Maytag JENN-AIR User manual

SAFETY PRECAUTIONS
THIS MANUAL, AS WELL AS THE INFORMATION CONTAINED IN IT, IS TO BE
USED ONLY BY AMAYTAG AUTHORIZED SERVICE TECHNICIAN FAMILIAR WITH
AND KNOWLEDGEABLE OF PROPER SAFETY AND SERVICING PROCEDURES
AND POSSESSING HIGH QUALITY TESTING EQUIPMENT ASSOCIATED WITH
MICROWAVE, GAS,
AND ELECTRICAL APPLIANCE REPAIR.
ALL INDIVIDUALS WHO ATTEMPT REPAIRS BY IMPROPER MEANS OR ADJUST-
MENTS, SUBJECTTHEMSELVES AND OTHERS TO THE RISK
OF SERIOUS OR
FATAL INJUR~
USE ONLYGENUINE MAYTAG APPROVED FACTORYREPLACEMENTCOMPO-
NENTS.

INTRODUCTION
The information presented in this manual is printed in aloose format and is divided into
sections relating
to ageneral group of components and/or service procedures. Each
section is
further subdivided to describe aparticular component or service procedure.
Anything of aunique nature concerning these models has been detailed and labeled as
such in the manual.
The
subdividing of the subject matter, plus the loose leaf form will facilitate the updat-
ing
ofthe manual as new or revised components are added or new models are intro-
duced.
Each page
of the manual will be identified in the lower right-hand corner, and as new or
revised pages are published, the manual can easily be updated by following the file
instructions on
the cover letter of the supplement.
The service manual is avaluable
tool and care should be taken to keep it up to date by
prompt and proper filing of subsequent pages as they are used.
MODELS COVERED IN THIS MANUAL
JW1000
JW2000
JW3000
16007667 ©1996 Maytag Corporation
INTRODUCTION

16007667 ©1996 Maytag Corporation INTRODUCTION ii

CONTENTS
SECTION 1. INSTALLATION 1-1
PRE-INSTALLATION REQUIREMENT 1-1
Water Supply Requirements 1-1
Drain Requirements 1-1
Electrical Requirements 1-2
INSTALLATION PROCEDURE 1-2
SECTION 2. OUTLINE OF MECHANICAL OPERATION 2-1
CLUTCH ASSEMBLy 2-1
AGITATION 2-2
SPIN 2-2
SECTION 3. CABINET ASSEMBLY COMPONENTS 3-1
CABINET BODY ASSEMBLY 3-1
Front Panel 3-1
Rear Access Panel 3-2
TOP ASSEMBLy 3-3
DOOR
ASSEMBLy 3-4
CONTROL PANEL ASSEMBLY 3-4
Disassembly 3-4
BASE
ASSEMBLy 3-7
STABILIZER ASSEMBLY 3-8
SECTION 4. WATER RELATED COMPONENTS 4-1
WATER MIXING VALVE 4-2
WATER INLET FLUME 4-3
AIR BELL 4-3
HOSES 4-3
TUB TOP 4-4
AGITATOR 4-4
SPIN BASKET 4-5
OUTER TUB ASSEMBLY 4-5
PUMP ASSEMBLY 4-6
SECTION 5. SUSPENSION SYSTEM 5-1
SUSPENSION HOUSING , 5-2
TUB BRACES 5-2
SUSPENSION SPRINGS 5-2
SECTION 6. TRANSMISSION AND RELATED COMPONENTS 6-1
CENTER POST ASSEMBLY 6-2
BEARING
AND SEAL HOUSING 6-2
TUB SEAL 6-2
SPIN BEARING 6-5
16007667 ©1996 Maytag Corporation Contents iii

