.
WARNING
White Wi e

3-6
REASSEMBLY NOTES:
1. When installing a new gas valve, make
sure that the rubber grommet is in place on
the valve and the mounting screw washer.
2. Do not overtighten the gas valve mounting
screw.
b) Remove the mounting screw from the
gas manifold and remove the valve and
its rubber grommet from the manifold.
Rubbe
G ommets
Gas Line
Sc ew
Manifold
4. To emove a gas valve:
a) Remove the gas line from the gas valve.

3-7
3. To emove a spa k module:
a) Disconnect the wires from the termi-
nals.
b) Use a 1/4˝ socket and remove the hex-
head screw at the top of the module and
unhook the bottom tab from the chassis
slot. NOTE: The left module controls
the left front (LF) and right front (RF)
burners. The right module controls the
center front (CF), right rear (RR), cen-
ter rear (CR), and left rear (LR) burners.
Spa k Modules
REMOVING A SPARK MODULE &
THE POWER SUPPLY CORD
1. Turn off the gas and electrical power going
to the cooktop.
2. Remove the front panel (see page 3-4 for
the procedure).
CAUTION: When you work on the cooktop, be
careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
1/4˝ Hex-Head
Sc ew
Spa k Module
Fo LF & RF Bu ne s
Spa k Module Fo
CF, RR, CR, & LR
Bu ne s
1/4˝ Hex-Head
Sc ew
Continued on the next page.
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the cooktop.
Check all gas line connections and replace
all panels before operating the cooktop.
Failure to do so could result in explosion, fire,
or other in ury.
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the
cooktop.
Replace all panels before operating cooktop.
Failure to do so can result in death or electri-
cal shock.
WARNING

3-8
4. To emove the powe supply co d:
a) Disconnect the ribbed wire from the
indicated left spark module terminal.
b) Disconnect the smooth wire from the
main wiring harness connector.
c) Remove the 1/4˝ hex head screw from
the green ground wire.
d) Remove the strain relief from the power
supply cord.
Powe Supply Co d
Powe Supply Co d
St ain Relief
(Remove F om
Othe Side Of
Panel)
G een G ound Wi e
Smooth Wi e
Connecto
Ribbed Wi e
Connecto

4-1
COMPONENT TESTING
Before testing any of the components, perform
the following checks:
• The most common cause for control failure is
corrosion on connectors. Therefore, discon-
nect and reconnect the wire connectors to
their terminals throughout any of the test
procedures.
• All tests and checks should be made with a
V M (volt-ohmmeter), or a DVM (digital
voltmeter), having a sensitivity of 20,000
ohms-per-volt DC, or greater.
• Check all of the connections before you
replace the components. Look for broken, or
loose wires, failed terminals, or wires that
are not pushed firmly onto their connectors.
• Voltage checks must be made with all con-
nectors attached to the boards.
• Resistance checks must be made with power
removed from the appliance, and with the
wiring harness or connectors disconnected.
IGNITION SWITCHES
TEST PROCEDURE
Refer to page 3-5 for the procedure for servic-
ing the ignition switches.
N TE: The ignition switches will be serviced
as a complete assembly. If a switch is defec-
tive, the complete assembly must be replaced.
Electrical Shock Hazard
Disconnect the electrical supply from the
unit before servicing.
Failure to do so could result in death or
electrical shock.
WARNING
1. Disconnect power to the cooktop.
2. Set the ohmmeter to the R x 1 scale.
3. Remove the front panel (see page 3-4 for
the procedure).
5. Turn all of the switches to the ff position.
6. Touch the test leads to the connectors on
the black and white switch wires. The
ohmmeter should indicate and open cir-
cuit (infinite ∞).
7. Turn each switch to the LITE position. The
ohmmeter should indicate a closed circuit
(0 ohms).
4. Locate the black and white ignition switch
connectors, (one is connected to the spark
module, and the other is connected to the
main wire harness), and disconnect them.
Ignition Switche
White Wire
Black Wire Connector

4-2
— NOTES —