1. Neptune - 2003 1 LED Display MAH5500B And 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

2. Neptune - 2003 2 Model/Serial Number Tag

3. Neptune - 2003 3 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.

4. Neptune - 2003 4 Installation Clearances

5. Neptune - 2003 5 Unpacking Cut two shipping straps Remove straps and cardboard

6. Neptune - 2003 6 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

7. Neptune - 2003 7 Cut Top Strap The top strap is a one piece strap, cut either side of the buckle and pull the strap completely out

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9. 9 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.

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11. Neptune - 2003 11 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.

12. Neptune - 2003 12 Drain Hose Installation Important installation notes attached to drain hose

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14. Neptune - 2003 14 Door Reversal Remove Two Hinge Screws And Remove Door Remove Two Hinge Covers Hinge Screws

15. Neptune - 2003 15 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

16. Neptune - 2003 16 Hanging Door Check operation of door Install painted screws in opposite hinge holes Install hinge screws Install door

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18. Neptune - 2003 18 Component Location Electronic Control 5500B-6500A-LED 7500A-LCD Component Location Neptune 5500B-6500A-7500A Heater 6500A & 7500A

19. Neptune - 2003 19 Removing Console To remove console, remove two ¼” screws, one on each side of cabinet

20. Neptune - 2003 20 With the two lower screws removed, tilt the console forward and remove four screws holding the metal cover to the console

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22. Neptune - 2003 22 Removing Door Remove the two hinge screws and remove door

23. Neptune - 2003 23 Removing Hinge Covers

24. Neptune - 2003 24 Removing Inner Door Panel To remove inner door panel, remove screws on three sides of door Screws

25. Neptune - 2003 25 Vent Tube and Balance Assembly Vent tube Balance assembly Outlet Inlet

26. Neptune - 2003 26 Check Valve Check valve assembly

27. Neptune - 2003 27 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

28. Neptune - 2003 28 Component Identification Unbalance Switch Motor Controller Drain Pump Boot Drain Heater Motor

29. Neptune - 2003 29 Wiring Harnesses Remove the three wiring harnesses

30. Neptune - 2003 30 Removing Motor Controller To remove motor controller: remove two 5/16” screws

31. Neptune - 2003 31 Remove Housing Lift motor controller housing assembly and remove

32. Neptune - 2003 32 Pump motor Drain pump Pressure Switch

33. Neptune - 2003 33 Pressure Switch Pressure switch is mounted on top of drain pump. It’s covered with a plastic bag. Bag removed

34. Neptune - 2003 34 Removing Switch Removing out of balance switch

35. Neptune - 2003 35 Heating Element Thermistor terminals Heater terminals

36. Neptune - 2003 36 Removing Heater To remove heater: Remove heater and thermistor wires Loosen 10mm nut

37. Neptune - 2003 37 Remove Heater

38. Neptune - 2003 38 View of gasket Nut Tightening the 10mm nut causes lower plate to compress the rubber gasket and seal against the tub housing

39. Neptune - 2003 39 Siphon tubes Bleach reservoir Fabric softener Dispenser outlet to tub Dispenser

40. Neptune - 2003 40 Dispenser Dispenser cover must be removed to raise top Remove four Phillips head screws

41. Neptune - 2003 41 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

42. Neptune - 2003 42 Release Top Remove Two Screws to Pop Top

43. Neptune - 2003 43 Components under top Balance Weight Boot Cable Inertial Unbalance Switch Dispenser Valves Fill Valves Door Lock Assembly Recirculating Hose Side Displacement Switch

44. Neptune - 2003 44 Inlet Hose Water inlet hose from dispenser assembly to tub

45. Neptune - 2003 45 Thermistor - Resistance decreases with temperature rise Inlet water valves

46. Neptune - 2003 46 Caution on rear panel Remove four screws to remove rear access panel

47. Neptune - 2003 47 Pump and Strut View from rear with access panel removed Pressure Switch, drain pump and motor Suspension strut Sump Drain

48. Neptune - 2003 48 Motor and Strut View from rear with access panel removed Drive motor Suspension strut Ribbed motor pulley Drive belt Tub drive pulley

49. Neptune - 2003 49 Removing Motor 2. Remove Bolt 1. Roll off Drive Belt

50. Neptune - 2003 50 Allow the mounting pin to drop out of the motor isolator as you pull the motor out from the front of the machine

51. Neptune - 2003 51 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

52. Neptune - 2003 52 Motor and controller used on 5500B and 7500A prior to series 88

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54. Neptune - 2003 54 Door Lock Assembly Door catch Actuator Button Light bulb

