Maytag Neptune TL FAV6800A Service

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Use & care manual (48 pages)

Installation instructions manual (17 pages)

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This manual is to be used by qualified appliance

technicians only. Maytag does not assume any

responsibility for property damage or personal

injury for improper service procedures done by

an unqualified person.

Neptune TL

This Base Manual covers general information

Refer to individual Technical Sheet

for information on specific models

This manual includes, but is

not limited to the following:

FAV6800A

FAV9800A

16022808

Revision 0

December 2003

Table of Contents

Troubleshooting

Summary of Contents for Maytag Neptune TL FAV6800A

Page 1 Service This manual is to be used by qualified appliance technicians only. Maytag does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person. Neptune TL This Base Manual covers general information...
Page 2: Important Information
Important Notices for Technicians and Consumers Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service.
Page 3: Table Of Contents
Heater Assembly Removal ........47 Hold Quick Spin Test ..........24 Motor Control Removal ..........47 Spinner Support Removal .......... 48 Appendix A Installation Instructions ..........50 Appendix B Use And Care ............57 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 4: Important Safety Information
Disconnect the power do not understand. cord by grasping the plug, not the cord. • Install the washer according to the Installation Instructions. All connections for water, drain, electrical power and grounding must comply with 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 5 • DO NOT use an extension cord with this appliance. • DO NOT use an adapter plug with this appliance. • DO NOT pinch power cord. Ground Neutral Neutral side 115±12 V.A.C. V.A.C. Round grounding 115±12 V.A.C. prong 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 6: Grounding Instructions
This unit should be plugged into a separate 60 hertz circuit with the electrical rating as shown in the appropriate drawing. Models operate with a supply voltage of 120 Volts. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 7 Important Safety Information KEEP CLEAR ROTATING BELTS AND PULLEYS 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 8: General Information
To locate an authorized technician: Complete registration card and promptly return. If • For Maytag call 1-800-462-9824 or visit the Web Site at registration card is missing: • For Maytag product call 1-800-688-9900 or visit the www.maytag.com.
Page 9: Model Nomenclature
Listing 120V-60hz 240V-60hz Product Type Canada 240V-60hz Automatic 220-240 V / 50-60 Hz Marketing Code Wash Position This identifies which version of production the Horizontal unit is. Vertical Feature Content 6800 Feature Package 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 12: Fav 6800Aw Trouble Shooting Trouble Shooting General Symptoms
WARNING To avoid risk of electrical shock, personal injury or death, disconnect power to unit before servicing, unless testing requires power. Maytag Neptune™ TL FAV6800AW Washer Diagnostic Code table follows later in this document. Will Not Spin Will Not Start •...
Page 13: Consumer Help Codes
S ee W et C lothes T roubleshooting. starting wash cycle. Im proper signal from T ub • D isconnect inlet hoses and clean screens. D isplacem ent Sensor. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 14: Service Mode
2) Spin to index speed 90 rpm and hold for 60 Temp ↑ (up) Mode) Cycle seconds. Pum p drains m achine. 3) Spin to index speed 150 rpm and hold for 6 seconds. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 15: Hold Quick Spin Step
3. Tumble using 48 rpm tumble for 10 seconds. There could be up to a 20 second delay before the 4. Tumble with hot fill: Continue tumble while energizing spinner starts rotating. hot water valve for 5 seconds. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 16: Board Functional Test Input Control Keys
Quick Wash* Toggle System Relay Board Functional Test Input Control Presoak Drain Pump Extra Rinse Keys Lid Unlock* While in Service Mode, pressing the Super Wash key will begin the Board Input Test. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 17: Display Diagnostic Codes
Displays "FL" wash cycles. cycles. opening the lid. Go Lid failed to Go to "Will not to "Lid Lock Test" The lid fails lock after 11 unlock" to lock attempts Troubleshooting Section 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 18: Exit Service Mode
