KitchenAid Commercial Mixer Instruction Manual

SERVICE MANUAL for KITCHENAID STAND MIXER Models K45SS KSM75 KSM90 KSM103 KSM110 KSM150 KSM151 K5SS KSM5 KSM50P KSMC50 KPM5 KPM50 KP50P Printed in U.S.A. September, 2005 LIT4177310-C

KITCHENAID Stand Mixer Service Manual Lit4177310-C 2005 KITCHENAID Safety Guidelines This Service Manual is written for the Professional Service Technician who has familiarity with the KitchenAid Stand Mixer. The following Safety Guidelines should be adhered to when servicing this product. SERVICE ENVIRONMENT •The workplace will be dry and sanitary at all times and all units should be inspected for cleanliness before any work is started. •Visually inspect the unit requiring service in a well luminated area. •A mild, non-abrasive dishwashing soap solution and clean towel can be used to wash any unit requiring attention. •The hands of the service technician should be clean at all times during service procedure. ELECTRICAL CONSIDERATIONS •The workplace for the stand mixer will have properly grounded AC outlets that adhere to all Local Electrical Codes that are applicable at the time of repair. •The Stand Mixer Power Cord should always be inspected first before testing the mixer operation. Do NOT run the mixer if the Power Cord is damaged -- replace it. •All disassembly and assembly procedures discussed in this manual should be conducted with the unit disconnected from the AC mains. •Do NOT leave the unit unattended while running the mixer for speed range and bowl clearance checks. Always unplug the unit immediately after concluding these tests. Technician •The Service Technician should wear Protective Eyewear at all times when conducting a repair on the Stand Mixer. •Loose fitting sweaters, shirts sleeves or bracelets should NOT be worn while servicing the Stand Mixer. SAFETY

KITCHENAID Stand Mixer Service Manual Lit4177310-C 2005 KITCHENAID INDEX: Stand Mixer Repair Manual K45SS KSM75 KSM90 KSM103 KSM110 KSM150 KSM151 K5SS KSM5 KSM50P KSMC50 KPM5 KPM50 KP50P SECTION SUBJECT PAGE - General Information 1 1 Disassembly of Gearcase and Planetary 2 2 Disassembly of Motor and Control Unit 6 3 Repairs to Motor and Control Unit 11 4 Repairs to Gearcase and Planetary 16 5 Repairs to Pedestal 21 6 Adjustment to Control Unit 22 7 Repairs to Bowl Lift Assembly 26 8 Troubleshooting the Bowl Lift Assembly 30 APPENDIX SUBJECT A Tools Required for Stand Mixer Service B Problem Solving Quick Reference Guide C Domestic Model Wiring Diagram D International Model Wiring Diagram - RF Filter E International Model Wiring Diagram - Bowl Interlock RF Filter F Stand Mixer Serial Number Codes Introduction All KitchenAid Stand Mixers are well designed and carefully built. Normally they will give continual use year after year without service attention. Careful records have been maintained over a period of years to determine and correct, through improved design, any troubles that might possibly develop. An effort has been made in preparation of this manual to cover them all. INDEX

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid Heating Under normal conditions, the mixer will not show any tendency to heat because of the built-in ventilating system in the motor. Under heavy loads with extended mixing time periods, the head may heat up to the point of being uncomfortable to touch. Speed Control The speed control of the mixer is attained through the use of a governor assembly mounted at the rear of the control plate assembly. The electrical circuit is made and broken by the action of the fly ball governor revolving against the control plate. When the switch lever is moved to an ON position, the position of the control plate with respect to the governor is changed by the action of the switch lever. Thus, when the control plate is set close to the governor, a relatively low speed of the motor causes the governor to make or break the mixer’s electrical circuit through the control plate. When the control plate is set farther away, a greater motor speed is required before the governor starts breaking the circuit. The action of the governor is such that the speed of the motor will remain constant for a given setting of the control plate within certain loads. After certain loads have been exceeded, the speed of the motor will drop to meet the torque requirements of the given load. Speed is controlled by the governor and the control plate in conjunction with the phase control. TRIAC RMS VOLTAGE BOTH CONTACTS OPEN - 40 VOLTS ONE CONTACT OPEN - 80 VOLTS BOTH CONTACTS CLOSED - FULL VOLTAGE NOTE: The triac regulates the power the motor sees depending on control board contacts. A device called a triac is a part of the phase control circuit. This device determines the amount of power the motor sees dependent upon the condition of the control board contacts. If both contacts are open, about 40 volts RMS is applied to the motor and about 80 volts is applied when either contact is closed and the other is open. GENERAL INFORMATION Normal Performance The KitchenAid Stand Mixer is powered with a universal motor which will operate on 50 or 60 hertz, alternating current only. The Voltage of the power supply should be within 10 volts either way of the voltage stamped on the mixer trimband and nameplate. A mixer in good running condition will start turning slowly when the switch lever is moved from the “OFF” position to the “STIR” position. As the switch lever is moved to successively higher positions, the speed of the beater increases until the #10 speed is reached. At stir position, the planetary should turn at approximately 60 RPM; at the #10 position all models turn at approximately 255 RPM, with the exception of K45SS models built before May 6th, 2002 (WM19), which turn at approximately 280 RPM. KITCHENAID STAND MIXER RPM SPEED *K45SS OTHER MODELS STIR 60 RPM 60 RPM #10 255 RPM 255 RPM Prior to May 6th, 2002, #10 280 RPM *Note: All models have similar RPM, except K45SS units built before May 6 th , 2002, which run at 280 RPM in the #10 position. The mixer will run quietly in the lower speed range; however, some noise can be expected on the higher speed settings due to hum of gears and the motor. When the mixer is first turned to the stir position, there may be a slight clattering, irregular noise. This noise will disappear as the lubrication in the gearcase warms up. The switch lever should move freely with the “feel” of definite positions for speed numbers stir, 2, 4, 6, 8 and 10. Speed numbers 3, 5, 7 and 9 do not have definite notches. Power A mixer will have full power on all speed settings. To check for full power, carefully hold the planetary with one hand and move the switch lever on and off with the other hand. At the stir position, it should not be possible to stall the planetary except by a very great effort; nor should the planetary slow down noticeably when the retarding pressure is applied. PAGE 1

