KitchenAid KGCG-2240P User manual

42” GAS COOKTOP
WITH BROILER/GRIDDLE
MODELS: KGCG-2240/KGCG-2240P
GSU-42-E-Z/GSU-42P
INSTALLATION
INSTRUCTIONS
INSTALLER: FINAL CHECK LIST
PLACEMENT OF UNIT
0 1, Specified clearances maintained to cabinet surfaces.
0 2. Burner box correctly positioned in countertop recess.
ELECTRICAL
0 1. Polarized three wire 120 VAC, 15 ampere receptacle with 15 ampere overcurrent
protection provided, for service cord connection.
GAS SUPPLY
E 1. Supply line of 11’2” black iron pipe provided
0 2. Pressure regulator shipped with unrt corlnected to manifold.
0 3. Manual gas shutoff valve installed in accessible location,
0 4. Unit tested for gas leaks.
OPERATIONAL
IJ 1. If used on LP gas, verify that pressure regulator and orifice hoods have been modified
for use with LP.
E 2. Top burners have burner pin in holes of drip pan.
E 3. Flashtubes on top and broiler burners Iproperly positioned.
0 4. Each burner lights satisfactorily both Individually and with other burner on same side
of unlit.
0 5. Flanle adjustment for 318” soft blue cone made on each top burner.
Cl 6. Low flame adjustment verified.
0 7. Griddle is level.
E 8. Grease pan is under platter at rear of burner box.
E 9. Griddle remains where placed when raised.
Cl 10. Drip rings and grates correctly positioned.
E 11. Place wooden cover over qriddle.
E 12. Unless instructed to leave for owner, remove all tags, labels and internal packing
material.
THANK YOU INSTALLER:
1, Comnlete Ins-tallation Check List.
2. Leave all literature for customer.
3. Notify dealer that installation is completed.
FORDETAILEDINSTRUCTIONS,FOLLOWMETHODSDESCRIBEDIN THISFOLDER,

IMPORTANT: Read Before lnstahg to Save Time! Work,
assure proper performance, and owner’s warranty protection.
CABINETRY ELECTRICAL SPECIFICATIONS
!I; ;..rsXU
i)~,t;tll::q 23 112” deep x 42-118” long x
7 ; L-i -,k;’’ in depth (irom top of finished counter
toil; I-ec;:rlrad for Inst~rllation. See Fig. 1 below for
$F:ibllS
Voltdge & Frequency 120 volts--60 hertz
Maximum Protective Device Size 15 amperes
Wirinq must conform to local code and/or National
Electrical Code.
INSTALLATION INSTRUCTI
Tije irlstal;atlorl of tfe cooktop must conform to local codes and utility regulatrons and should be made
(3Iii, by a competent technician. In the absence of local codes, the installation must follow the National
F ,J2 !;,js Code, ANSI Z 223.1-1964 and the National Electrical Code, ANSI/NFPA No. 70-1984. When
irljtiri/cci in a mobile hume, the installation must conform with Federal Standar-d for Mobile Home Construc-
tion <rid Safety, Title 24, HUD (part 280) or when such standard is not applicable, with local codes.
CABiNE i- CONSTRUCTION
)trs:atl tire urirt in an appropriate cabinet. See itlustratron below for correct clearances to adjacent vertical
sides ano Iear walls and proper opening dimensions.
1.I !L-ouct: the risk of turns or fire by reaching over heated surface units, cabinet storage above the surface
l.Anit: shouid be avoidetl. If cabinet storage is to be provided, the risk can be reduced by installing a range
hook, thdt projects horrzontally a minimum of 5 inches beyond the bottom of the cabinets.
CAElhET
-I OP Or’ENING
DihlEhiClONS