Exit Service Mode To exit: 1) Press Enviro Plus and Spin Only keys for 3 seconds again, or 2) press Off, or 3) unplug the machine. After five (5) minutes of inactivity (user key 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 19: Tub Displacement Sensor Diagnostics
Note: Oil in a new Transm ission is clear. During operation, the oil will turn a dark color caused by the special com pounds in som e of the bushings. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 20: Control Board Inputs Table
Note: When the Neptune TL is plugged in, the Machine Control Board will check the lid latch mechanism every 20 seconds. If found to be locked with no cycle running , the Control Board will send a signal to the switch to unlock the lid. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 21: Fav 9800Aw Trouble Shooting Trouble Shooting General Symptoms
W ARNING To avoid risk of electrical shock, personal injury, or death, disconnect power to washer before servicing, unless testing requires it. Maytag Neptune™ TL FAV9800AW Washer Diagnostic Code table follows later in this document. Will Not Spin Will Not Start •...
Page 22: Removing A Favorite Cycle
If the water heater is located a long distance from special service tests and view diagnostic displays. washer, the water line may need to be purged prior to starting wash cycle. • Disconnect inlet hoses and clean screens. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 23: Enter/Exit Service Mode
7) Spin to index speed 850 rpm and hold for 6 seconds. 8) Spin to index speed 1000 rpm and hold for 6 seconds. 9) Coast down to 0 rpm. 10) Unlock lid. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 24: Hold Quick Spin Test
• Check phase windings of the motor. See Illustration. If motor windings are good, replace the motor control board. If voltage is not present; • Check for loose electrical connections at Machine Control Board or broken wires in harness. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 25: Service Cycle
Go to "No Water Total fill 14 Fill" No Fill minutes Troubleshooting exceeded. Section Go to "Will not Lid failed to The lid fails unlock" lock after 11 to lock Troubleshooting attempts Section 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 26: Exit Service Mode
To exit: 1) Press exit service mode, or 2) press Off, or wash cycles. cycles. to "Lid Lock Test" 3) unplug the machine. After five (5) m inutes of inactivity (user key presses) in Service Mode, the machine will exit the Service Mode 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 27: Hose Reversal Detection And Correction
Display will show “tub unbalance”. #1 Mark NOTE: Moving the tube midway between mark #1 and mark #2 represents normal operation. Display will show “no unbalance”. Clamp Ring 15- 20 ft. lbs. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 28: Component Diagnostics
Note: Oil in a new Transmission is clear. During operation, the oil will turn a dark color caused by the special compounds in some of the bushings. Pin #14 Pin #9 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 29: Control Board Inputs Table
Home 5 & 3 Favorites 6 & 3 Back 5 & 4 5 & 7 Start/Pause 6 & 7 Help 6 & 4 Stain Brain 5 & 8 Cycle Library 6 & 8 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 30: Disassembly Procedures
5. Lift ribbon out of connector. Control Board Removal 1. Disconnect power supply to unit. 2. Remove Console. 3. Separate Back Panel from Console. 4. Pull up on side lock tabs of Ribbon Connector. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 31 Board to Console. 9. Main Wiring Harness Separates at plug, allowing Console to be completely removed. 8. Slide Control Board up and to the left to disengage tabs locking the right side in place. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 32: Lid Disassembly/Removal
The dart molded in the Inner Panel will disengage from the Outer Lid. 6. Separate hinge from Outer Lid. Slide lid to side, and remove. 4. Slide panel down, to disengage tabs and release Inner Panel. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 33: Top Cover Removal
3. Unsnap Splash Guard by starting in the lower right triangle. Then rotate down and snap into place across corner and working around perimeter until guard is the long side of the triangle while pushing up on the free. reservoir underneath. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 34: Lid Lock/Reed Switch Removal
