11

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

22

Neptune - 2003

Model/Serial Number Tag

33

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.

44

Neptune - 2003

Installation Clearances

55

Neptune - 2003

Unpacking

Cut two shipping straps

Remove straps and cardboard

66

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

77

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

88

Neptune - 2003

99

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.

1010

Neptune - 2003

1111

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.

1212

Neptune - 2003

Drain Hose Installation

Important installation notes attached to drain hose

1313

Neptune - 2003

1414

Neptune - 2003

Door Reversal

Remove Two Hinge Screws And Remove Door

Remove Two Hinge Covers

Hinge Screws

1515

Neptune - 2003

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

1616

Neptune - 2003

Hanging Door

Check operation of door

Install painted screws in opposite hinge holes

Install hinge screws

Install door

1717

Neptune - 2003

1818

Neptune - 2003

Component LocationComponent LocationElectronic Control

5500B-6500A-LED

7500A-LCD

Component LocationNeptune 5500B-6500A-7500A

Heater 6500A & 7500A

1919

Neptune - 2003

Removing Console

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

2020

Neptune - 2003

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

2121

Neptune - 2003

2222

Neptune - 2003

Removing Door

Remove the two hinge screws and remove door

2323

Neptune - 2003

Removing Hinge Covers

2424

Neptune - 2003

Removing Inner Door Panel

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

Screws

2525

Neptune - 2003

Vent Tube and Balance Assembly

Vent tube

Balance assembly

Outlet

Inlet

2626

Neptune - 2003

Check Valve

Check valve assembly

2727

Neptune - 2003

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

2828

Neptune - 2003

Component Identification

Unbalance SwitchMotor Controller

Drain Pump

Boot DrainHeater

Motor

2929

Neptune - 2003

Wiring Harnesses

Remove the three wiring harnesses

3030

Neptune - 2003

Removing Motor Controller

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

3131

Neptune - 2003

Remove Housing

Lift motor controller housing assembly and remove

3232

Neptune - 2003

Pump motor

Drain pump

Pressure Switch

3333

Neptune - 2003

Pressure Switch

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

Bag removed

3434

Neptune - 2003

Removing Switch

Removing out of balance switch

3535

Neptune - 2003

Heating Element

Thermistor terminals

Heater terminals

3636

Neptune - 2003

Removing Heater

To remove heater:

Remove heater and thermistor wires

Loosen 10mm nut

3737

Neptune - 2003

Remove Heater

3838

Neptune - 2003

View of gasket

Nut

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

3939

Neptune - 2003

Siphon tubes

Bleach reservoir

Fabric softener

Dispenser outlet to tub

Dispenser

4040

Neptune - 2003

Dispenser

Dispenser cover must be removed to raise top

Remove four Phillips head screws

4141

Neptune - 2003

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

4242

Neptune - 2003

Release Top

Remove Two Screws to Pop Top

4343

Neptune - 2003

Components under top Balance Weight

Boot Cable

Inertial Unbalance Switch

Dispenser Valves

Fill Valves

Door Lock Assembly

Recirculating Hose

Side Displacement Switch

4444

Neptune - 2003

Inlet Hose

Water inlet hose from dispenser assembly to tub

4545

Neptune - 2003

Thermistor - Resistance decreases with temperature rise

Inlet water valves

4646

Neptune - 2003

Caution on rear panel Remove four screws to

remove rear access panel

4747

Neptune - 2003

Pump and Strut

View from rear with access panel removed

Pressure Switch, drain pump and motor

Suspension strut

Sump Drain

4848

Neptune - 2003

Motor and Strut

View from rear with access panel removed

Drive motorSuspension strut

Ribbed motor pulley

Drive beltTub drive pulley

4949

Neptune - 2003

Removing Motor

2. Remove Bolt

1. Roll off Drive Belt

5050

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

5151

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

5252

Neptune - 2003

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

5353

Neptune - 2003

5454

Neptune - 2003

Door Lock Assembly

Door catch

Actuator Button

Light bulb

5555

Neptune - 2003

Removing door lock Remove two 5/16” screws and

remove door lock assembly

5656

Neptune - 2003

Removing Front Shroud

After removing door lock assembly the front shroud can be removed

5757

Neptune - 2003

Remove screws holding metal support bracket and remove bracket

5858

Neptune - 2003

Boot and Cable

Removing or replacing boot cable

5959

Neptune - 2003

Removing Cable

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

6060

Neptune - 2003

Unhooking Spring

6161

Neptune - 2003

Spring Unhooked

Expand spring to to hook or unhook

6262

Neptune - 2003

Removing Baffles Remove two T-20

Torx screws

Removing baffles

6363

Neptune - 2003

Removing nut

Three ½” nuts secure the tub to the spinner support

Torque nuts to 18ft lbs.

