neptune - 2003 1 led display mah5500b and 6500a lcd display mah7500 both the led and lcd models...

Neptune - 2003LED Display MAH5500BAnd 6500A

LCD Display MAH7500

Both the LED and LCD models incorporate the same mechanical systems; the major difference between the two models is the electronic control board and display. The LCD version features an interactive liquid crystal display window.

Series Numbers: The first 2 characters in a Maytag serial number are used to identify design changes. When ordering parts, the series designation is necessary to ensure the correct part is selected.

Example: Serial Number 74 903713ZY

SEE NOTE: Series

Neptune

Neptune - 2003

Model/Serial Number Tag

Neptune - 2003

Installation Notes

Floor stability and proper leveling are extremely important for any Neptune installation, if the floor is not sturdy enough to support the washer properly, or the machine is not properly leveled, the vibration detection system will not allow the machine to reach it’s top spin speed.

Neptune - 2003

Installation Clearances

Neptune - 2003

Unpacking

Cut two shipping straps

Remove straps and cardboard

Neptune - 2003

Use large flat blade screwdriver to remove two shipping staples. One end of the staple is embedded in the crate and the other end hooks into the washer

Neptune - 2003

Cut Top Strap

The top strap is a one piece strap, cut either side of the buckle and pull the strap

completely out

Neptune - 2003

Cutting Lower Straps

The lower strap is actually two separate straps. The straps loop around the tub on the left and right sides of the machine. Make sure to cut both sides of buckle and separate straps when you pull them out.

Neptune - 2003

Neptune - 2003Warning!Warning!

Failure to remove the shipping straps completely can result in the straps becoming entangled in the motor and pulley assembly. This can result in odor complaints or failure of the spinner to rotate at designed speed.

Neptune - 2003

Drain Hose Installation

Important installation notes attached to drain hose

Neptune - 2003

Door Reversal

Remove Two Hinge Screws And Remove Door

Remove Two Hinge Covers

Hinge Screws

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Changing Hinges

Install hinge covers on opposite side

Install hinges on opposite side of door

Remove screws securing hinges

Remove four painted screws covering hinge

holes on door

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Hanging Door

Check operation of door

Install painted screws in opposite hinge holes

Install hinge screws

Install door

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Component LocationComponent LocationElectronic Control

5500B-6500A-LED

7500A-LCD

Component LocationNeptune 5500B-6500A-7500A

Heater 6500A & 7500A

Neptune - 2003

Removing Console

To remove console, remove two ¼” screws, one on each side of cabinet

Neptune - 2003

With the two lower screws removed, tilt the console forward and remove four screws holding the metal cover to the console

Neptune - 2003

Removing Door

Remove the two hinge screws and remove door

Neptune - 2003

Removing Hinge Covers

Neptune - 2003

Removing Inner Door Panel

To remove inner door panel, remove screws on three sides of door

Screws

Neptune - 2003

Vent Tube and Balance Assembly

Vent tube

Balance assembly

Outlet

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Check Valve

Check valve assembly

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Removing Front Panel

Grasp the right and left sides of front panel. Rotate the posts away from the door opening and pull out

Lift the front panel off the bottom clips and

remove

Neptune - 2003

Component Identification

Unbalance SwitchMotor Controller

Drain Pump

Boot DrainHeater

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Wiring Harnesses

Remove the three wiring harnesses

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Removing Motor Controller

To remove motor controller: remove two 5/16” screws

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Remove Housing

Lift motor controller housing assembly and remove

Neptune - 2003

Pump motor

Drain pump

Pressure Switch

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Pressure Switch

Pressure switch is mounted on top of drain pump. It’s covered with a plastic bag.

Bag removed

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Removing Switch

Removing out of balance switch

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Heating Element

Thermistor terminals

Heater terminals

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Removing Heater

To remove heater:

Remove heater and thermistor wires

Loosen 10mm nut

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Remove Heater

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View of gasket

Tightening the 10mm nut causes lower plate to compress the rubber gasket and seal against the tub housing

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Siphon tubes

Bleach reservoir

Fabric softener

Dispenser outlet to tub

Dispenser

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Dispenser

Dispenser cover must be removed to raise top

Remove four Phillips head screws

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Door Release Cord

Removing siphon reservoir allows easier access to release cord

To release door lock–pull line to left while pulling on the door

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Release Top

Remove Two Screws to Pop Top

Neptune - 2003

Components under top Balance Weight

Boot Cable

Inertial Unbalance Switch

Dispenser Valves

Fill Valves

Door Lock Assembly

Recirculating Hose

Side Displacement Switch

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Inlet Hose

Water inlet hose from dispenser assembly to tub

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Thermistor - Resistance decreases with temperature rise