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid When both contacts are closed, the triac is full on; consequently, full power is applied to the motor. In this way, the speed is controlled. If the mixer motor begins to run too fast for a particular speed setting, one or both contacts open, which cuts back on the voltage the motor sees, thus slowing it up. If the motor operation becomes too slow, one or both contacts will close, applying the needed voltage to the motor to sufficiently increase motor speed. This is always accomplished through the triac. The control plate contacts control the triac, and in turn, controls the amount of power supplied to the motor. BEATER The beater should fit freely on the beater shaft located in the planetary. Power is transmitted from the motor to the center-bevel gear assembly by means of the worm gear. The center-bevel gear assembly engages the beater pinion, located in the planetary, to turn the beater shaft. The attachment hub bevel gear also meshes with the center-bevel gear assembly to transmit power when various attachments are being used. LUBRICATION Under normal service conditions, the mixer will not require lubrication for many years. The gear case is lubricated with an ample supply of Benalene 930-2 grease (6 fluid ounces), which lubricates all the gears and shafts. GEARCASE LUBRICATION All KitchenAid Stand Mixer Gearcases are lubricated with 6 Fluid Ounces of: BENALENE 930-2 GREASE (OR EQUIVALENT) NOTE: Gearcases lubricated with this grease will not require lubrication for years. The motor bearing and the beater shaft bearing are oil impregnated. The rear motor bearing has a felt washer which has been presoaked in oil. The front motor bearing in the mixer housing is a ball bearing. SECTION 1 DISASSEMBLY OF THE GEARCASE AND PLANETARY A. All solid state KitchenAid mixers have the same motor and control parts and the gears in the gearcase are alike, with one exception: “K45SS units built prior to May 6th, 2002.” Planetary parts are all the same, except that some early production K5SS had a lead weight. Gearing and motor instructions are for both tilt head and bowl lift machines and any differences will be pointed out. BOWL LIFT - Models K5SS,KSM5,KSM50, KSMC50,KPM5, KPM50, KP50. The bowl is raised and lowered into position. TILT HEAD - Models K45SS, KSM45, KSM75, KSM90, KSM103, KSM110, KSM150, KSM151, KSM152. The mixer head is tilted up and down into position. Bowl, column, base and bowl lift details are covered separately in section 7. B. Before repairs are attempted on any KitchenAid mixer, a wattmeter test should be made. To make the test, set the wattmeter to the proper voltage. Next, plug the cord from the mixer into the wattmeter. Turn on the current and run the mixer. If the wattmeter shows up to 135 watts, going from stir to #10 speed, the mixer is in good condition. If the wattmeter reading is 175 to 400 watts, there is a problem. High wattage mixer readings indicate either electrical or mechanical problems. Check first for bearing/gear drag, then for motor/brush problems. CAUTION: Always remove power cord from electrical outlet before servicing any part of the mixer. PAGE 2 KitchenAid stand mixer shown with a digital wattmeter

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid C. Note: remove the bowl and any attachments before disassembly of unit. Remove the #6-32x3/8” (tapered head) screw from the end cover (Fig. 1). Remove the two #6-32x3/16” screws that hold the trimband to the gearcase-motor housing (Fig. 2). With the screws removed, take the trimband off and set aside. D. To save the paint, lay the unit in a padded cradle or on a cloth pad. To remove the pedestal from the gearcase-bottom cover, turn the unit upside down in a padded cradle. Loosen the set screw with a screwdriver (Fig. 3) Using a drift punch and hammer, drive out the hinge pin (Fig. 4) and lift the pedestal off the gearcase-bottom cover. E. To remove the planetary, first remove the drip ring . Use a screwdriver on the upper edge of the drip ring and gently tap the screwdriver to remove the drip ring (Fig. 5). PAGE 3 FIG # 1 Fig. 1 The end cover is removed by removing the tapered head endcover screw. Fig. 2 The trimband can be removed after removing the trimband screws. Fig. 3 Loosen the hinge pin setscrew to remove the pedestal from the bottomcover. Fig. 4 A drift punch and hammer is used to drive out the hinge pin.