55. Neptune - 2003 55 Removing door lock Remove two 5/16” screws and remove door lock assembly

56. Neptune - 2003 56 Removing Front Shroud After removing door lock assembly the front shroud can be removed

57. Neptune - 2003 57 Remove screws holding metal support bracket and remove bracket

58. Neptune - 2003 58 Boot and Cable Removing or replacing boot cable

59. Neptune - 2003 59 Removing Cable Grasp cable end with needle nose and spring hook with suspension spring tool

60. Neptune - 2003 60 Unhooking Spring

61. Neptune - 2003 61 Spring Unhooked Expand spring to to hook or unhook

62. Neptune - 2003 62 Removing Baffles Remove two T-20 Torx screws Removing baffles

63. Neptune - 2003 63 Removing nut Three ½” nuts secure the tub to the spinner support Torque nuts to 18ft lbs.

64. Neptune - 2003 64 Remove three ½” nuts, profile washers and spinner supports

65. Neptune - 2003 65 Removing Spinner Assembly

66. Neptune - 2003 66 Spinner Support A plastic washer is installed between the spinner support and the tub

67. Neptune - 2003 67 Plastic Washer TubSpinner support Plastic washer

68. Neptune - 2003 68 Remove pulley Torque to 30-33 ft. lbs.when reassembling

69. Neptune - 2003 69 Removing Support With the spinner drive pulley removed, remove the spinner support

70. Neptune - 2003 70 Journal area “O” Ring Spinner support shaft Replace the “o” ring and lubricate journals when servicing Use PN#22002123 Molykote

71. Neptune - 2003 71 View of seal with spinner support removed Remove sleeve Remove sealView of bearing with seal removed

72. Neptune - 2003 72 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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75. Neptune - 2003 75 Bead on tub cover Lip on gasket Bead lip

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77. Neptune - 2003 77 Start at 6 o’clock position and work both sides to top 4 2 1 3

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79. Neptune - 2003 79 Display window Display Window Cycle Pads

80. Neptune - 2003 80 Option Pads MAH6500A

81. Neptune - 2003 81 Start Pause Pad Start/Pause Pad Initially depressing the start pad starts the unit, depressing the pad a second time will pause the operation

82. Neptune - 2003 82 Temperature Selector Water Temperature Selector Up Arrow Down Arrow

83. Neptune - 2003 83 Fabric Selection Pads Fabric Selector-matches the proper wash action for each fabric type

84. Neptune - 2003 84 Troubleshooting The 10 most common Neptune Consumer complaints: 1. Won’t fill 2.Leaking 3.Wet clothes 4.Noisy 5.Wrong water temperature 6.Won’t start 7.Over sudsing- Tub full of suds 8.Won’t tumble 9.Won’t unlock 10. Will not lock

85. Neptune - 2003 85 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 parts  Located 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

86. Neptune - 2003 86 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 PadsUnbalance Switches Water ValvesPumpHeater 6500A and 7500A Motor Sensor Resistance 6500A &7500A Pressure Switch Tub Light Motor Controller

87. Neptune - 2003 87 Technical Data Sheet Technical data sheet located in console

88. Neptune - 2003 88 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.

89. Neptune - 2003 89 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”

90. Neptune - 2003 90 Special Tests Chart

91. Neptune - 2003 91 Diagnostic Codes When 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

92. Neptune - 2003 92 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.

93. Neptune - 2003 93 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.

94. Neptune - 2003 94 Output Test Chart KEYFunction Performed Cotton SturdyEnergizes Hot Water valve Wrinkle FreeEnergizes Cold Water Valve DelicatesEnergizes Bleach Valve Hand WashEnergizes Fabric Softener Valve PresoakEnergizes Drain Pump Stain Cycle Energizes Motor Control 120 VAC supplied to motor controller, motor does not run. Extra RinseUnlock Door ( pulse every 2 seconds) Max Extract Lock Door ( pulse every 2 seconds) (Lock Light Illuminates)

95. Neptune - 2003 95 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.

96. Neptune - 2003 96 Input Test

97. Neptune - 2003 97 Quick Service Cycle Pressing 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.

98. Neptune - 2003 98 Quick Spin Test While 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 Locks 2. Spin to 350 rpm and holds for 6 seconds 3. Spin to 550 rpm and hold for 6 seconds 4. Spin to 600 rpm and hold for 6 seconds 5. Spin to 650 rpm and hold for 6 seconds 6. Spin to 800 rpm and hold for 6 seconds 7. 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.

99. Neptune - 2003 99 Quick Spin Test Speed rangeDisplayed as 0-99 rpm 0-99 100-999 rpm 2 digit speed X 10 Speed in excess of 1000 rpm Letter and digit A = >1000 but <1100 B = >1100 but <1200 C = >1200 but <1300 2 nd digit = tens Examples: A2 = 1020 rpm B6 = 1160 rpm

100. Neptune - 2003 100 Membrane Pad Check The 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 start a membrane pad switch check

101. Neptune - 2003 101 Troubleshooting Referencing Ground vs. Neutral Control Board Input and Output Chart

102. Neptune - 2003 102 Schematic 6500A

103. Neptune - 2003 103 Troubleshooting Diagnostic Codes Low Voltage Reference Points Diagnostic Codes

104. Neptune - 2003 104 Circuit Board

105. Neptune - 2003 105 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.

106. Neptune - 2003 106 Troubleshooting Motor Drive System Machine Control Output Test Motor and Motor Control Test Jumper Cord Test

107. Neptune - 2003 107 JP4 disconnected Remove JP4 connector and follow instructions on technical data sheet for motor and controller test JP4 connector

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