5. Repeat procedure for Lid Lock on right side. 6. The left Lid Lock is a combination lock and Reed Switch. Access the magnet by lifting the lid and removing the Inner Lid. Pull Housing Away Depress Depress 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 35: Inlet Water Valve Removal
2. Remove water lines to the back of washer. 8. Slide Water Valve to the right to release from Top 3. Lift Top Cover. Cover. 4. Remove wire harness from Water Valve. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 36: Detergent Dispenser Water Valve Removal
6. Remove screw attaching valve to housing. with kit. Detergent Dispenser Water Valve Removal 1. Disconnect power supply to unit. 2. Lift Top Cover. 3. Remove wire harness from left and right side of valve. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 37: Top Cover Removal
BACK LEFT RIGHT FRONT 4. Remove Tumbler Cap with a flat blade screwdriver. Do not mar or create a burr on the Tumbler, or Tumbler Cap, which could snag clothes. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 38 Tumbler Side Designation Angle IMPORTANT: The spinner also has “L” and “R” molded into the plastic under the tumbler. Insure the correct tumbler is used for the corresponding side of the spin- ner. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 39: Tumbler Bearing Removal
“R” visible in the bottom of the Spinner when the Tumbler is removed. Tumbler Bearing Removal 1. Disconnect power supply to unit. 2. Lift lid. 3. Remove Tumbler. 4. Remove Torx™ screws 3 each side. BACK LEFT RIGHT 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 40: Transmission/O-Ring Seal Removal
Transmission O-Ring Seal. Apply a small amount of detergent for lubrication before install ing new O-Ring Seal. Strut Assembly NOTE: A small amount of oil under the transmission is Mounting Screws normal. Transmission O-Ring Seal 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 41: Front Panel Removal
3. Remove 2 screws on the back side of the Front Panel. Strain Relief Wire Clip 4. Tip the Front Panel forward and lift upward, clearing the J clips through the bottom of the panel. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 42 Tub Displacement Sensor to the terminal area. Slide the wire harness connector onto the sensor. Reroute wires through wire clips and strain relief’s. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 43: Front Strut Removal
5. Raise washer off floor. 8. Remove 3/8" lock nut on bottom of strut while holding white collar nut. 6. Use a 4"x4" wood block or equivalent to support tub. 7. Remove strut ball from tub socket. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 44: Drain Pump/Pressure Switch Removal
1. Disconnect power supply to unit. 2. Lift Top Cover. 3. Remove Front Panel. 4. Disconnect hose at tub drain. 5. Disconnect outlet hose at pump. 6. Disconnect wiring harness plugs. 7. Turn Drain Pump counterclockwise approximately 45°. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 45: Spinner Removal
Six Spinner Bolts Torque to 15-20 ft. lbs. # 15 Torx™ screws CAUTION: When working around stamped metal, edges may be sharp. 5. Remove Outer Tub Cover. 6. Remove left and right Tumblers. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 46: Drive Motor Removal
5. Loosen Drive Motor tension bolt. 16.Unplug Heater Harness from Heater Assembly. Remove Heater Harness Strain Relief from Outer Tub (Heater Models Only). 17.Unhook Tub Displacement Sensor and tuck out of Loosen Bolt way. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 47: Pulley/Clutch Removal
NOTE: When reinstalling, properly seat Pulley with a 1/16-1/8" gap between the Pulley face and shaft end. On reinstallation, tighten Pulley Bolt to 96 inch pounds. 5/16 Screw LEFT RIGHT Release Wire Harness from Clips 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 48: Spinner Support Removal
22.Remove Drive Belt. 23.Remove Pulley Bolt and Pulley. 24.Remove the Spinner Nut. Special wrench is available from Maytag to aid in removal. Place the Spinner Support Removal Tool over nut and locked in place. BACK 8. Unplug connectors from board.
Page 49 A new seal and sleeve should be inserted into the Outer Tub. NOTE: When installing a new seal, make sure the sleeve from the previous seal has been removed and discarded. 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 50: Installation Instructions
A A A A A ppendix ppendix ppendix A A A A A ppendix ppendix 16022808 Rev. 0 ©2003 Maytag Appliances Company...
Page 57: Appendix B Use And Care
A A A A A ppendix B ppendix B ppendix B ppendix B ppendix B 16022808 Rev. 0 ©2003 Maytag Appliances Company...

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