Inlet water valves

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Caution on rear panel Remove four screws to

remove rear access panel

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Pump and Strut

View from rear with access panel removed

Pressure Switch, drain pump and motor

Suspension strut

Sump Drain

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Motor and Strut

View from rear with access panel removed

Drive motorSuspension strut

Ribbed motor pulley

Drive beltTub drive pulley

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Removing Motor

2. Remove Bolt

1. Roll off Drive Belt

Neptune - 2003

Allow the mounting pin to drop out of the motor isolator as you pull the motor

out from the front of the machine

Neptune - 2003

Be careful not to damage the rear housing of the motor when servicing

New motor and controller introduced on the 6500A – incorporated in the 5500B and 7500A

model lines series 88 and newer

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Motor and controller used on 5500B and 7500A prior to series 88

Neptune - 2003

Door Lock Assembly

Door catch

Actuator Button

Light bulb

Neptune - 2003

Removing door lock Remove two 5/16” screws and

remove door lock assembly

Neptune - 2003

Removing Front Shroud

After removing door lock assembly the front shroud can be removed

Neptune - 2003

Remove screws holding metal support bracket and remove bracket

Neptune - 2003

Boot and Cable

Removing or replacing boot cable

Neptune - 2003

Removing Cable

Grasp cable end with needle nose and spring hook with suspension spring tool

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Unhooking Spring

Neptune - 2003

Spring Unhooked

Expand spring to to hook or unhook

Neptune - 2003

Removing Baffles Remove two T-20

Torx screws

Removing baffles

Neptune - 2003

Removing nut

Three ½” nuts secure the tub to the spinner support

Torque nuts to 18ft lbs.

Neptune - 2003

Remove three ½” nuts, profile washers and spinner supports

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Removing Spinner Assembly

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Spinner Support

A plastic washer is installed between the spinner support

and the tub

Neptune - 2003

Plastic Washer

Tub Spinner support

Plastic washer

Neptune - 2003Remove pulley

Torque to 30-33 ft. lbs.when reassembling

Neptune - 2003

Removing Support

With the spinner drive pulley removed, remove the spinner support

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Journal area

“O” Ring

Spinner support shaft

Replace the “o” ring and lubricate journals when servicing

Use PN#22002123 Molykote

Neptune - 2003

View of seal with spinner support removed

Remove sleeve

Remove seal View of bearing with seal removed

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New seal kit contains a seal insertion tool. Use tool to press

seal into into housing. Part # of tool only is 22004082

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Bead on tub cover

Lip on gasket

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Start at 6 o’clock position and work both sides to top

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Display window

Display Window

Cycle Pads

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Option Pads

MAH6500A

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Start Pause Pad

Start/Pause Pad

Initially depressing the start pad starts the unit, depressing the pad a second time will pause the operation

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Temperature Selector

Water Temperature Selector

Up Arrow

Down Arrow

Neptune - 2003

Fabric Selection Pads

Fabric Selector-matches the proper wash action for each fabric type

Neptune - 2003

Troubleshooting

The 10 most common Neptune Consumer complaints:

1. Won’t fill2. Leaking3. Wet clothes 4. Noisy5. Wrong water temperature6. Won’t start7. Over sudsing- Tub full of suds8. Won’t tumble9. Won’t unlock10. Will not lock

Neptune - 2003

LED Control

LCD Control

LCD Washer Control Board

LED Washer Control Board

Software revisions have been made – you might notice slight differences between old and new product. Always supply the correct serial number when ordering replacement partsLocated in the control console.Location of the Pin connectors is different between the LED and LCD models

Note:The electronic control board is the most often misdiagnosed component on the Neptune product. Returns indicate that less than 20% of the boards are defective.

Electronic Controls

Neptune - 2003

Electronic Control Inputs and Outputs

Inputs To Control Board

Outputs to Load Components

Door Lock Solenoid

Door Unlock Solenoid

Electronic Control Board

Door Latch Switch

Door Lock Switch

Touch Pads Unbalance Switches

Water Valves Pump Heater 6500A and 7500A

Sensor Resistance

6500A &7500A

Pressure SwitchTub

Motor Controller

Neptune - 2003

Technical Data Sheet

Technical data sheet located in console

Neptune - 2003

Consumer Help Codes LED Models

• The electronic control may automatically display codes to help the consumer better understand what is occurring with the washer. The following information is located in the User Guide. The meaning of the code is explained as well as the recommended solution.