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid Fig. 5 The Drip Cup fits tightly and must be started off by tapping it. With a 5/32” drift punch, remove the groove pin that holds the planetary to the vertical center shaft (Fig. 6). With the pin out, the planetary can be removed from the center shaft. Using two (2) screwdrivers, pry the planetary up and off the shaft (Fig. 7). F. Remove the power cord from the bottom cover by sliding the molded strain relief out of the slot in the bottom cover (Fig. 8). To remove the power cord with the Heyco strain relief used on older models, use a pair of pliers to squeeze the strain relief while pulling up (Fig. 9). Reverse this procedure to reinstall it. G. To remove the bottom cover from the gearcase- motor housing, unscrew the five (5) #10-24 special screws (Fig. 10). These screws hold the internal gear into the bottom cover. Next remove the four (4) filister head screws from the bottom cover (Fig. 11). Page 4 Fig. 6 Removal of the groove pin that holds the planetary to the vertical center shaft Fig. 7 Use two screwdrivers to pry the planetary off the shaft. Fig. 8 Pull back on the molded strain relief to remove the power cord from the slot in the bottom cover. Fig. 9 Removal of Heyco strain relief using pliers.

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid Fig. 11 The bottom cover is removed after removing the four #10-24 filister head screws. To remove the bottom cover from the gearcase- motor housing, insert a drift punch through the hole in the center shaft and lift, while using a screwdriver to break the bottom cover loose. Use the slots in the side of the gearcase to do this (Fig. 12). Do NOT pry in the area of the transmission gasket, as this may prevent the gasket from sealing properly upon reassembly. The transmission gears will come out with the bottom cover. Be careful not to allow any grease to fall into the motor area of the housing. Fig. 12 While lifting up on the center shaft, use a screw driver to gently pry the bottom cover from the housing. H. Remove the attachment hub bevel gear from the gearcase-motor housing. This gear is removed by simply pulling it out of the attachment hub (Fig. 13). The gear will clear the worm of the motor’s armature shaft and should be easy to remove. Note: For clarity, the pictures in this manual have no grease shown in the gearcase. Normally the gearcase has 6 oz. of grease surrounding the gears. I. Clean out the gearcase and remove as much of the grease as possible. The gearcase may be thoroughly cleaned when the motor has been removed. Fig. 10 Removal of the 5 special screws holding the internal gear in the bottom cover. Page 5 Fig. 13 The attachment hub bevel gear being removed from the mixer attachment hub bearing.

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid SECTION 2 DISASSEMBLY OF STAND MIXER MOTOR AND CONTROL UNIT A. Start the disassembly of the control unit by removing the cord flag terminals from the control board and the ground wire from the bearing bracket (Fig. 14). Remove the motor stator flag terminals from the control board ( Fig. 15). Note: All service operations discussed here should be performed with the mixer disconnected from the A. C. mains. Remove the end seal and disconnect the phase control flag terminals from the control board (Fig. 16). Unhook the control board spring at the bottom of the control board (Fig. 17). Unlock the two lock nuts on the control board a unscrew the two adjusting screws. The mixer control board can now be removed a set aside for later evaluation (Fig. 18 ). Fig. 14 Removal of the cord flag terminals and cord ground wire. nd nd Fig. 15 The removal of the motor stator flag terminals from the control board. Fig. 16 After removing the end seal, remove the phase control flag terminals. Fig. 17 Unhook the control board spring. Page 6

KITCHENAID Stand Mixer Service Manual LIT4177310-C 2005 KitchenAid B. The phase control can now be disassembled from the bearing bracket, if necessary, by unscrewing the #4-40 x 1/4” pan head screw (Figs. 19 & 20). C. With a pair of needle nose pliers, carefully pry off the governor assembly. (Fig. 21) Do NOT bend. Remove the governor drive pin and lay it aside so it will not be lost (Fig. 22). Fig. 18 Mixer housing with end seal and control board removed. Fig. 19 Removal of the phase control (Triac) from the bearing bracket. Fig. 20 Phase control or (triac) shown removed in lower center. Fig. 21 Needle nose plier used to pry governor off the motor shaft. Fig. 22 Governor shown removed from the shaft of the motor. Page 7

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KitchenAid Commercial Mixer Instruction Manual

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