23:;” 19”
l-9/16" cm--, 9”
t
4-;15116’
1
~Burner Box Bottom
MOUNTING DETAIL
OPENING LOCATIONS & DlhlENSIO!VS
ELECTRICAL
PLUG WITH GROUND PRONG
WARNING: THIS COOKTOP IS PROVIDED WITH A POLARIZED
PROPERLY POLARIZED AND
THREE PRONG PLUG. IT IS IMPERATIVE THAT THE OULET
GROUNDED RECEPTACLE 0
TO WHICH THIS PLUG IS CONNECTED BE PR0PERL.Y POLAR-
IZED AND GROUNDED. IF THE RECEPTACLE IS NOT THE
PROPER GROUNDING TYPE, A QUALIFIED ELECTRICIAN
SHOULD BE CONTACTED.
This unit requires a polarized three wire grounded receptacle con-
nected to a 120 VAC, single phase, 60 hertz, 15 ampere overcurrent protected circuit. The receptacle must
be installed below the cooktop so that the 3-l/2’ service cord supplied with the unit may be easily removed
for servicing or cleaning the cooktop. (See illustration under “Connecting Unit to Gas” for location of cord
under bottom of unit.) This unit must be electrically grounded in accordance with local codes, or in their
absence, with the National Electrical Code, ANSI/NFPA No. 70-1984.
UNPACKING THE UNIT
Take unit out of the carton and remove all packing materials, so that the grates and drip rings may be
removed from the top of the unit. Check to see that pressure regulator and all hardware is removed before
carton is properly disposed of.
Prior to installation, test the electrical service to assur-e thaT it agrees with the specifications on the cooktop
data plate.
Study all tags and labels and follow their InstructIon: dur!ny Installation.
INSTALLING IN CABINET
This unit is heavy and two people may be required to properly place unit in cabinet opening.
Place service cord through hole in bottom of opening.
Grasp unit by burner openings in cooktop and lower into opening. Make sure that unit is as far back in
opening as possible and that the gap in either side is the same.
CONNECTING UNIT TO GAS
All gas supply connections should be made by a competent technician and in accordance with local codes
or ordinances. In the absence of a local code, the installation must conform to the National Fuel Gas Code
ANSI Z 223.1-1984. The manifold and pressure regulator supplied with the unit have l/2” NPT connec-

! 0!1i. ,iezing of the
!Jressure reguiator is 6 in. water column (W C.) for natural gas and 10 in. W.C. for LP
gas In order to check pressure regulator, the inlet test pressure must be at least one (1”) W.C. gretaer than
setlrrig (7” for natural and 11” for LP). Maximum pressure to regulator must not exceed 14” W.C.
.f t.*ead sealant resistarit to natural and i.P gases is to be used on all threaded gas connections.
-1he end of the rnanr’oid extends out of the burner box in the lower right corner. Connect the gas pressure
reiguiator (supplied vvlttr the unit) with the arrow on the bottom of the regulator pointing up directly to the
e Ed of the manifold.
G&S PRESSURE I-----
F?tG!?LATOR
:j 3,’ 1fi ---I i *--l-:3/16" )_
’ I
SilUTOFF VALVE
iTo Be F urnirhed
bv Installer;
Tie regulator should oe positioned so that the access cap is accessible for removal after the regulator has
been installed. A l/2 ’ NPT manual shut off valve shou!d be installed in the gas supply line in an accessible
ocatiorf, so that the gas may be turned off if servicing of the unit is requried.
‘Tire appliance and its individclal shutoff valve must be disconnected from the gas supply piping system
drlring any pressure testing of tha? system at test pressures in excess of % psig.
The appliance must bl-! isolated from the gas supply piping system by closing its individual manual shutoff
valve during any nressure testing of the gas supply plping system at test pressures equal to or less than 1/Z
psig
CHECKOUT AND ADJUSTMENT
1.i-rs unli iias been built and st’t for use with natural gas. IF 1.T !S TO BE USED ON LP GAS - PROCEED
AS F C>L LOWS BEFOF’E MAKING CHECKS,
.TV?
i i) :;or!vert regula;or for L.P gas, remove regulator access cap. Either turn cap over or reverse plunger
rzstirlg on spring. This: should expose the LP marking on cap or plunger. Tighten cap on regulator.
et
F;!-:“$!?VE GRID& E, SHC>iiEH PAN, BROILER BURNER ASSEMBLY AND TOP
I 1he gr!duld is *eni,Jvecl by turning broiler handle on left side to raise griddle. Grasp griddle on both
+des an:] ;lrde ,.:J to release hook holding it to broiler burner assembly.
1
1he broiler buner assernbiy is taken out of the broiler box by iiftrng up the rear of the burner until
+n is free fron eyebolt. The tilt left srde of burner and slide out of burner bearing and off orifice
c4r.2
J Iiernove top b\, loosening nuts located under each corner of the cooktop. Use of 3/8” deep well
socket is suqges;ed for removal of the nuts.
1;
P’dce all parts ti.. c;r~e side for reinstallation.
P,re IJrifice hoods tire set approxrmately 2% to 3 turns from the end of the orifice needles for natural
gas operation. For LP gas, the hoods must be tightened until they just touch the end of the needle. DO
NOT FORCE AGAiNST NEEDLE.
4-

