Service Manual Modular Crescent Cuber Models KM-1301SAJ-E hoshizakiamerica.
WARNING Only qualified service technicians should install and service the icemaker. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki-europe.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the icemaker in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 5 I.
IV. Refrigeration Circuit and Component Service Information.............................................. 38 A. Refrigeration Circuit Service Information..................................................................... 38 B. Component Service Information................................................................................... 41 V. Maintenance..................................................................................................................... 42 VI.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the appliance or property. IMPORTANT Indicates important information about the use and care of the appliance.
WARNING, continued • The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. • Children should be properly supervised around the appliance. • Do not climb, stand, or hang on the appliance or allow children or animals to do so.
I. Construction and Water/Refrigeration Circuit Diagram A. KM Construction 1.
B. Bin Control 1. Single Bin Control Mechanical Bin Control Connection Overview Wire Harness Bin Control Cable Connector to Connector B Wire Harness Connector A (for upper unit) Wire Harness Control Board Red K4 Connector Connection Detail Wire Harness Connector B (for upper unit) Bin Control Cable Connector Wire Harness Connector A Control Board Red K4 Connector Bin Control Bracket Thumbscrews Bin Control Assembly Wire Saddle Bin Control Cable Bracket Bin Control Cable 2.
Water Circuit Check Valve Water Pump Pump-Out Evaporator Inlet Water Valve Spray Tubes Freeze/Harvest Pump Timer Refrigeration Circuit Water Tank Spray Tubes Condenser Drain Float Switch Compressor Service Valve Discharge Line Suction Line Drier Strainer Hot Gas Valve High-Pressure Switch Thermostatic Expansion Valves Service Valve Heat Exchanger Liquid Line Valve Fan Cleaning Valve Thermistor Water Supply Check Valves C. Water/Refrigeration Circuit Diagram 1.
Startup Cycle Steps Legend: BC–bin control CB–control board Comp–compressor FM–fan motor FS–float switch HGV–hot gas valve HPT–harvest pump time LLV–liquid line valve PM–pump motor WV–inlet water valve 10 FS check Comp energized FM energized PM energized LLV energized HGV de-energized FS closed 5-min. minimum freeze timer in control Slush Control Thermistor temperature reaches 36°F (2.2°C) (5.8 kΩ). PM de-energized for 10 sec.
BC Operation Shutdown and Restart 11 Legend: BC–bin control BC open (BC actuator paddle engaged) Green "BC CLOSED" LED off Yellow "BC OPEN" LED on All components de-energized. 2. Icemaker Off Yellow "BC OPEN" LED continues. All components de‑energized. Shutdown Delay: • Fill Cycle–15 sec. after activation. • Harvest Cycle–At the end of the harvest cycle, or up to 15 sec. into the freeze cycle if activated at the end of the harvest cycle. • Freeze Cycle– 15 sec.
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Control switch in "OFF" position does not de‑energize all loads Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
1. Operation Diagnosis 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5‑sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on. If yellow "BC OPEN" LED is on (indicating a full bin), check BC. Move ice away from BC actuator paddle. If yellow "BC OPEN" LED stays on, see "II.D. Bin Control Check.". Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is interrupted (K2 connector). • Check CB using the steps in "II.C.
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, FMR, HGV, and X10 relay energize. CB monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). WV and X11 relay are energized during harvest for a maximum of 6 min.
5c) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.F. Thermistor Check." If 1-min. fill cycle starts after harvest timer terminates, check that FS is clean and operating properly, see "II.E. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle.
e) FM and LLV Diagnosis: If FM or LLV does not energize, check for 115VAC at CB K1 #3 (BK) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present: For FM, check capacitor, motor winding, and blade for binding. For LLV, check coil voltage and continuity. f) Refrigerant Pressures and TXV Diagnosis: If evaporator is still not cooling, check refrigerant pressures. See "VIII.A. Specification and Performance Data." Next, check TXV for proper operation.
Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect CB black K5 connector (FS connector). Check that PM stops and re-starts. Next, check that PM rotation is correct (water flowing down the drain through CV). If PM does not stop and re-start, check that CB LEDs 1, 3, and 2 are on. If not, replace CB. If LEDs 1, 3, and 2 are on and PM does not energize, check for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB.
C. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB while CB is beeping. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the icemaker starts at the 1-minute fill cycle. For audible alarm information, see "III.B.
D. Bin Control Check 1. Bin Control Check This appliance uses a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required. To check BC, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the control box cover, then clear any ice away from BC. Connection Detail Wire Harness 4) Check BC wire harness connections. See Fig. 1.
2. Bin Control Cleaning Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick. In this case, BC should be cleaned. WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the dispense unit/ice storage bin. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Clear any ice away from BC.
E. Float Switch Check and Cleaning FS is used to determine that there is sufficient water in the water tank after the 1‑min. fill cycle and after each harvest cycle. FS is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle. No adjustment is required. 1. Float Switch Check To check FS, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position.
2. Float Switch Cleaning Depending on local water conditions, scale may build up on FS. Scale on the switch can cause the float to stick. In this case, FS should be cleaned. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Remove the insulation panel, then remove the drain plug located on the lower front part of the ice chute. See Fig. 3. Allow the water tank to drain. 4) Replace the drain plug in its correct position.
F. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel. Move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor from the refrigerant tubing. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min. 6) Disconnect the thermistor connector from CB K3 connector and check the resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ.
H. Diagnostic Tables 1. No Ice Production No Ice Production - Possible Cause 1. Power Supply a) Off, blown fuse, or tripped breaker. b) Not within specifications. 2. Main Transformer a) Voltage tap switch not set to proper voltage. 3. Fuse (Control Box) a) Blown. 4. Control Switch a) In "OFF" or "WASH" position. b) Coil winding open or shorted. b) Bad contacts. 5. High-Pressure Switch a) Dirty condenser. b) Fan motor not operating. c) Refrigerant overcharged. d) Bad contacts.
No Ice Production - Possible Cause 16 Thermostatic Expansion Valve a) Bulb loose. b) Operating erratically. 17. Liquid Line Valve a) Closed in freeze cycle. b) Open in harvest cycle. 18. Fan Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor. 19. Water System a) Water leaks causing short freeze time. 2. Low Ice Production Low Ice Production - Possible Cause Long Harvest Cycle 1. Evaporator a) Scaled up. 2. Spray Tubes and/or Spray Guides a) Dirty. 3.
Low Ice Production - Possible Cause Long Freeze Cycle 1. Evaporator a) Scaled up, dirty. 2. Float Switch See "II.E. Float Switch Check and Cleaning" a) Scaled up, dirty. 3. Inlet Water Valve a) Leaking by. b) Float sticking. c) Defective switch. 4. Hot Gas Valve a) Erratic or open. 5. Condenser a) Clogged. 6. Control Board See "II.C. Control Board Check" a) Float switch connection loose (K5). 7. Refrigerant Charge a) Low. 8. Thermostatic Expansion Valve a) Bulb loose. b) Defective.
Freeze-Up - Possible Cause 8. Control Board See "II.C. Control Board Check" and "III.C. Settings and Adjustments" a) Harvest timer (S4 dip switch 1 & 2) set too short. 9. Bin Control See "II.D. Bin Control Check" a) Actuator does not move or defective. b) Harvest pump time (harvest assist) (S4 dip switch 7) not in factory default position. c) Defective. 10. Thermistor See "II.F. Thermistor Check" a) Loose, disconnected, or defective. 11. Thermostatic Expansion Valve a) Defective. 12.
I. Freeze-Up Check List PLEASE COMPLETE WHEN DIAGNOSING A FREEZE-UP REFRIGERANT LEAK OR LOW CHARGE TECHNICAL SUPPORT FAX 1-800-843-1056 “MAKE COPIES AND USE AS NEEDED” MODEL#_____________________SERIAL#_________________INSTALL DATE_____________FAIL DATE________________ 1. Single unit or stacked equipment? Single Stack [ ] [ ] 2. Is the float switch dirty? YES [ ] NO [ ] 3. Is the water pump always running in freeze? [ ] [ ] 4. Is the thermistor properly mounted? [ ] [ ] 19.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM and KMH series appliances. • All models are pretested and factory adjusted. • For a control board check procedure, see "II.C. Control Board Check." NOTICE • Fragile, handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the icemaker when handling or replacing the control board.
