Maytag 16010107 User Manual

Maytag Gemini™

Range

Service Manual

16010107

Issued 10/00

INTRODUCTION

The manual is printed in a loose format and is divided into sections relating to a general group of components and/or service procedures. Each section is further subdivided to describe a particular component or service procedure.

The subdividing of the subject matter, plus the loose leaf form, will facilitate the updating of the manual as new revised components are added or new models are introduced.

Each page of the manual will be identified in the lower, left and right-hand corners, and as new or revised pages are published, the manual can easily be updated by following the filing instructions on the cover letter of the supplement.

This service manual is a valuable tool and care should be taken to keep it up-to-date by promptly and proper filing of subsequent pages as they are used.

MODELS COVERED IN THIS MANUAL:

MER6770AAW

MER6770AAB MER6770AAC

16010107 Introduction

CONTENTS

INTRODUCTION............................................................................................................................... i

CONTENTS..................................................................................................................................... iii

SECTION 1. GENERAL INFORMATION .................................................................................... 1-1

SECTION 2. ELECTRICAL COMPONENTS & TESTING........................................................... 2-1

SECTION 3. COMPONENT ACCESS .........................................................................................3-1

EXPLODED VIEW ......................................................................................................................3-1

MAIN TOP ..................................................................................................................................3-2

ELEMENTS................................................................................................................................. 3-2

Ceran Element ......................................................................................................................3-2

Bake Element ........................................................................................................................3-3

Broil Element ........................................................................................................................ 3-3

Oven Sensor ......................................................................................................................... 3-3

Oven Cavity Components (Electric) ...................................................................................3-4

Convect Fan Motor and Blade (Electric) ............................................................................ 3-5

ELECTRONIC CLOCK AND OVEN CONTROL ......................................................................... 3-6

INFINITE SWITCH (Current Sensing) .......................................................................................3-6

Signal Lights ......................................................................................................................... 3-7

"Hot Surface" Light ...............................................................................................................3-7

Oven Light Replacement ..................................................................................................... 3-7

HI-LIMIT THERMOSTAT............................................................................................................ 3-8

OVEN DOOR(S).........................................................................................................................3-8

UPPER DOOR ............................................................................................................................ 3-9

LOWER DOOR ......................................................................................................................... 3-10

Lower Latch Assembly ...................................................................................................... 3-10

LOWER LATCH ASSEMBLY....................................................................................................3-11

Oven Door Hinge ...............................................................................................................3-11

LEVELING LEGS....................................................................................................................... 3-12

CONVENIENCE OUTLET (Canadian Models Only)...............................................................3-12

SPECIFICATIONS.....................................................................................................................3-12

OVEN RACKS .......................................................................................................................... 3-12

RACK POSITIONS ................................................................................................................... 3-13

HALF RACK ACCESSORY ...................................................................................................... 3-13

SECTION 4. ELECTRICAL ...........................................................................................................4-1

TOASTING CIRCUIT (Upper Oven Only) ................................................................................. 4-1

OVEN CIRCUITS ........................................................................................................................ 4-1

SURFACE ELEMENTS - CERAN ............................................................................................... 4-2

DUEL ELEMENT.........................................................................................................................4-2

PROBE, SENSOR / BOTH OVENS............................................................................................ 4-2

HOT SURF ACE LIGHTS............................................................................................................. 4-3

SURFACE INICATOR LIGHTS....................................................................................................4-3

TRANSFORMER, STEPDOWN (12V) .......................................................................................4-4

16010107 Contents

iii

SURFACE ELEMENT SWITCH ..................................................................................................4-4

DUAL ELEMENT SWITCH ......................................................................................................... 4-4

ELECTRICAL CONNECTIONS/VOLTAGE.................................................................................4-5

SECTION 5. TROUBLESHOOTING............................................................................................ 5-1

GEMINI DOUBLE OVEN CONTROLS....................................................................................... 5-1

FAULT CODES ...........................................................................................................................5-2

