Whirlpool GLS3064RS User manual

CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
JOB AID
KR-37
Part No. 8178526
30˝& 36˝FLUSH-MOUNT
GAS COOKTOPS
Model GLS3064R S
Model GLS3665R S

- ii -
WHIRLPOOL CORPORATION assumes no responsibility for any repairs
made on our products by anyone other than Authorized Service Technicians.
FORWARD
This Whirlpool Job Aid, “30˝& 36˝Flush-Mount Gas Cooktops” (Part No. 8178526), provides
the technician with information on the installation and service of the 30˝& 36˝Flush-Mount
Gas Cooktops. For specific information on the model being serviced, refer to the “Use and Care
Guide” provided with the 30˝& 36˝Flush-Mount Gas Cooktops.
The Wiring Diagrams used in this Job Aid are typical and should be used for training purposes
only. Always use the Wiring Diagram supplied with the product when servicing the unit.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide information that will enable the service technician to prop-
erly diagnose malfunctions and repair the 30˝& 36˝Flush-Mount Gas Cooktops.
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 cooktop to its proper operational status.
•
•
•
•
Copyright © 2005, Whirlpool Corporation, Benton Harbor, MI 49022

- iii -
TABLE OF CONTENTS
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Whirlpool Model & Serial Number Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Model & Serial Number Label Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Whirlpool Gas Cooktop Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
INSTALLATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
L.P Gas Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
COMPONENT ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removing The Burners And Cooktop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removing A Burner Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing An Ignition Switch And Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing An Ignitor And A Spark Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removing The Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

- iv -
— NOTES —

1-1
GENERAL
SAFETY FIRST
Your safety and the safety of others is very important.
We have provided many important safety messages in this Job Aid and on the appliance.
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 follow the safety alert symbol and either the word
“DANGER” or “WARNING.” These words mean:
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance
of injury, and tell you what can happen if the instructions are not followed.
You can be killed or seriously injured if you don’t
immediately follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
DANGER
WARNING

1-2
WHIRLPOOL MODEL & SERIAL NUMBER DESIGNATIONS
MODEL NUMBER
SERIAL NUMBER
SERIAL NUMBER XD S 32 02111
DIVISION RESPONSIBILITY
XD = OXFORD / CNP INDUSTRIES
YEAR OF PRODUCTION
S = 2005
WEEK OF PRODUCTION
32ND WEEK
PRODUCT SEQUENCE NUMBER
MODEL NUMBER G L S 30 64 R S 0
PRODUCT GROUP
R = ELECTRIC COOKING PRODUCTS
S = GAS COOKING PRODUCTS
G = WHIRLPOOL GOLD
PRODUCT IDENTIFICATION
C = BUILT-IN COOKTOP
J = GOLD ELECTRIC COOKTOP
L = GOLD GAS COOKTOP
CONFIGURATION
S = PORCELAIN / STEEL TOP
T = TEMPERED GLASS TOP (GAS ONLY)
C = CERAMIC GLASS TOP
M = MODULAR DOWNDRAFT
MODEL SIZE
20 = 20˝
30 = 30˝
36 = 36˝
FEATURE VARIATIONS
0 = LOW SPEED COIL ELECTRIC / OPEN
LOW END BURNER GAS / OPEN BAYS
1 = HIGH SPEED COIL ELECTRIC / SEALED BURNERS
2 = CERAMIC RADIANT ELECTRIC
3 = CERAMIC RADIANT / DUAL
4 = MODULAR
6 = FLUSH MOUNT
0 = NO ELEMENTS / BURNERS
2 = TWO ELEMENT / BURNER
4 = FOUR ELEMENT / BURNER
5 = FIVE ELEMENT / BURNER
YEAR OF INTRODUCTION
R = 2005
COLOR CODE
S = STAINLESS STEEL
ENGINEERING CHANGE (0, 1, 2, ETC.)

