Maytag GEMINI User Manual

Maytag Gemini™

Range

Service Manual

16010107

Issued 10/00

GENERAL SAFETY PRECAUTIONS

Information contained in this manual is intended for use by a qualified service technician. All tests and repairs should be performed by a qualified service technician equipped with proper tools and measuring devices. All component replacements should be made by a qualified service technician using only factory approved replacement parts.

Improper assembly or adjustment may occur if service or repair is attempted by persons other than qualified service technicians or if parts other than approved replacement parts are used. Improper assembly or adjustment can create hazardous conditions.

There can be a risk of injury or electrical shock while performing services or repairs. Injury or electrical shock can be serious or even fatal. Consequently, extreme caution should be taken when performing voltage checks on individual components of a product. PLEASE NOTE: Except as necessary to perform a particular step in servicing a product, the electrical power supply should ALWAYS be disconnected when servicing a product.

Further, this appliance MUST be properly grounded. Never plug in or direct-wire an appliance unless it is properly grounded and in accordance with all local and national codes. See installation instructions that accompany the product for grounding this appliance.

USE ONLY GENUINE MAYTAG APPROVED FACTORY REPLACEMENT COMPONENTS.

IMPORTANT SAFETY NOTICE

THE INFORMATION INCLUDED IN THIS SERVICE MANUAL IS INTENDED FOR THE USE OF QUALIFIED SERVICE PERSONNNEL ONLY. ANY ATTEMPT TO SERVICE THE APPLIANCE COULD RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE.

DISCONNECT ELECTRICAL SUPPLY

BEFORE SERVICING.

IMPORTANT

ALL GROUNDING DEVICES MUST BE

RECONNECTED AND PROPERLY FASTENED.

GROUND PATH SPECIFICATIONS

GROUND PATH RESISTANCE: 0.1 Ω MAX. INSULATION RESISTANCE: 250k Ω MIN.

ELECTRICAL CONNECTIONS

This range must be connected to a power source that has the correct, voltage and frequency as required by the rating plate. The rating plate can be found on the back left side of control panel on a lift up pivot bracket.

Wiring must be in accordance with local codes and the National Electrical Code (NEC).

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 SURFACE 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 tem-

perature.

Description Part Number

Analog Test Meter 20000005

Digital Watt/Amp/Volt/Ohm/

Temperature Meter

Clamp-On Ammeter 20000002

AC Voltage Sensor 20000081

20000019

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

proper safety precautions can

be observed. The tip of the sensor will glow bright red, if voltage is between 110-600 volts AC.

can be used to alert you

if AC voltage is present so

bar graph to show tendencies. Includes: AC power adaptor for measuring wattage and meter leads.

16010107 Section 2. Electrical Components & Testing

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

To 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.

To Remove Glass Top 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 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:

1. Disconnect the appliance from power source before servicing.

16010107 Section 3. Component Description

Ceran Element

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

• Left rear element wattage: 208/240 volts @ 1580/2200 watts. Approximately 27Ω.

• Dual element wattage: 208/240 volts @ 1580/2200 watts. Approximately 27Ω for the outer element. 208/240 volts @ 580/ 750 watts. Approximately 73Ω for the inner element.

3-2

Bake Element

To Access Broil Element:

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

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.

To 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

To 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

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