DRIVE PULLEY AND CAMS 6-5
BRAKE
ASSEMBLy 6-9
BASKET DRIVE TUBE
AND COVER ASSEMBLy 6-10
AGITATOR DRIVE
SHAFT AND LINKAGE ASSEMBLy 6-10
CRANK GEAR 6-11
CLUSTER GEAR 6-11
CLUTCH ASSEMBLY 6-11
TRANSMISSION HOUSING
ASSEMBLy 6-14
Oil Seal Replacement 6-14
LOWER BEARING ASSEMBLY 6-14
DIAGNOSING TRANSMISSION PROBLEMS 6-16
Knocking Noise 6-16
Whining Noise In Agitation 6-16
Oil Leaks 6-16
Slow Spin Speed 6-16
OIL REQUIREMENTS 6-19
SECTION 7. ELECTRICAL COMPONENTS AND TESTING 7·1
TIMER 7-1
TIMER SEQUENCE CHART 7-2
MOTOR 7-3
MOTOR SWITCH 7-3
MOTOR
MOUNTING 7-6
MOTOR CIRCUIT TESTING 7-7
Overload Protector 7-7
Motor Switch 7-8
Motor 7-8
WATER MIXING VALVE 7-8
WATER LEVEL SWITCH 7-9
SELECTOR SWITCHES 7-11
SAFETY SPIN SWITCH 7-11
SECTION 8. SCHEMATIC DIAGRAM 8·1
SECTION 9. TROUBLESHOOTING 9·1
SECTION 10. ELECTRONIC CONTROL MODEL 10·1
OPERATING INSTRUCTIONS 10-1
CYCLE DESCRIPTION 10-2
CONTROL SHIELD
AND ELECTRONIC ASSEMBLy :10-3
CONTROL PANEL DISASSEMBLY 10-4
SCHEMATIC DIAGRAM 10-6
TESTING THE ELECTRONIC CONTROL 10-9
WATER LEVEL SWITCH 10-9
WATER LEVEL SWITCH OPERATION 10-10
TESTING THE WATER LEVEL SWITCH 10-10
16007667 ©1996
Maytag Corporation Contents
iv

SAFETY NOTES
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID
POSSIBLE EXPOSURE TO EXCESSIVE DANGER AND ELECTRICAL SHOCK:
1. Disconnect electrical supply before servicing machine.
2. If electricity is required for a test:
(A) First, disconnect electrical supply;
(B) Second, make any connections
or adjustments required for the test;
(C) Third, connect electrical supply;
(D) Fourth,
perform the test. If service is required, disconnect electrical
supply before servicing machine.
3. Please use caution when servicing the machine with the front panel
removed because there is danger of injury due to potential contact
with spinning transmission.
4. Please use caution when servicing the machine with the front panel
removed because
there is danger of injury due to contact with a
potential"pinch point" between the turned up edge of the transmission
cover and the tub support flange.
16007667 ©1996 Maytag Corporation
SAFETY NOTES V

16007667 ©1996 Maytag Corporation SAFETY NOTES vi

SPECIFICATIONS
WASHER WEIGHT
Shipping -185 pounds approximately
Operating -160 pounds approximately
DIMENSIONS
Width 27"
Depth 27"
Height to top of cabinet
353/4"
Height to top of control panel
431/16"
Height with door open (front to rear opening door) 531/2"
FINISH
Cabinet Top - powdered paint
Clothes Door - powdered paint
Outer Tub - constructed entirely of polypropylene
Basket - polypropylene
Cabinet -baked enamel
Base and other finished parts -baked primer
CAPACITY
Up to 22 pounds of clothes (dry weight)
DRAIN HEIGHT
32 inch minimum
60 inch minimum
MOTOR
3/4 H.P., reversible, 115 volt, 60 cycle A.C.
TRANSMISSION
Linkage type, incorporating reduction gears and
reciprocating levers
16007667 ©1996 Maytag Corporation SPECIFICATIONS vii