- I
‘/LI?T!(:r’.
3.: PClf I
D CHANGE AIR SHUTTER SETTING
1. Top Burner
L.oosen air shutter screw and open air shutter to l/4”, using l/4” drill bit to check.
The unit is now ready to be checked out by first testing ALL gas connections for leaks. BE SURE THAT
TiiE ELECTRICITY iS “OFF” BEFORE TURNING ON GAS SUPPLY. Test with pressure gauge or apply
soapy solution or leak detector solution on all gas connections. Repair any leaks that may appear before
putting unit in opealion.
TOP BURNER CHECKOUT
Make sure that eacn burner is resting on the burner support in three locations, the two legs and at the
venturi connection. Necessary adjustments are made by loosening the screws holding venturi to the burner.
Tighten screws after adjustment and recheck for gas leak.
See that flash tubes are in correct position.
TOP VIEW
I
I
j FLASH TUBE
I--~ tlOAlZONT,4L
GAS PCRT
L
LIGHTER Jtl
--
SIDE VIEW
IMake basic air shutter adjustment on each burner. On natural gas, the air shutter opening should be 3/16”.
This may be checked with 3/16” drill bit. As previously stated in the LP conversion, the opening for LP gas
should be l/4”.
‘VISUAL BROILER BURNER CHECKOUT
4eplace broiler burrler assembly be reversing procedure shown in section B-3. Be sure that burner bell is
IrestIng in the broiler burner neck bearing on right side and that broiler burner shaft is resting in slot of
broiler burner coupl!ng. Put broiler pan back on sling links and griddle on top of broiler burner assembly,
making sure that hook is fully engaged.
See that flash tube is in proper position,
!
ip
9/32
1. ~---~ y--
-+ ? -1
- ---_ ___~
-Ilk v i : ( ’ ’
i 512
I
I
5-

Check air shutter setting. On natural and LP gas there should be
a 3/4” slot in burner at both top and bottom. %
The unit is now ready to plug service cord into receptacle. Make
sure that power supply neutral is connected to the wide blade
slot in receptacle. It is essential that the electrical outlet to
which the plug is connected be properly grounded and polarized.
If this is in doubt, a qualified electrician should be contacted to
check the outlet.
Initial checks are made either with or without cooktop de-
pending upon whether or not the unit was converted for LP gas,
1” OPENING -\
TOP AND
BOTTOM
Test each top burner one at a time by setting knob to “light”
position. This is done by pushing in on knob and turning knob to left or counterclockwise. Repeat at least
four times.
A clicking sound should be heard as soon as the knob is turned to “light” position. If it is not present, turn
burner “off” and make sure that power is being supplied to unit. Check to see that service cord is firmly in
place in receptacle or for a blown fuse or tripped circuit breaker.
If these are not at fault, remove knobs and handles, four (4) screws from control panel to check connec-
tions at valve switches. Remove left rear drip pan, burner, and remove module cover to check connections
at spark module. Make sure that solid gt-ound connection is made from spark module,
The broiler- burner ignition is checked in the same manner as the top burner, Since it must be done with the
griddle level with the cooktop, ignition is observed through the right hand opening between the griddle and
the cooktop. If ignition does not take place, remove drip pan in right rear burner and reduce air shutter
opening.
After all burners have been individually checked, reattach top, if it has been removed, and put drip pans in
place, Recheck top burner ignition and make initial flame adjustment one burner at a time. If flames lift
from burner, reduce air shutter opening; if flames, are yellow, increase operling, until 3/8” soft blue inner
cone is present. Check ignition on each burner at least four (4) times.
If burner fails to light and ignitor is clicking, turn gas “off”, remove
drip pan and recheck flash tube alignment. A visual check should be
made to make sure that the ignitor is producing a spark. If spark is
not present, recheck connections. Should failure continue after these
checks, reduce air shutter opening. Replace drip pan and check
ignition again. (Try at least 4 times.)
Now proceed to check ignition on both front and back burners at
one time. Sometimes the air shutter opening must be adjusted to get proper ignition when the other burner
is burning. Repeat check four (4) times on each side as before.
LOW FLAME ADJUSTMENT
Top Burners
Low flame adjustment IS made by lighting burner, turning knob to “low” and removing knob, Hold base of
valve stem with pliers and insert narrow (3/16”) standard blade screwdriver in adjustment screw slot
(located in center of valve stem). Turn screw until flame is l/8” long, Replace knob.
“Lo” SETTING VALVE AIR SHUTI’J3R
ADJUSTMENT SCREW AIR SHIJTTER SCREW
MANIFOLD
BURNER VALVE 2 NEEDIE

