Service Manual Modular Crescent Cuber Models KM-520MAJ-E KM-660MAJ-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.
VIII. Technical Information..................................................................................................... 45 A. Specification and Performance Data Sheets................................................................ 45 1. KM-520MAJ-E......................................................................................................... 45 2. KM-660MAJ-E........................................................................................................ 46 B. Wiring Diagrams ....
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 • Children should be properly supervised around this appliance. • Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged. • Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire. • Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance.
I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1.
Drain Evaporator 8 Water Circuit Refrigeration Circuit Water Tank Float Switch Spray Tubes Water Pump Drain Valve Bypass Valve Thermistor Water Supply Inlet Water Valve Drier Compressor Suction Line Discharge Line Thermostatic Expansion Valve Heat Exchanger Liquid Line Valve Fan Condenser Strainer Hot Gas Valve High-Pressure Switch B. Water/Refrigeration Circuit Diagram 1.
Comp energized HGV energized WV energized FS closed Thermistor in control FS check 9 Slush Control Thermistor temperature reaches 36°F (2.2°C) (5.8 kΩ). PM de-energized for 10 sec. FS opens or freeze timer terminates FS in control Comp energized DV energized HGV energized PM de-energizes for 2 sec., then energizes for 10/20 sec. FM de-energized LLV de-energized • Factory set for every 10th cycle (S4 dip switch 5) • Pump motor de-energizes for 2 sec., then energizes for 10/20 sec.
BC Operation Shutdown and Restart 10 Legend: BC–bin control BC open (BC sensor engaged) Green UBC LED off Yellow "BC OPEN" LED on All components de-energized. 2. Icemaker Off BC closed (BC sensor disengaged) Green UBC LED on Yellow "BC OPEN" LED off To 1. 1-Minute Fill Cycle Icemaker starts at "1. 1-Minute Fill Cycle." 3. Ice Level Lowered Control board retains freeze-time correction count data between bin control restarts. Yellow "BC OPEN" LED continues. All components de‑energized.
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. Sequence and Component Diagnosis 3) Power On: Plug the power supply cord back into the electrical outlet, then move the control switch to the "ON" position and the mode switch to the "ICE" position. A 5‑sec. delay occurs. CB red "POWER OK" LED turns on. If CB yellow "BC OPEN" LED is on (indicating a full bin), move ice away from BC sensing area or see "II.D. Bin Control Check and Adjustment." Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is interrupted (K2 connector).
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV continues. Comp and HGV 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 is energized during harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), whichever is shorter. See step 5b below.
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 and LED 2 is on, check for 115VAC at CB K1 #1 (V). If 115VAC is present at #1 (V) and not at #3 (BK), replace CB. If 115VAC is present and LED 2 is on: For FM, check capacitor, motor winding, and blade for binding. For LLV, check coil voltage and continuity. Note: LED 2 is on for LLV/FM and off for HGV.
7) Pump-Out Cycle – LEDs 1, 3, and 5 are on (10/20 second pump-out). Timing of the first pump-out is determined by S4 dip switch 5. See the table below. Control Board Settings S4 Dip Switch Setting Pump-Out Frequency Control Board OFF Every 10 cycles After 11th freeze cycle ON Every cycle After 2nd freeze cycle No. 5 Comp continues, HGV energizes. Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV energizes. NOTICE! S5 dip switch 1 must not be adjusted.
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 and Adjustment WARNING • All parts are factory-adjusted. Improper adjustments may adversely affect safety, performance, component life, and warranty coverage. • In Hoshizaki DB and DM dispenser applications, the bin control controller setting must be adjusted to 2. For Coca-Cola Freestyle® Dispenser and other dispenser applications, the bin control controller setting must be adjusted to 3.
4) As water begins to fill the water tank (1-min. fill), place an object 5" to 7" (127 to 178 mm) away from the bin control lens. See Fig. 3. 15 sec. later, the icemaker shuts down. Remove the object from the bin control lens. 30 sec. later, the icemaker restarts. Bin Control Lens Fig. 3 Cycle at Bin Shutdown Control Activation Fill Cycle 15 sec. after activation. Harvest Cycle If engaged 15 sec. or longer, at the end of harvest cycle. Freeze Cycle 15 sec.