Setting Gallons
*Depth Inches
*Basket
Perforations
Low
10.5
6"
31/2"
Medium
14.1
81/2" 5"
High 19.5 11" 7"
Super 23.3 131/2" 91/4"
*Allowable variations are plus or minus 1/2 inch.
AGITATOR SPEED
Regular Cycle
Slow (Fine Wash) Cycle
SPIN SPEED
Regular Cycle
Slow (Fine Wash) Cycle
69.5 Oscillations per
minute
45 Oscillations per minute
600 R.P.M.
400 R.P.M.
TABLE 0-1. AMPERAGE CHART
WATER
CYCLE LEVEL *AMPS
Agitate-Regular Full Tub 10.4
Agitate-Slow Full Tub 7.6
Agitate-Regular
Dry Tub 7.5
Spin-Regular Dry Tub 10.2
Spin-Slow Dry Tub 7.6
t-'ump Uut-Hegular
rull IUb
1U.~
Pump Out-Slow t-ull tub 8.0
TABLE 0-2. RESISTANCE CHART
*RESISTANCE
COMPONENTS (OHMS)
Timer Motor
2360
Mixing Valve
Cold Solenoid 853
Hot Solenoid 867
Drive
Motor
High Speed 1.3
Low Speed 2.3
::start
;:S.l
* These values can vary slightly.
16007667
TABLE 0-2. RESISTANCE CHART
*WATTAGE
CYCLE RANGE
Agitate-Regular
Full Tub
610-640/670 (MAX.)
Agitate-Slow
Full Tub
370-400/420 (MAX.)
Agitate-Regular
Dry Tub 460-470/480 (MAX.)
Agitate-Slow
Dry Tub
350-360/370 (MAX.)
Pump Out-Regular 760
Pump Out-Slow 510
Spin-Regular
Full Tub 460
Spin-Slow
Full Tub 340
* These will vary with washer load and line voltage.
SPECIFICATIONS viii
©1996 Maytag Corporation

SPECIAL TOOLS
All special tools are manufactured by Robinaire with the exception of the 35·2442 Brake Removal Tool
and 35·2968 Spanner Wrench· Basket Hub. These tools are privately manufactured for and stocked
by May tag CustomerService.
NOTE: The tools listed below can be ordered from any authorized May tag Customer Service parts
distributor.
I@
If--~D
o
Transmission Seal Tool, Part Number 14242
Brake Removal Tool, Part
Number 35-2442
Spanner Wrench-Basket Hub, Part
Number 35-2968
16007667
Spring Tool Kit, Part Number 21001138
Motor Test Cord, Part Number 038183
SPECIAL TOOLS ix
©1996 Maytag Corporation

16007667 ©1996 Maytag Corporation SPECIAL TOOLS X

SECTION 1. INSTALLATION
PRE-INSTALLATION REQUIRE-
MENTS
PLEASE READ ALL Installation Instruc-
tions and requirements before installing.
...--- GENERAL INFORMATION -----,
DO NOT INSTALL THE WASHER ON
ACARPETED FLOOR.
DO
NOT INSTALL OR STORE THE
WASHER WHERE IT
WILL BE EX-
POSED TO THE WEATHER.
Installation in any location subject to
freezing temperatures is not recom-
mended.
Ifthe washer must be installed
in such alocation,
it should be thor-
oughly drained after each use as follows:
•Turn off hot and cold water faucets.
•Disconnect
both water inlet hoses at
the faucets.
Lower them to the floor.
•
With the service cord connected to
the electrical outlet, rotate the timer to
the normal start or fill position and
pull
timer knob to start washer. Turn
water temperature selector switch to
warm.
•When water stops draining from the
hoses,
disconnect service cord.
8 Lower the drain hose to the floor and
allow it to drain into a floor drain or
shallow pan.
In below-freezing temperatures, ice
may
form in the ufill" flume. Raise the room
16007667
temperature and allow time for the ice to
melt before using the washer.
Water Supply Requirements
1. Hot and cold water must be available
at apressure
between 25 and
125
P.S.1. at the machine.
2. Shut off faucets with standard hose
connectors should be available in
both
hot and cold water lines so that
the water can always be turned off
when the washer is not in use.
3. The installation should be in accor-
dance
with local plumbing code
requirements.
Drain Requirements
Adrain that will permit 23 gpm flow is
required
to evacuate the washer. A
standpipe at least 32 inches high,
but no
more than 60 inches high, should be
installed at
the drain. The standpipe
should have a 1 1/2 inch
minimum inter-
nal
diameter to prevent siphoning.
Tight connections between the drain
hose and the drain (standpipe, etc.) are
not recommended since they violate
most local plumbing codes. In cases
where a tight connection is required,
an anti-siphoning valve,
part number
33-4260, should be placed in the drain
hose to prevent siphoning from the
washer or facility during agitation.
SECTION 1. INSTALLATION 1-1
©1996 Maytag Corporation