1-3
MODEL & SERIAL NUMBER LABEL LOCATION
The Model/Serial Number label location is shown below.
Model/Serial Number Label

1-4
SPECIFICATIONS
Model Number GLS3064R S GLS3665R S
Model Description Steel cooktop Steel cooktop
Size-Configuration 30" 36"
Dimensions/Specifications
Overall Width (in) 30" 36"
Overall Depth (in) 20 1/8" 20 1/8"
Cutout Width (in) 29 3/8" 35 3/8"
Cutout Depth (in) 19 1/2" 19 1/2"
Ratings
Electric 120 Volts/60Hz 120 Volts/60Hz
Circuit Amps 15 AMP 15 AMP
Exterior
Cooktop Burners Stainless Stainless
Control Type Knob Metal Metal
Simmer Switch No No
Hot Surface Indicator No No
Cooktop Burners
Burner Configuration 2 front, 2 rear 2 front, 3 rear
Gas Burner Type Sealed Sealed
Gas R Front Output (BTU)(Nat/LP) 9,000 9,000
Gas L Front Output (BTU)(Nat/LP) 15,000 12,000
Gas R Rear Output (BTU)(Nat/LP) 12,000 12,000
Gas L Rear Output (BTU)(Nat/LP) 9,000 9,000
Gas Center Rear Output (BTU)(Nat/LP) N/A 15,000
Gas Ignition Electronic Electronic
Gas Auto Reignition Yes Yes
Gas Valves Degrees 210 210
LP Conversion Kit Included Kit Included
Miscellaneous
Installation Instructions 9761893 9761893
Use & Care Guide 9761890 9761890
Wiring Diagram In installation
instructions In installation instructions
Agency Approvals UL, CUL UL, CUL
Approved to Install Over BI Oven No No
Hardware Included Yes Yes
Residential Use Only Yes Yes
Warranty Yes Yes
Full 12 months 12 months
Extended 5 Yr. limited
(burners) 5 Yr. limited (burners)

1-5
WHIRLPOOL GAS COOKTOP WARRANTY
FULL ONE-YEAR WARRANTY
For one year from the date of purchase, when this appliance is operated and maintained according
to instructions attached to or furnished with the product, Whirlpool Corporation will pay for FSP®
replacement parts and repair labor to correct defects in materials or workmanship. Service must
be provided by a Whirlpool designated service company.
FIVE-YEAR LIMITED WARRANTY
On cooktop burners, in the second through fifth years from the date of purchase, when this ap-
pliance is operated and maintained according to instructions attached to or furnished with the
product, Whirlpool Corporation will pay for FSP®replacement parts for any gas burner to correct
defects in materials or workmanship. Service must be provided by a Whirlpool designated service
company.
Whirlpool Corporation will not pay for:
1. Service calls to correct the installation of your appliance, to instruct you how to use your ap-
pliance, to replace house fuses or correct house wiring, or to replace owner-accessible light
bulbs.
2. Repairs when your appliance is used in other than normal, single-family household use.
3. Pickup and delivery. Your appliance is designed to be repaired in the home.
4. Damage resulting from accident, alteration, misuse, abuse, fire, flood, improper installation,
acts of God or use of products not approved by Whirlpool Corporation or Whirlpool Canada
Inc.
5. Repairs to parts or systems resulting from unauthorized modifications made to the appli-
ance.
6. Replacement parts or repair labor costs for units operated outside the United States or
Canada.
7. In Canada, travel or transportation expenses for customers who reside in remote areas.
8. Any labor costs during limited warranty.
WHIRLPOOL CORPORATION AND WHIRLPOOL CANADA SHALL NOT
BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Some states or provinces do not allow the exclusion or limitation of incidental or consequential
damages, so this exclusion or limitation may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which may vary from state to state or province
to province.
Outside the 50 United States and Canada, this warranty does not apply. Contact your au-
thorized Whirlpool dealer to determine if another warranty applies.
If you need service, first see the “Troubleshooting” section of the Use and Care Guide. After
checking “Troubleshooting,” additional help can be found by checking the “Assistance or Service”
section or by calling the Whirlpool Customer Interaction Center, 1-800-253-1301 (toll-free), from
anywhere in the U.S.A. For parts and service in Canada, please call 1-800-807-6777. For product
related questions in Canada, please call 1-800-461-5681.