L:yht burner, then iurn left handle to raise gl-ill until slots in burner heat shield are seen. Turn burner to
“low” and remove iknob. Hold base of valve stem with pliers, insert narrow (3/16”) standard blade screw-
dr 1ve: inlo adjustment screw slot, Looking through the slots in the heat shield, adjust until flame with
7, 16’ soft blue innFIr corle is reached.
li16”
SOFT BLUE
INNER CORE
BHOILER/‘GRIDDL.E ADJUSTMENT
The Brolleritirlddle has been properly adjusted at the factory. Should it be out of adjustment at time of
installation as a resL)t of vibration or handling during shipping, correct as shown below.
1 Btoller Handle ~- Correct position tor handle on left (facing cooktop) is straight up and down. Before
making any adjustments, make sure that set screw in handle is tight. Removal of the top, both burners
ano the burner support on the left side is suggested for the easiest access to the adjustment hardware.
The hand!e is adjusted loosening the nuts holding the connecting bar to the griddle lift spring casting.
iJ;ing a 7/“16” ooeln end wrench, loosen front nut to lower handle, the rear nut to raise. Tighten both
r:l-!tb to lock after handle is properly positioned.
2. Griddle Not Prcperly Counter Balanced To Keep In Set Position - Broiler lift spring is designed to
balance the weight of the griddle, burner and heat shield. Once again the removal of the top and left-
hand parts is suggested. Hold hook bolt firm with pliers or screwdriver. Use a 3/8” open wrench to
tighten or ioosery nut to obtain desired spring tension to hold griddle in place as it is moved,
-;,
-. Broi!er Pan ~- TLlis should be level (both front to back and right to left) or parallel with the top surface
when pan IS in i:s highest position. This situation is corrected by loosening the lock nuts on the front
sling adjustment hook which is connected to the sling link assembly. The sling link assembly connects
rhe front and rear siing links to provide for the raising or lowering of the broiler pan. The broiler pan
should slope towards the front when broiling to allow the grease to run into the cup of the pan. This
adiustrnent may ;Je lnade through the right front burner opening.
!‘I. GriddIE - Tne f,ont of the griddle should rest on the front flange of the griddle opening in the top and
on the :op of four (4) screws in the heat shield when in the cooking position. The griddle may be
leveled by raisinG or lowering the four screws.
7-o c(3rrect a!ignrnent of the griddle, so that the right and left spacing is equal and parallel to the edges
of the too openiiig, loosen screws on the broiler burner neck and shift burner to correct.
-7-

SCHEMATIC WIRING DIAGRAM
THE POWER CORD ON THIS APPLIANCE IS EQUIPPED WITH A
THREE PRONGED (GROUNDING) PLUG WHICH MATES WITH STANDARD
THREE PRONGED (GROUNDING) WALL RECEPTACLES.
NEUTRAL
5116” WIDE BLADE
PLUG
*------\
114” WIDE BLADE
ROUND BLADE
RIBBED SIDE OF
SERVICE CORD CONNECTOR
,250 TERMINALS
‘4-h
+ SWITCH ON VALVES
ELECTRIC CIRCUIT CLOSED
+r- WHEN VALVE KNOB IS
ROTATED 142’TO 160’
e-0 COUNTER CLOCKWISE
FROM OFF.
SPARK IGNITOR LEADS
.llO TERMINAL
WITH HEAT SHRINK
INSULATION
120 VAC 60 Hertz 1 Amp. Max.
SWITCH LEADS
.llOTERMINAL
WITH HEAT SHRINK
INSULATION
The cord power lead (l/4” wide blade of the plug) is attached to the connector and to the switches. The
other lead from the switches connects to “L” connection on the spark module. The “N” connection on the
module is connected to the cord neutral lead (5/16” wide blade of the plug). The ignitors are connected to
the markings on the module and the ignitors are secured to brackets at the flash tubes.
Specifications Subject to Change Without Notice
FORM 4177886 (15962)
PRINTED IN U.S.A.