Electrical Requirements
1. Provide an individual 120 volt,
60 HZ, branch
circuit with ground for
the washer. This circuit must be
rated
for 15 amperes or more.
2. Protectthe washer1s electrical circuit
with a15 ampere time delayfuse or
circuit breaker.
3. Install in accordance with National
Electrical Code and all local codes
and ordinances.
GROUNDING INSTRUCTIONS
The
washer must be grounded. In the
event of amalfunction or breakdown,
grounding will reduce the risk of electri-
cal
shock by providing apath of least
resistance
for electrical current.
The
washer is equipped with a power
supply cord which has a grounding
conductor and three-prong grounding
plug. For proper grounding, the three-
prong
grounding plug must be plugged
into an appropriate
three-prong
grounded receptacle or outlet (see the
following figure). The receptacle must
be properly installed and grounded in
accordance
with the National Electrical
Code and all local codes and ordinances.
WARNING: Improper connection
of the
grounding conductor or the three-prong
grounding plug
of the power supply
cord may resultin an electrical shock
hazard. If there is any doubt as to
whether the washer is properly
grounded, have
the installation checked
by aqualified electrician.
DO NOT MODIFY THE PLUG PROVIDED
WITH THE WASHER
-If the plug will not
fit the outlet, have a proper outlet in-
stalled
by aqualified technician.
INSTALLATION PROCEDURE
To remove the carton, cut along the
dotted line. Lift the carton and top cap
assembly up and clear
of the washer.
NOTE: Retain
the corner posts for later
use.
1. Untape and raise the washer lid;
remove the items shipped in the spin
basket. Save the literature
for future
reference. Close and tape lid.
2. Place two (2) carton corner posts on
the
floor to protect the unit and care-
fully lay the washer on its back on
top of the corner posts. DO NOT
LOWER
OR RAISE THE WASHER BY
THE CONTROL
PANEl.
Three-prong grounding plug
power supply cord. Approved
grounding type wall recep-
tacles, Pass &Seymour,
No.5261, Bryant No. 5261,
(Nema No.5 15 R) or equiva-
lent.
3. Remove the two hex-head screws
holding the
wooden shipping base.
Ifthe unit has abase made
of poly-
propylene,
only one hex-head screw
is used.
16007667 SECTION
1. INSTALLATION 1-2
©1996 Maytag Corporation

Remove
Cardboard
Protector
Remove Hex
Head
Screws
Shipping
Base
Control
Panel
washers are pushed in tightly. Attach the
hose end
with the flat washer to the water
mixing valve. Hot and cold connections are
identified
by H&Cstamped in the cabinet.
Tighten hose connections by hand until
snug. Then,
turn another 2/3 of an inch,
with pliers.
Water :::1Htttm~~~1
Connections
Cold Water
Inlet
Water
~oses
-~
Proceed as follows:
•Place the washer as close to its
final operating location
as possible.
The front legs are threaded and can
be adjusted up and down to level
the unit.
These models are equippedwith
self-adjusting legs on the rear which
will automatically stabilize the unit.
Stabilizer Model
Hot Water
Inlet
6. Move washing machine to the loca-
tion where it
will be used. Amini-
mum of 1/4" clearance on all sides
ofthe washer is recommended.
7. LEVELING AND/OR STABILIZING THE
WASHER
4. Install the drain hose by placing the
clamp over the hose (clamp provided
in parts envelope). Push the hose
onto the pump outlet of the washer.
Be sure to position the hose in the
direction
of the standpipe. Squeeze
the clamp ears
with pliers, push the
clamp up the hose and attach to
the pump outlet.
Pump Clamp Hose
~ Cit ~_"-""--:
5. Place aflat rubber washer on one end
of the water hose, making sure the
16007667
•Make sure rearfeet move up and
down freely.
SECTION 1. INSTALLATION 1-3
©1996 Maytag Corporation

