After using our first kitchenaid for a while to make some breads and pizza dough, we found that it was unable to hold up under the larger batches we wanted to make. So Erin got me a professional 600 series Kitchenaid series. We figured that since it was bigger with a more powerful motor that it would be able to stand up to some of the bigger or tougher doughs.
Well, one day I was making a batch of pizza dough which uses 7 cups of flour. It’s enough to choke the old mixer, but I’ve made it several times before and hadn’t had problems. This time, the motor started choking on the dough after it had been mixing for a few minutes. It slowed down and just would not move anymore. I removed the dough and tried again…it wouldn’t move even with no load.
I figured that the temperature protection switch had flipped and it would just start working again in a bit, so I waited another hour and tried again. Still nothing. Well, I’d already finished the pizza dough, so I put the mixer away to work on another day.
I pulled the top of the mixer off. I found that I was unable to move the rotor, so I figured the gears may have been messed up. I pulled out the four screws from the gearbox and pulled the top off.
All of the gears looked fine. When I later pulled the motor out, I found that I could move all of the gears smoothly. It turned out that the motor wasn’t turning at all. Something inside it appeared to have fused or otherwise started binding.
After doing some electrical testing to make sure that the motor didn’t appear to have any shorts or opens, I decided to pull the motor out. I labeled the four wires that wrap around the motor and connect to the control board. Two of the wires come from the plug, and two connect to the motor. I unscrewed the motor and pulled it out. The gearbox needs to be open to remove the motor.
After removing the motor, I found that I was unable to turn the motor shaft, even with pliers. Looking into the motor, I couldn’t see anything wrong. The bearings also looked ok from the outside. So I kept digging. The motor has a bridge piece that braces the shaft right as it enters the gearbox. That piece can be unscrewed on either side, but doesn’t immediately come off. In order to get further into the motor, I had to remove the fan from the back end of the motor and hammer the shaft from the back. Using a screw driver and rubber mallet, I hammered the rotor out of the motor.
It was being difficult to get out, even after I freed the shaft from the rear bearing. It became obvious after a little inspection what the problem was. Some of the insulation from the rotor had actually melted and flowed out of the rotor and solidified on the outside of the rotor. This melted insulation caused the binding between the rotor and stator.
Between a flat-head screwdriver and a piece of sandpaper, I was able to remove most of the melted insulation. The rotor fits very tightly into the motor, so any amount of melted insulation can be a problem.
When reassembling the motor, the brushes were a bit of a pain to get out of the way. I used Erin’s help to pin them back with some screw drivers pushed through the back end of the motor. There’s probably a much easier way to do it, maybe using paperclips bent properly, but this worked.
I reassembled the mixer and it worked at all speeds. I have yet to make more dough, but I’m hoping that it will continue to work under a load. I guess that the moral of this story is that your kitchenaid may not trip the heat protection switch early enough. If you are making multiple batches of dough, give the mixer a break. Even though it is labeled as professional grade, that doesn’t mean it can be run like a professional might run it. If the mixer is having trouble turning to the point that the dough hook stops for more than a moment or two, it is at risk of melting insulation.
Skype was actually useful for this, Doug was able to see the problem and together we were able to figure out how to get everything apart.
Hopefully this helps someone. There is very little information out there for the professional kitchenaid series. Maybe someone else can also revive their mixer instead of converting it to a paperweight.