RELAY BOARD ..........................................................................................................................5-3

TROUBLESHOOTING GUIDE....................................................................................................5-4

PARTS LIST................................................................................................................................5-6

FAULT IDENTIFICATIONS SUMMARY.....................................................................................5-7

SECTION 6. WIRING DIAGRAMS .............................................................................................. 6-1

16010107 Contents

SECTION 1. GENERAL INFORMATION

Bake: There will be two separate bake keys,

one for each oven. When the upper oven is chosen there will be a rapid preheat activated which turns both elements on. If the lower oven is selected the elements will cycle at the normal rate. The normal rates for the bake functions in both ovens are: 6 seconds for the broil element, followed by 54 seconds for the bake element.

Broil: There will be two separate broil keys, one for each oven. The HI broil function controls the broil element at 100%, the LO broil is controlled at 80% on time of a 60 second duty cycle. HI broil will be maintained to reach a maximum temperature of 550ºF, LO boil will be maintained at a maximum of 450ºF.

Toasting: Available in upper oven only. Toasting has a maximum allowable time of 10 minutes and maximum temperature of 550ºF. Toasting is only available when the lower oven is not in use. If chosen during lower oven operation the display will scroll an information message regarding use.

Keep Warm: The keep warm function controls only the bake element and is available in the upper oven only. Allowable temperature range is 145 to 190ºF.

Clean: Only one oven is permitted to be cleaned at a time. Both ovens will lock during clean cycle. The clean cycle controls both the broil and the bake element, the broil element is on 100% for the first 40 minutes of the cycle followed by the bake element on 100% for the duration of the cycle. The bake element is cycled once the clean temperature of 865º is reached.

Motorized Door Lock: A 3 RPM motor is used on the door lock assemblies, with each assembly having a locked and unlocked switch. The motor will only run when a clean cycle is chosen and the door actuated switch is in the closed position.

16010107 Section 1. General Information

1-1

16010107 Section 1. General Information

1-2

SECTION 2. ELECTRICAL COMPONENTS & TESTING

ELECTRICAL TEST EQUIPMENT

The equipment required to service Maytag products depends largely upon the condition you encounter. Locating a malfunction will often require the use of electrical testing equipment such as:

Analog Test Meter

can be used to check for open or closed circuits, measure resistance, AC and DC volts, and temperature.

Descript ion Part Number

Analog Test Meter 20000005

Digital Watt /Amp/Volt/Ohm/

Temp erature Meter

20000019

Clamp-On Ammeter 20000002

AC Volt age Sensor 20000081

Clamp-On Ammeter

can be used to detect shorts. Overloads on the circuit breaker or fuse can be traced to either the dryer or circuit breaker by checking the dryer current draw.

AC Voltage Sensor Digital Watt/Amp/Volt/Ohm/Temperature Meter

Measures power (wattage), AC/DC volts, AC/ DC amps, temperature (C & F) OHMS resistance, continuity and capacitance. Features large LCD display w/backlight and analog bar graph to show tendencies. Includes: AC power adaptor for measuring wattage and meter leads.

16010107 Section 2. Electrical Components & Testing

will glow bright red, if voltage is between 110-600 volts AC.

proper safety precautions can

be observed. The tip of the sensor

can be used to alert you

if AC voltage is present so

2-1

16010107 Section 2. Electrical Components & Testing

2-2

SECTION 3. COMPONENT ACCESS

EXPLODED VIEW

16010107 Section 3. Component Description

3-1

As a general rule, the appliance should ALWAYS be disconnected from power source before servicing appliance or replacing component parts. Failure to disconnect the power increases the likelihood that a servicing error or mistake will result in serious or fatal injuries.

MAIN TOP

T o Raise Ceran Cooktop

2. Remove the two screws securing the main top to the frame.

3. Lift up slightly and slide the main top forward to access the wire harness. Disconnect the harness.

4. Lift the top off and lay aside securely with under side up.

5. Remove the screws securing element to main top.

When cool open the door and remove the two screws securing the cook top to the frame. Once the screws are removed raise cook top and slide forward slightly. With the cook top forward disconnect the wire harness and remove the cooktop.