Rock Washer
With Hands
~~
0
,1
Make Sure Rear Feet
Move Freely
Up and Down
•Place washer in final location.
Front foot adjustment for side to side
leveling -Loosen the locknut, making
sure it turns freely on the threads.
•When the machine is in place, screw
front feet out of base against the
floor until the machine is acceptably
level across the front.
8. Place the gooseneck end of the drain
hose into the standpipe
or laundry
tub. The drain hose should
fit loosely
in the standpipe
to prevent siphoning.
(An anti-siphon valve and associated
parts are available
from your dealer,
part
number 33-4260).
•While holding
foot still, turn the ad-
justing
locknut clockwise until the nut
is tightened firmly against base.
NOTE: BE SURE THE DRAIN HOSE
IS
NOT TWISTED OR KINKED.
LOCkN~--=7
---¥-Le
g
Foot---U
T
32" Min.
60" Max.
1
Tilt machine forward until rear of cabi-
net is approximately 4 inches off the
floor, then lower the machine back to
the floor on the rear feet. This operation
will cause the rear stabilizing feet to
conform to the contour of the floor and
seat them solidly. Rock washer with
hands on opposite corners to check
stability.
9. Insert the screens and washers (pro-
vided in the parts envelope) into the
remaining ends
of the water hoses.
Attach the
water hoses to the hot
and cold faucets. BE SURE HOT
WATER INLET IS CONNECTED TO
HOT WATER FAUCET. Tighten by
hand until snug, and then a2/3 turn
with pliers.
16007667 SECTION
1. INSTALLATION 1-4
©1996 Maytag Corporation

DO NOT OVER TIGHTEN. Turn on Fau-
cets and check for leaks. Tighten to stop
leaks if necessary.
II
@ @~---Washer
I I
_ ~"---Screen
, '---Hose
1 O. Plug the power cord into an outlet.
11. Start the washer in aspin cycle,
per operating instructions, to center
basket.
12. Start the washer in awash cycle, as
per operating instructions. Allow
water to fill in machine until it
reaches the level
of the bottom row
of holes in the wash basket. Then,
stop the washer by pushing on
timer knob.
16007997
..::::::..
·.'. ......
·. .
........ '. .
:: ... .:...~ ~: .:.:
• ,JJ. - ---,- • •
'" '"
Ifthe water is not level with the bottom
row of holes all around the basket, read-
just the leveling feet as required to level.
Then
remove the water by selecting a
spin cycle.
FINAL CHECK OUT
1. Have all installation requirements
been observed?
2. Have locknuts on front feet been
tightened?
3. Are there any kinks in the hoses?
4. Are any water leaks evident?
SECTION 1. INSTALLATION 1·5
©1996 Maytag Corporation

16007667 ©1996 Maytag Corporation SECTION
1. INSTALLATION 1-6

SECTION 2. OUTLINE OF MECHANICAL OPERATION
GENERAL INFORMATION CLUTCH ASSEMBLY
The washer utilizes areversible type
motor which runs clockwise during the
agitate cycle and counterclockwise
during the spin cycle.
Note: The rotation directions as stated
in this outline, are
when viewing the
component from its pulley end.
The clutch assembly consists of the drive
shaft and hub assembly, clutch spring,
drive pinion, and the anti-backup spring.
The anti-backup spring, also the clutch
type spring, is
mounted on the smaller
machined hub of the drive pinion and
secured
with a flat washer and retaining
ring. One end
of the clutch spring fits
Asingle
belt is used to transmit power
from the motor pulley to the drive pulley
and
pump pulley.
Shaft & Hub Assy.
Screw
Washer Thrust
(Nylon)
Pinion
Input
Washer
WasherThrust
Spring Clutch
Ring
Drive
Shaft &
Hub Assy.
/
Washer
Clutch ___
Spring
Anti-Backup
Spring -.......:r
The drive pulley which drives the trans-
mission
drive shaft and hub assembly,
and
the pump pulley and hub assembly,
and
the pump pulley which drives the
pump impeller, are in operation when-
ever the motor is running.
The
transmission assembly converts the
power from the motor to either drive the
agitator or spin the basket. The direction
the clutch assembly rotates determines
which action takes place.
over the drive hub which is pinned to the
drive shaft, 'and the
other end fits over the
larger machined hub
of the drive pinion.
The drive shaft serves
only as abearing
surface
for the drive pinion to revolve on,
and
no direct drive is imparted from the
shaft directly to the pinion.
The inside diameter of the clutch spring
is so designed
that when the drive shaft
16007667 SECTION
2. OUTLINE OF MECHANICAL OPERATION 2·1
©1996 Maytag Corporation