1-6
— NOTES —

2-1
INSTALLATION INFORMATION
L.P. GAS CONVERSION
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
NOTE: Gas conversion from natural to L.P.
gas must be done by a qualified installer.
To convert the cooktop for use with L.P. gas,
perform the following steps.
1. Unplug cooktop or disconnect power.
2. Turn off gas supply to cooktop.
3. Use a screwdriver and remove the ac-
cess cap on the gas distribution valve.
Access Cap
Gas Distribution
Valve
4. Turn the access cap over so that the let-
ters L.P. are facing up, and then reinstall
the cap on the valve.
NAT Position L.P. Position
5. To convert the cooktop burners for
use with L.P. gas:
a) Remove the grates and burner caps.
Grates
Burner Cap (4)
b) Remove the two screws from the burn-
ers and remove the burners from the
cooktop.
Burners
Burner Screws
(30˝Cooktop Shown)

2-2
d) Use a 7 mm socket wrench and remove
the orifices from the burner bases.
NOTE: Place a small piece of masking
tape along the inside edge of the socket
to help hold each orifice in the driver.
c) Open the L.P. Conversion pack and
remove the contents.
NOTE: Each burner, and its associated gas
valve, has a plastic bag containing an L.P.
gas orifice and a bypass jet pin. The bags
are marked with the burner/valve B.T.U. rat-
ing. Match the B.T.U. rating on the bag with
the burner and valve locations (shown in the
drawings at the bottom right column) for the
cooktop you are converting. Do not open the
bags until you are ready to use them.
Orifice Bags (36˝Model)
Bypass Jet Pin
(Gas Valve)
L.P. Orifice
(Burner)
1
2
3
4
1
4
3
2
9,000 BTU
12,000 BTU
15,000 BTU
9,000 BTU
1
5
3
4
12,000 BTU
9,000 BTU
9,000 BTU
1
22345
12,000 BTU
15,000 BTU
30˝Model Cooktop
36˝Model Cooktop
e) Install the L.P. orifices in their appro-
priate burner bases (be careful not to
crossthread or overtighten the orifices).
Burner Orifice
IMPORTANT: Once removed, place the natu-
ral gas orifice on top of the appropriate orifice
bag. After the L.P. orifice from the bag is in-
stalled, place the natural gas orifice in the bag
for reuse if the cooktop is ever converted back
to natural gas. Also do this for the bypass jet
pins in step 6. Be careful not to interchange
the natural and L.P. gas orifices and pins.
f) Reinstall the burners on the cooktop.
g) Replace the burner caps on the burn-
ers.

2-3
7. To check the burner operation:
a) Turn on the power and gas supply to
the cooktop.
b) Light a burner, and quickly turn the gas
valve from low to high, and then back
to low. Both the high and low flames
should be on steady and not go out.
If the flame should go out at the high
or low setting, it should automatically
reignite.
c) Repeat the previous step for the re-
maining burners.
d) Reinstall the cooktop grates.
6. To convert the gas valves for use with
L.P. gas:
a) Remove the control knobs from the
gas valves.
b) Reach inside the control panel open-
ings with your fingers, and slide
the rubber guards off the gas valve
stems.
c) Using a small screwdriver, unscrew
and remove the bypass jet pins from
the gas valves.
d) Install the L.P. bypass jet pins in the
gas valves until they are just snug. Do
not overtighten the pins.
Bypass Jet Pin
e) Reinstall the control knobs on the gas
valves.
f) Remove the backing from the L.P. con-
version sticker, and press the sticker
onto the bottom of the cooktop chassis
near the model/serial number label.