A. Control Board Layout "J" Control Board • Bin Control Switch Closed LED (green) • "ALARM RESET" Button • S4 Dip Switch • K3 (white) Connector Thermistor (harvest control and high temperature safety) • Bin Control Switch Open LED (yellow) • Alarm Buzzer • K4 (red) Connector Bin Control • S5 Dip Switch • Ext. Harvest LED (yellow) (lights when water line thermistor initiates extended harvest) Not used this model • K5 (black) Connector Float Switch (water level) • POWER OK LED (red) (lights when 10.
B. LED Lights and Audible Alarm Safeties Beep occurs and red "POWER OK" LED turns on when control switch is moved to "ICE" position. Sequence Green LEDs 1 through 4 turn on and sequence from initial startup as listed in the table below. Order of green LEDs from the outer edge of control board is 1, 4, 3, 2. Sequence Step LED Energized Components Time LEDs are On Min. Max.
C. Settings and Adjustments NOTICE Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact your Hoshizaki Service Center. 1. Default Dip Switch Settings The dip switches are factory-adjusted to the following positions: S4 Dip Switch S4 Dip Switch No. KM-1301SAJ-E 1 2 3 4 5 6 7 8 9 10 OFF OFF ON ON ON ON ON OFF ON ON S5 Dip Switch (Do Not Adjust) S5 Dip Switch No.
2. Harvest Time (S4 dip switch 1 & 2) The harvest timer starts counting when the thermistor reaches 48°F (9°C) at the evaporator outlet and the control board reads 3.9 kΩ from the thermistor. The harvest timer is factory set, and generally no adjustment is required. However, a setting longer than the factory setting may be advised in cases where the drain provided at harvest needs to be prolonged for extra cleaning.
4. Pump-Out Frequency Control (S4 dip switch 5) The pump-out frequency control is factory set to drain the water tank every 10 cycles. Generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump‑out frequency can be adjusted. The pump-out frequency control can be set to have a pump‑out occur every cycle, or every 10 cycles. The first pump-out is dependent on S4 dip switch 5. See the table below.
6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the appliance. Depending on S4 dip switch 7 setting, the pump motor either stays off or is energized during the last seconds of the harvest cycle. When the pump motor is energized (S4 dip switch 7 on), water circulates over the evaporator.
8. Freeze Timer (S4 dip switch 9 & 10) NOTICE Adjust to proper specification, or the icemaker may not operate correctly. The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of the freeze timer, the control board initiates the harvest cycle or pump-out cycle. After 2 consecutive freeze timer terminations, the control board shuts down the icemaker. In this case, see "II.H.3. Low Ice Production" for possible solutions.
10. Refill Counter (S5 dip switch 2 and 3) NOTICE Do not adjust. These must be left in the factory default position or the icemaker will not operate correctly. S5 Dip Switch Setting No. 2 No. 3 Refill Counter OFF OFF 0 OFF ON 1 refill ON OFF 9 refills ON ON 10 refills 11. Minimum Harvest Time (S5 dip switch 4) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside the factory default setting may result in damage to the appliance. S5 Dip Switch Setting No.
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the control switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF" position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. • Do not use silver alloy or copper alloy containing arsenic. 1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used. 6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
B. Component Service Information NOTICE When replacing a component listed below, see the notes to help ensure proper operation. Component Notes Compressor 1 phase: Install a new start capacitor, run capacitor, and start relay. Thermostatic Expansion Valves • Attach the thermostatic expansion valve bulb to the suction line in the same location as the previous bulb. • The bulb should be between the 10 and 2 o'clock positions on the tube. • Secure the bulb with the clamp and holder, then insulate it.
V. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch or service switch with damp hands • Before servicing: Move the control switch to the "OFF" position and turn off the power supply.
VI. Preparing the Icemaker for Periods of Non-Use NOTICE • When storing the appliance for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. • To prevent damage to the water pump, do not operate the appliance with the control switch in the "WASH" position when the water tank is empty. When the appliance is not used for two or three days under normal conditions, it is sufficient to move the control switch to the "OFF" position.
VII. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
VIII. Technical Information We reserve the right to make changes in specifications and design without prior notice. A. Specification and Performance Data Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 1. KM-1301SAJ-E Specification Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) APPROXIMATE ICE PRODUCTION PER 24 HR.
* 46 412±22 0 PSIG 327±22 PSIG Cut-out Cut-in Air-Cooled Model * High-Pressure Switch B.