hub is driven in aclockwise direction, the
clutch spring tightens on the
two hubs
and becomes apositive
drive link be-
tween them. When the drive shaft hub
runs counterclockwise,
the clutch spring
relaxes in an
override situation. In the
override,
or relaxed position the clutch
spring still maintains a
drive link between
the
two hubs. The override tension, or
torque is used to drive the spin basket.
The anti-backup spring
is aclutch type
spring, one end which terminates in an
an extended leg and
hook configuration.
The coil
portion of the spring is mounted
over the drive pinion hub as previously
described, and the extended leg
portion
is fitted with its hooked end secured in a
slotted boss in
the transmission housing.
When
the drive pinion rotates in aclock-
wise direction, the spring relaxes and
exerts no appreciable force on the drive
pinion.
When the drive pinion starts to
revolve counterclockwise, the spring
tightens on
the hub of the pinion and
prevents
it from turning.
Note: Later models use an anti-backup
cam
stop under the crank gear, instead of
the anti-backup spring.
CLUTCH ASSEMBLY· DUAL DRIVE
The clutch assembly consists of the drive
shaft and hub assembly, clutch spring, and
input pinion with gear lock assembly. The
gear lock mechanism is
part of the input
pinion. The
drive shaft serves only as a
bearing surface
for the drive pinion to
revolve on. No direct drive is imparted
from the shaft directly to the pinion. The
inside
diameter of the clutch spring is
designed so that when the drive shaft is
driven in aclockwise direction, the clutch
spring tightens on the
two hubs and be-
comes apositive link between them.
When the
drive shaft hub runs counter-
clockwise, the clutch spring relaxes in an
override situation. In the override,
or
relaxed position, the clutch spring still
maintains a
drive link between the two
hubs. The override tension, or torque, is
used
to drive the spin basket. The gear
lock mechanism consists
of two "wings"
that project out from the input pinion.
When the drive pinion rotates in aclock-
wise direction, the gear lock mechanism
exerts no force on the
input pinion.
When the
input pinion starts to revolve
counterclockwise, the "wings"
drop into
detents in the
lower housing preventing
the pinion
from turning.
AGITATION
The clockwise (agitate) rotation of the
drive shaft and the hub assembly is trans-
mitted to the drive pinion by the clutch
spring. The drive pinion meshes
with the
cluster gear which, in turn, meshes
with
the crank gear. The circular motion of the
crank gear is converted
to the oscillating
action
of the agitator shaft by alinkage
arrangement
which consists of aconnect-
ing rod that
mounts over astud on the
crank gear, and alever assembly.
Any
tendency of the transmission housing to
turn or "creep" is prevented by the en-
gaged brake assembly located on the
under side
of the suspension housing.
AGITATION· DUAL DRIVE
The clockwise (agitate) rotation ofthe
drive shaft and hub assembly is transmit-
ted to the
input pinion by the clutch
spring. The
input pinion meshes with the
dual cluster gears which, in
turn, mesh
with the dual crank gears. The circular
motion of the dual crank gears is con-
16007667 SECTION
2. OUTLINE OF MECHANICAL OPERATION 2-2
©1996 Maytag Corporation