ELEMENTS

Ceran Element Cooktop

Cooking areas are identified by patterns in the Ceran surface. The elements consist of coil(s) contained in the element housing. Power to the element (240 volts) is provided and controlled by an infinite switch. Each heating element is equipped with a temperature limiter, which prevents heat surges and ensures that the heating elements will not overheat. The element and temperature limiter is available as a complete unit or individual parts.

6. Disconnect wiring to element and replace element.

7. Reverse procedure to reinstall.

T o Remove Glass T op Assembly

1. Disconnect the appliance from power source before servicing.

2. Remove two (2) screws securing glass top to frame. The screws are located in the front left and right corners with the door open.

3. Grasp front edge of cooktop and slide out slightly. With the top moved forward disconnect the wiring harness.

4. Lift the top off the unit and lay aside securely.

5. Reverse the procedure to reinstall.

When a cooking area is turned ON, the coil element under the cook top will heat up and

Ceran Element

glow. The element will cycle on and off to maintain the heat setting. When the element cycles on, it is normal to see a red glow through the smooth top.

Note: It is normal for the element to cycle when set on the high setting.

To Remove Element:

• Left front and right rear element wattage: 208/240 volts @ 900/1200 watts. Approximately 48

Ω.

• Left rear element wattage: 208/240 volts

@ 1580/2200 watts. Approximately 27

• Dual element wattage: 208/240 volts @ 1580/2200 watts. Approximately 27

1. Disconnect the appliance from power source before servicing.

the outer element. 208/240 volts @ 580/ 750 watts. Approximately 73 inner element.

16010107 Section 3. Component Description

Ω.

Ω for

Ω for the

3-2

Bake Element

T o Access Broil Element:

Element Wattage: 208/240 volts @ 2250/3000 watts. Approximately 19

The bake function controls the Bake and Broil heating elements. During a Bake cycle, the Broil element will be on 6 seconds of a 60-second duty cycle, and then the Bake element will be on the remaining 54 seconds. The Bake and Broil elements will be staged with the exception of the rapid preheat. In the rapid preheat, available when the upper oven is used alone, the bake and broil elements will be on at 100% until temperature is reached. Once temperature is reached, the elements will cycle as outlined above.

Note: The Bake element will be the first element to turn on at the beginning of any conventional bake cycle.

T o Access Bake Element:

1. Disconnect the appliance from power source before servicing.

2. Remove lift off door for more accessibility.

1. Disconnect the appliance from power source before servicing.

2. Remove lift off door for more accessibility.

3. Remove broil support brackets (2) and remove screws securing broil element to back oven.

4. Gently pull element through cavity wall until terminals can be accessed.

5. Disconnect wiring.

6. Remove/Replace element as necessary.

7. Reverse procedure to reinstall.

Oven Sensor

The oven sensor is located inside the oven cavity, attached to the rear wall of the cavity. As the oven temperature increases, the resistance of the oven sensor increases. The resistance is measured by the electronic control to determine the oven temperature.

3. Remove four (4) screws securing bake element to back of oven cavity.

4. Gently pull element through cavity wall until terminals can be accessed.

5. Disconnect wiring.

6. Remove/replace element as necessary.

7. Reverse procedure to reinstall.

Broil Element

T o Access Oven Sensor:

1. Disconnect the appliance from power source before servicing.

2. Open oven door and remove two (2) screws securing sensor to oven cavity. Gently pull through cavity wall.

3. Disconnect the oven sensor at the connector blocks and remove/replace as necessary.

4. Reattach the connector blocks and reassemble.

The broil function controls only the broil element. The bake element is inactive during a broil cycle. During a broil cycle, the control will monitor the oven temperature and cycle the broil element on and off to obtain the selected temperature.