2. Bin Control Adjustment WARNING • All parts are factory-adjusted. Improper adjustments may adversely affect safety, performance, component life, and warranty coverage. • In Hoshizaki DB and DM dispenser applications, the bin control controller setting must be adjusted to 2. For Coca-Cola Freestyle® Dispenser and non-Hoshizaki dispenser applications, the bin control controller setting must be adjusted to 3.
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 base cover, disconnect the water tank end of the pump tubing to drain the water tank. See Fig. 5. After the water tank has drained, reconnect the pump tubing.
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, then remove the top and right side panels. 3) Remove the thermistor from the refrigerant tubing. 4) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min. 5) Disconnect the thermistor connector from CB K3 connector and check the resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ.
I. 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. Fuse (Control Box or Power Supply Cord) a) Blown. 3. Control Switch a) In "OFF" or "PUMP" position. b) Defective. 4. Main Transformer a) Defective. 5. High-Pressure Switch a) Dirty condenser. b) Fan motor not operating. c) Refrigerant overcharged. d) Bad contacts. e) Refrigerant lines or components plugged. 6.
No Ice Production - Possible Cause 16. Pump Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor. d) Mechanical seal worn out. 17. Thermostatic Expansion Valve a) Bulb loose. b) Operating erratically. 18. Liquid Line Valve a) Closed in freeze cycle. b) Open in harvest cycle. 19. Fan Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor. 20. Water System a) Water leaks causing short freeze time. 2.
Freeze-Up - Possible Cause 10. Thermistor See "II.F. Thermistor Check" a) Loose, disconnected, or defective. 11. Thermostatic Expansion Valve a) Defective. 12. Hot Gas Valve a) Defective. 13. Liquid Line Valve a) Defective. Freeze Cycle 1. Evaporator a) Scaled up. b) Damaged. 2. Spray Tubes and/or Spray Guides a) Dirty. 3. Refrigerant Charge a) Low. 4. Control Board See "II.C. Control Board Check" a) Freeze timer (S4 dip switch 9 & 10) set incorrectly. 5. Inlet Water Valve a) Leaking by.
Low Ice Production - Possible Cause 9. Compressor a) Inefficient or off. 10. Liquid Line Valve a) Erratic or open. 11. Thermostatic Expansion Valve a) Defective. 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. 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.
J. Freeze-Up Check List Freeze-Up Check List Please Complete When Diagnosing a Freeze-Up, Refrigerant Leak, or Low Charge Technical Support Fax #: 770-487-3360 Make Copies And Use As Needed Model #___________________________ Serial # _________________________Install Date______________Fail Date___________ List model and manufacture of bin or dispenser__________________________. Date appliance was last cleaned:__________.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM 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 1. "K" Control Board "K" Control Board • "ALARM RESET" Button • S4 Dip Switch • "OUTPUT TEST" Button (used to test relays on control board) • Bin Control Switch Open LED (yellow) • K3 (white) Connector Thermistor (harvest control and high temperature safety) • K9 (white) (Cleaning and Sanitizing Circuit) • K4 (red) Connector Bin Control • Ext.
B. LED Lights and Audible Alarm Safeties Beep occurs and red CB "POWER OK" LED turns on when control switch is moved to "ICE" position. Sequence Green LEDs 1 through 5 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, 5, 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 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. a) Harvest Pump Time (Harvest Assist) 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.I.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 Compressor Notes 1 phase: Install a new start capacitor, run capacitor, and start relay. Thermostatic • Attach the thermostatic expansion valve bulb to the suction line in the same location as Expansion Valves 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 Appliance 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 Sheets Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 1. KM-520MAJ-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.
2. KM-660MAJ-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.FOR EUROPE MARKET lbs./day (kg/day) SHAPE OF ICE ICE PRODUCTION PER CYCLE BIN CONTROL SYSTEM REFRIGERANT CHARGE Performance Data Sheet APPROXIMATE ICE PRODUCTION PER 24 HR. 230/1/50 8.4 A (5 Min. Freeze AT 104°F/WT 80°F) 15 A 15 A 90/70°F 70/50°F 1170 (4.85) 1080 (4.18) 79 (13.
* 47 412±22 0 PSIG 327±22 PSIG Cut-out Cut-in Air Models * High-Pressure Switch B. Wiring Diagrams 1.