Neptune - 2003

Service Mode The service mode provides service personnel the ability to verify the

operation of the washing machine. The service mode can be initiated in the middle of any wash cycle.

While in the service mode the technician can implement special service tests such as:

* service cycle * user interface check * quick spin * control system diagnostic mode

Diagnostic codes and additional help codes can be accessed and the information will be displayed in the control window.

Accessing the Service Mode: (LED DISPLAY, 5500B or 6500A) Depressing the delicates and heavy soil keys for 3 seconds places

the machine in the service mode. The display on the will indicate “00”

Neptune - 2003

Special Tests ChartThere are special tests that can be accessed by the technician while in the service mode. Pressing the indicated key will activate the test. Additional detail is in the manual.

Key Special Test/Function

Presoak Diagnostic Codes

Stain Cycle Help Codes

Rinse Board Output test

Hand Wash Board Input Test

Delicates Quick Service Cycle

Spin Quick Spin Test

Wrinkle Free Membrane Pad Check

Neptune - 2003

Diagnostic CodesWhen a problem with the wash system is detected a diagnostic code is assigned and logged into the control board memory with the last cycle count at which it occurred. The initiation of a diagnostic code indicates the washer needs to be serviced. The control board will allow as many diagnostics as possible for the machine to continue running. In some cases, when the washer shuts down, a code will be displayed in the control window until the consumer selects the off key. See the diagnostic code table for specific actions or references. Accessing Diagnostic Codes After the electronic control board is in the service mode, pressing the presoak key will display a “d” in the window and illuminate the LED above the presoak key

Neptune - 2003

Service Help Codes

When the washer operates differently than designed, a help code is initiated and stored in the control memory. Unlike customer help codes, which are displayed automatically, these codes can only be accessed in the service mode. The severity of the irregularity indicated by a help code is generally less than that of a diagnostic code. Help codes can be useful in diagnosing mechanical failures as well as improper machine use and intermittent operation. Accessing Service Help Codes Place the washer in the service mode and then press the stain cycle key. “h” will be displayed in the window and the LED above the stain cycle key will illuminate.

Neptune - 2003

Board Output Test At times it is to the technician’s advantage if they can energize

certain components as they see fit instead of when the machine wants to. The Board Output Test can be used to activate any of (the different components in the machine. This can greatly accelerate the testing procedure. If component does not turn on,suspect poor wiring connections or failed component.

This test will turn on a specified output with a press of a key. All outputs will be turned off after 10 minutes, unless another

output is selected. Accessing Board Output Test While in the service mode, press the rinse key.

Neptune - 2003

Output Test ChartKEY Function Performed

Cotton Sturdy Energizes Hot Water valve

Wrinkle Free Energizes Cold Water Valve

Delicates Energizes Bleach Valve

Hand Wash Energizes Fabric Softener Valve

Presoak Energizes Drain Pump

Stain CycleEnergizes Motor Control120 VAC supplied to motor controller, motor does not run.

Extra Rinse Unlock Door ( pulse every 2 seconds)

Max ExtractLock Door ( pulse every 2 seconds) (Lock Light Illuminates)

Neptune - 2003

Board Input Test A common method of checking switches and controls is

to make a resistance measurement of the circuit. Neptune control boards have the ability to report back the state of switches and other inputs to the board.

Use of the Board Input test enables a technician to diagnose certain failures in a very short period of time.

When in the service mode. Press the hand wash keypad.The Board input test allows the service technician to check the logic information supplied to the control board.

Neptune - 2003

Input TestKey Function Feedback Cotton Sturdy

Door position “do” Open “d1” Closed

Delicates Latch Position “LO” Unlocked “L1” Locked

Wrinkle Free

High Water Level

“- 0” Below Level “- 1” Above Level

Hand Wash Low Water Level

“_ 0” Below Level “_ 1” Above Level

Temp Down Unbalance Circuit

“uO” Balanced “u1” Unbalanced

Temp Up Water Temperature

Degrees* F.

Neptune - 2003

Quick Service CyclePressing the Delicates key will start a quick service cycle.

Enter the service mode

Press the Delicates keypad

The following sequence of events will occur automatically when connected to water:

1. Energize the cold water and bleach valves. Fill to low level, and then turn cold and bleach valves off.

• 2. Energize the hot water and fabric softener valves. Fill to high level, then turn all valves off.

• 3. Lock the door if not locked.