2-4
— NOTES —

3-1
COMPONENT LOCATIONS
This section instructs you on how to service each component inside the 30˝& 36˝flush-mount
gas cooktops. The components and their locations are shown below.
COMPONENT ACCESS
Ignitor
Spark Modules
Gas Valves &
Ignition Switches
Burner Base
Cooktop
Cooktop Chassis
Power Supply Cord
30˝Model Cooktop
36˝Model Cooktop
Spark Modules
Burner Base
Cooktop Chassis
Ignitor
Gas Valves &
Ignition Switches
Power Supply Cord
Cooktop

3-2
REMOVING THE BURNERS AND COOKTOP
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
1. Unplug cooktop or disconnect power.
2. Turn off gas supply to cooktop.
3. Lift the burner grates off the cooktop.
4. Lift the burner caps off the burners.
5. Pull the control knobs off the gas valve
stems.
6. Remove the two screws from each of the
burners and remove the burners from the
cooktop.
7. Remove the eight screws from the cook-
top.
8. Remove the screws from the side of the
control panel, and lift the control panel off
the cooktop chassis.
Grates
Burner Cap (4) Control Knobs (4)
Burners
Burner Screws
4 Control Panel Screws
8 Cooktop Screws
Control Panel
WARNING
(30˝Model Cooktop Shown)

3-3
9. Lift the cooktop off the cooktop chassis,
disconnect the wires from the ignitor ter-
minals, and remove the cooktop.
Ignitors
REASSEMBLY NOTE: Since each of the
burner ignitors for the 30˝and 36˝cooktops
has its own spark module, make sure that you
connect each of the module output wires to its
corresponding ignitor.
RF
RR
4 Spark
Module
Output
Wires To
Ignitors
RF
LF
LR
RR
Spark Modules
LF
LR
C
5 Spark
Module
Output
Wires To
Ignitors
LR
LF
C
RF
RR
LF
LR
RR
RF

3-4
REMOVING A BURNER BASE
1. Unplug cooktop or disconnect power.
2. Turn off gas supply to cooktop.
3. Remove the cooktop from the unit (see page
3-2 for the procedure).
Burner Bases
4. Remove the 9/16˝gas line nut from the
burner base.
5. Remove the two screws from the burn-
er base and remove the base from the
cooktop chassis.
6. Remove the orifice from the burner base
using a 7 mm socket, and install the ori-
fice in the new burner base. Do not over-
tighten the orifice when you install it.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
Burner
Orifice
9/16˝Gas
Line Nut
Burner
Base
Screws
IMPORTANT: Refer to the “Reassembly Note”
on page 3-3.
(36˝Model Cooktop)
(30˝Model Cooktop)

3-5
REMOVING AN IGNITION SWITCH AND GAS VALVE
1. Unplug cooktop or disconnect power.
2. Turn off gas supply to cooktop.
3. Remove the grates and pull the control
knobs off the gas valve stems.
4. Remove the screws from the control pan-
el, then lift and remove the control panel
from the unit.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
5. Lift the rubber guard off the gas valve you
are servicing.
6. To remove an ignition switch:
a) Disconnect the two wire connectors
from the switch terminals.
b) Unclip the e-ring from the gas valve
shaft.
c) Pull the switch straight up and off the
gas valve.
7. To remove a gas valve:
a) Remove the ignition switch (see step 6).
b) Remove the 9/16˝gas line nut from
the valve.
c) Remove the 5/16˝hex-head screw
from the valve clamp and remove the
clamp.
d) Remove the gas valve from the manifold.
Rubber
Guard
e-Ring
Wires
Ignition
Switch
9/16˝Gas
Line Nut
5/16˝Clamp Screw
4 Screws
Control Panel
Knobs

3-6
REMOVING AN IGNITOR AND A SPARK MODULE
1. Unplug cooktop or disconnect power.
2. Turn off gas supply to cooktop.
3. To remove an ignitor:
a) Remove the cooktop from the unit (see
page 3-2 for the procedure).
Spark Modules
Ignitor
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
b) Disconnect the wire from the ignitor
terminal (if not already done).
c) Unclip the e-ring and remove the ig-
nitor from the cooktop.
Ignitor e-Ring
Ignitor Wire
4. To remove a spark module:
a) Remove the grates and pull the con-
trol knobs off the gas valve stems.
b) Remove the screws from the control
panel, then lift and remove the control
panel from the unit.
4 Screws
Control Panel
Knobs