16010107 Section 3. Component Description

3-3

Oven Cavity Components (Electric)

Open or remove the oven door. The following components are accessible:

Sensor

Broil Element

Convect

Fan

• Racks

• Oven Sensor

• Broil Element

• Convect Fan Cover

• Bake Element

Convection Fan (Electric)

Remove six screws (as shown) from the perimeter of the convection fan cover. This will loosen the cover, but it cannot be removed easily without positioning it to clear the rack guides. Care should be used when moving parts and tools around inside the oven cavity to avoid marring or chipping the procelain surfaces.

Convect Fan Cover

Bake Element

Screws

Three screws (shown) secure the convection fan mounting plate, remove these, to allow access to the motor and connectors.

Screws

Also shown here are the screws that secure the bake and broil elements.

16010107 Section 3. Component Description

Screws

3-4

Convect Fan Motor and Blade (Electric)

Motor Connectors

Motor

After the convect fan mounting plate is removed, motor connectors, motor, motor mount and insulation is accessible. Motor connectors are also exposed by removing the back panel (see range back removal).

The convect fan blade is attached to the motor’s “D” shaft using a hex set screw. The fan blade must be loosened and taken off the motor shaft before the motor can be removed. The motor mounting screws are found on the front side of the convect fan assembly. When reassembling, be sure to reinstall the small piece of insulation under the motor mount. The insulation provides sound dampening and prevents heat loss. When reinstalling the convect fan blade, be sure that the blade has adequate clearance at all points around the mounting plate. The blade should “stand off” approximately 1/8” with very little apparent warping.

Motor Mount

Insulation

Mounting Screws

Hex Head Set Screw

Note: When reinstalling the convect assembly, be sure to check that no loose insulation is visible in the fan area or anywhere in the oven cavity.

16010107 Section 3. Component Description

3-5

ELECTRONIC CLOCK AND OVEN CONTROL

T o Gain Access T o Electronic Oven Control

1. Disconnect the appliance from power source before servicing.

removes voltage from the heating element. Control is attained by regulating the ratio of the time between the opening and closing of the contacts. This is usually referred to as input percentage and is controlled by a cam, which can provide virtually any infinitely adjustable performance. This performance is assured when the switch is subjected to elevated ambient temperatures through automatic temperature compensation.

2. Remove two screws securing backguard panel to the end caps.

3. Remove two (2) screws securing backguard panel to backguard housing. (Screws located between control panel and main top).

4. Lift backguard panel up, tilt forward, and lay panel on protected surface of main top for servicing.

5. Remove two (2) screws securing controlmounting plate to backguard.

6. Remove four (4) screws securing control to control mounting plate.

7. Disconnect wiring and remove/replace control.

The infinite switch stems are color coded for identification. The silver colored stem controls the left front and right rear element, the silver colored stem with a red dot controls the left rear, and the brass colored stem controls the right front element. Amperage is rated at 3-15.5A range +/- 10%.

Note: When replacing the infinite switch, the switch must be matched to the element.

T o Access Control:

1. Disconnect the appliance from power source before servicing.

2. Remove control knobs.

3. Remove two screws from backguard panel securing panel to housing.

8. Reverse procedure to replace.

4. Remove two screws securing backguard panel to end cap.

INFINITE SWITCH (Current Sensing)

5. Lift backguard panel up, tilt forward, and lay panel on protected surface on main

This unit is equipped with controls that

top for servicing.

provide an infinite choice of settings from LOW to HIGH. The control can be set on any of the numbered settings. To operate, push in and turn control knob to the desired

6. Remove two (2) mounting screws securing infinite switch to backguard panel.

setting.

7. Disconnect wiring and remove/replace

Note: The infinite switch is a current

control.

sensing switch.

8. Reverse procedure to replace.

The infinite switch is a rotary switch, which controls the power dissipated by a heating element. A heater-bimetal opens and closes the cycling contacts, which applies and

16010107 Section 3. Component Description

3-6

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