6464

Neptune - 2003

Remove three ½” nuts, profile washers and spinner supports

6565

Neptune - 2003

Removing Spinner Assembly

6666

Neptune - 2003

Spinner Support

A plastic washer is installed between the spinner support

and the tub

6767

Neptune - 2003

Plastic Washer

Tub Spinner support

Plastic washer

6868

Neptune - 2003Remove pulley

Torque to 30-33 ft. lbs.when reassembling

6969

Neptune - 2003

Removing Support

With the spinner drive pulley removed, remove the spinner support

7070

Neptune - 2003

Journal area

“O” Ring

Spinner support shaft

Replace the “o” ring and lubricate journals when servicing

Use PN#22002123 Molykote

7171

Neptune - 2003

View of seal with spinner support removed

Remove sleeve

Remove seal View of bearing with seal removed

7272

Neptune - 2003

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

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

7373

Neptune - 2003

7474

Neptune - 2003

7575

Neptune - 2003

Bead on tub cover

Lip on gasket

Bead

lip

7676

Neptune - 2003

7777

Neptune - 2003

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

4

21

3

7878

Neptune - 2003

7979

Neptune - 2003

Display window

Display Window

Cycle Pads

8080

Neptune - 2003

Option Pads

Option Pads

MAH6500A

8181

Neptune - 2003

Start Pause Pad

Start/Pause Pad

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

8282

Neptune - 2003

Temperature Selector

Water Temperature Selector

Up Arrow

Down Arrow

8383

Neptune - 2003

Fabric Selection Pads

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

8484

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

8585

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

8686

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

Motor

Sensor Resistance

6500A &7500A

Pressure SwitchTub

Light

Motor Controller

8787

Neptune - 2003

Technical Data Sheet

Technical data sheet located in console

8888

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.

8989

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”

9090

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

9191

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

9292

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.

9393

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.

9494

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)

9595

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.

9696

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.

9797

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.

9898

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.

9999

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

MOTOR

PRESSURE SWITCH

TUBDISPLACEMENT

SWITCH

FRONT WEIGHTDISPLACEMENT

SWITCH

INERTIALUNBALANCE

SWITCH

DOOR LOCKSWITCH

WATERVALVE

DRAIN PUMP

62725590

CONNP1

CONNP2

CONNP3

CONNP8

CONNP6

BR_1

4

OR_7

YL _38

BR_2

1

YL _36

BU_9

BK_8

BR_5

YL_6

RD_3

5

GY_4

GN

DOOR CLOSEDSWITCH

DOOR LOCKSOLENOID

LAMP

GY_3

7

GY_11

BU_2

3

BU_40

BK_8

BU_26

BU_11

OR_1

2

WH_1

3

WH_1

3

BU_4

BU_3

MACHINE CONTROL

BOARD MOUNTED RELAYS

GROU

ND

OUT OF

BAL

ANCE 24 V

DC

24 V

DCLO

WER

LEVE

L SE

NSE

VALV

E TH

ERMI

STOR

VALV

E TH

ERMI

STOR

DOOR

LOC

K SW

ITCH

INPUT

MOTO

R CO

NTRO

L TA

CH

TORQ

UE P

WM

MOTO

R CO

NTRO

L SIG

NAL CO

MMON NEUT

RAL L1

DRAIN

PUM

P

L1 TO

MOTO

R CO

NTRO

L

DOOR

UNL

OCK

OUTP

UT

DOOR

SWITC

H INPU

T

BU_2

6

RD_2

3BR

_21

BK_8

BK_8

GY_4

BU_11

GY_37

YL_3

8

GY_1

1

RD_3

5

BR_1

4OR

_7BU

_9BR

_5YL

_6YL

_36

DOOR

LOC

K OU

TPUT

HOT VA

LVE

COLD

VAL

VEBL

EACH

SOFT

ENER

HIGH

LEV

EL S

ENSE

WH_1

3

LOCK

UNLOCK

COM

RD_23

EMIFILTER

120 VACLINE

120 VACNEUTRAL

BU_3

3

BU_34

WH_1

1

YL_3

2

WHBK

BR

GYGY

GN

HEAT

ER (N)

BK_1

1

WH_32

OR_4

0

WH_1

3

WH_13WH_13

BK_4

4

WH_1

3

WH_1

3

BK_L1

WH_1

3

CONNP4

BK_2

7

WH_13

PK_3

3

PK_3

4

HEAT

ER (

L1)

WH_13BK_27

BK_L1

BK_L1

OR_40

PK_34

PK_33

BK_11

YL _32

WH_13

BU_23

BU_34

BU_33

YL_2

9

YL _29

RD_3

0

RD_30

BU_3

1

BU_31

COMNO

34- NO

14- NO

32- NC31- COM

11- COM12- NC

GND

COLD

BLEA

CH

HOT

FAB. S

OFTE

NER

THER

MIST

ORt ░8

76

54

32

132187654321 4 3 2 1

t ░

DOOROPEN

DOORCLOSED

COM

DOOR LOCKSOLENOIDOUTPUT K7

HOT VALVEK10

COLD VALVEK6

BLEACH VALVEK9

SOFTENER VALVEK8

TRANSFORMERT1

DRAIN PUMPK5

DOOR UNLOCKSOLENOID

OUTPUT K4

120 V

24 V 5 V

MOTOR POWERK2

MOTOR POWERK12

MEMBRANESWITCHES

P7

3 2 1

85

74

63

21

T

MOTORCONTROL

16

32

52

41

J P4

34

57

63

52

41

MN4L N

1 2

t░

HEATERTHERMISTER

HEATER

6 POSINLINE

CONN

1 2 3 4

COM NC

COM NC

COM NC

6500A

103103

Neptune - 2003

Troubleshooting Diagnostic Codes

• Low Voltage Reference Points

• Diagnostic Codes

104104

Neptune - 2003

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