• 4. Tumble

• 5. Turn the drain pump on.

• 6. Spin to 800 rpm using default rate

• 7. End Spin and coast down

• 8. Unlock the door when the RPM is zero.

• 9. Display ‘PA’ continuously for 10 seconds.

Neptune - 2003

Quick Spin TestWhile in the service mode, pressing the spin key will start the washer in the quick spin mode. The following are the Quick Spin test steps 1. Door Locks2. Spin to 350 rpm and holds for 6 seconds3. Spin to 550 rpm and hold for 6 seconds4. Spin to 600 rpm and hold for 6 seconds5. Spin to 650 rpm and hold for 6 seconds6. Spin to 800 rpm and hold for 6 seconds7. Spin to 1000 rpm and hold for 6 seconds Pressing the Spin key again during the Quick Spin Test will cause the current speed to be held indefinitely. Pressing the Spin key again will revert back to original sequence.

Neptune - 2003

Quick Spin Test

Speed range Displayed as

0-99 rpm 0-99

100-999 rpm 2 digit speed X 10

Speed in excess of 1000 rpm

Letter and digitA = >1000 but <1100B = >1100 but <1200C = >1200 but <13002nd digit = tens

Examples: A2 = 1020 rpmB6 = 1160 rpm

100100

Neptune - 2003

Membrane Pad CheckThe membrane check involves turning all the embedded LED’s on

the membrane off except for the wrinkle free keypad. All the LED’s can be toggled by pressing the key associated with the LED.

At any point, if there are 5 seconds of inactivity, the test will stop without any display

Accessing the Membrane Pad Check Enter the service mode. Press the Wrinkle free keypad

While in the service mode, pressing the Wrinkle Free key will starta membrane pad switch check

101101

Neptune - 2003Troubleshooting

Referencing Ground vs. Neutral

Control Board Input and Output Chart

102102

Neptune - 2003

Schematic

PRESSURE SWITCH

TUBDISPLACEMENT

SWITCH

FRONT WEIGHTDISPLACEMENT

SWITCH

INERTIALUNBALANCE

SWITCH

DOOR LOCKSWITCH

WATERVALVE

DRAIN PUMP

62725590

CONNP1

CONNP2

CONNP3

CONNP8

CONNP6

YL _38

YL _36

DOOR CLOSEDSWITCH

DOOR LOCKSOLENOID

MACHINE CONTROL

BOARD MOUNTED RELAYS

OUT OF

ANCE 24 V

NAL CO

MMON NEUT

RAL L1

H INPU

HOT VA

UNLOCK

EMIFILTER

120 VACLINE

120 VACNEUTRAL

ER (N)

WH_13WH_13

CONNP4

WH_13BK_27

YL _32

YL _29

34- NO

14- NO

32- NC31- COM

11- COM12- NC

FAB. S

ORt ░8

132187654321 4 3 2 1

DOOROPEN

DOORCLOSED

DOOR LOCKSOLENOIDOUTPUT K7

HOT VALVEK10

COLD VALVEK6

BLEACH VALVEK9

SOFTENER VALVEK8

TRANSFORMERT1

DRAIN PUMPK5

DOOR UNLOCKSOLENOID

OUTPUT K4

24 V 5 V

MOTOR POWERK2

MOTOR POWERK12

MEMBRANESWITCHES

MOTORCONTROL

MN4L N

HEATERTHERMISTER

HEATER

6 POSINLINE

1 2 3 4

COM NC

103103

Neptune - 2003

Troubleshooting Diagnostic Codes

• Low Voltage Reference Points

• Diagnostic Codes

104104

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Circuit Board

105105

Neptune - 2003

Troubleshooting Door Lock Circuit

The door lock can be verified by putting the washer into the service mode and manually locking and unlocking the door mechanism through the control panel.

Note: The relay on the control board for the for the door lock mechanism is disabled if the motor control board indicates the spinner speed is > 7 rpm.

1. Place the washer in the service model 2. Advance to the Board output test and press Max Extract to

lock the door and Extra Rinse to unlock the door.

106106

Neptune - 2003

Troubleshooting Motor Drive System

• Machine Control Output Test

• Motor and Motor Control Test

• Jumper Cord Test

107107

Neptune - 2003

JP4 disconnected Remove JP4 connector and follow instructions on technical data sheet for

motor and controller test

JP4 connector

108108

Neptune - 2003

109109

Neptune - 2003

neptune - 2003 1 led display mah5500b and 6500a lcd display mah7500 both the led and lcd models...

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