Hoshizaki KML-325MWJ Service Manual
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Hoshizaki KML-325MWJ Service Manual

Modular crescent cuber
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Service Manual
Modular Crescent Cuber with
Models
KML-325MAJ, MWJ
KML-500MAJ, MWJ
KML-700MAJ, MWJ, MRJ
hoshizakiamerica.com
Number: 73215
Issued: 6-16-2017

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Summary of Contents for Hoshizaki KML-325MWJ

  • Page 1 Service Manual Modular Crescent Cuber with Models KML-325MAJ, MWJ KML-500MAJ, MWJ KML-700MAJ, MWJ, MRJ Number: 73215 hoshizakiamerica.com Issued: 6-16-2017...
  • Page 2 Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance. Phone: 1-800-233-1940; (770) 487-2331 Fax: 1-800-843-1056;...

  • Page 3: Table Of Contents

    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 ....................
  • Page 4 VII. Disposal ......................... 47 VIII. Technical Information ....................48 A. Specification and Performance Data Sheets ............... 48 1. KML-325MAJ ......................48 2. KML-325MWJ ......................49 3. KML-500MAJ ......................50 4. KML-500MWJ ......................51 5. KML-700MAJ ......................52 6. KML-700MWJ ......................53 7.

  • Page 5: Important Safety Information

    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.
  • Page 6 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.

  • Page 7: Construction And Water/Refrigeration Circuit Diagram

    I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1. Air-Cooled (MAJ) Drain Valve Thermostatic Cleaning Valve Expansion Valve Water Supply Inlet Spray Tubes Inlet Water Valve Thermostatic Bin Control Condenser Pump Motor Fan Motor Control Box High-Pressure Switch Float Switch Control Switch Service Switch Liquid Line Valve...

  • Page 8: Water-Cooled (Mwj)

    Water Regulating Drain Valve Valve Cleaning Valve Inlet Water Valve Condenser Thermostatic High-Pressure Bin Control Switch Control Box Pump Motor Float Switch Drier Liquid Line Valve Control Switch Compressor Service Switch Thermostatic Bin Control Bracket & Bulb Holder Model Shown: KML-325MWJ...

  • Page 9: Remote Air-Cooled (Mrj)

    3. Remote Air-Cooled (MRJ) Thermostatic Spray Tubes Expansion Valve Drain Valve Water Supply Inlet Hot Gas Valve Cleaning Valve Inlet Water Valve Control Box High-Pressure Control Switch Switch Service Switch Reciever Pump Motor Float Switch Drier Thermostatic Liquid Line Valve Bin Control Compressor Crankcase Heater...

  • Page 10: Water/Refrigeration Circuit Diagram

    B. Water/Refrigeration Circuit Diagram 1. Air-Cooled Models (MAJ) Spray Tubes Condenser Water Supply Inlet Condenser Fan Motor High-Pressure Inlet Water Valve Switch Drier Cleaning Valve Heat Exchanger Drain Valve Thermistor Hot Gas Valve Water Pump Float Switch Strainer Compressor Drain Thermostatic Expansion Valve...

  • Page 11: Water-Cooled Models (Mwj)

    2. Water-Cooled Models (MWJ) Water Regulating Valve Spray Tubes Condenser Water Supply Inlet Inlet Water Valve Drier Cleaning Valve High-Pressure Switch Heat Exchanger Drain Valve Thermistor Hot Gas Valve Water Pump Float Switch Strainer Compressor Drain Thermostatic Expansion Valve...

  • Page 12: Remote Models (Mrj)

    3. Remote Models (MRJ) Condenser Condenser Headmaster Fan Motor High-Pressure Switch Spray Tubes Water Supply Inlet Drier Inlet Water Valve Receiver Cleaning Valve Liquid Line Valve Heat Exchanger Drain Valve Thermistor Hot Gas Valve Water Pump Float Switch Strainer Compressor Drain Thermostatic Expansion Valve...

  • Page 13: Sequence Of Operation And Service Diagnosis

    II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart 1. Operation Flow Chart...

  • Page 14: Shutdown Flow Chart

    2. Shutdown Flow Chart...

  • Page 15: Service Diagnosis

    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.
  • Page 16 1. 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 missing or loose jumper (4A4883G01)), check that the jumper is securely in place.
  • Page 17 5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, HGV, X10, X12, and X14 relays 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...
  • Page 18 d) Control Switch Diagnosis: If 115VAC is present at X10 relay #3 (R), check for 115VAC at control switch #6 red (R) wire to neutral (W). Next, check for 115VAC at control switch #5 (Y) to neutral (W). If 115VAC is present at control switch #6 red (R) wire and not at control switch #5 (Y), check control switch continuity.
  • Page 19 c) WV and HGV Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB. If 115VAC is not present, replace WV (bypassing). If HGV did not de-energize at the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W).
  • Page 20 i) Short Freeze Cycle Diagnosis: Confirm water tank fills and overflows during 1 min. fill and harvest cycles. If not, check water supply filters, shut-off valve, WV screen. If water tank empties before 5 min. timer terminates and freeze cycle is short, check that DV is not leaking by or energized (water flowing through DV).
  • Page 21 e) X13 Relay - If 115VAC is present at X12 terminal #3 (DBU) to neutral and PM and DV are not energized, check for 115VAC at X13 terminal #8 (DBU) to neutral (W). If 115VAC is present and X13 relay is de-energized, replace X13 relay. (1) For PM and X13 Relay: If 115VAC is present at X13 terminal #8 (DBU), check for 115VAC at X13 relay #6 (BK) and X13 relay #4 (Y) to neutral (W).

  • Page 22: Control Board Check

    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.

  • Page 23: Bin Control Check

    D. Bin Control Check 1. Thermostatic Bin Control Check TBC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb, regardless of the cycle at activation. NOTICE When the ambient temperature is below 45°F (7°C), TBC opens and shuts down the appliance even if the ice storage bin is empty.

  • Page 24: Switches

    E. Switches Two control switches are used to control operation. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. 1. Control Switch The control switch has three positions: "OFF" for power off, "ICE" for icemaking, and "SERVICE"...

  • Page 25: Float Switch Check And Cleaning

    F. 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.

  • Page 26: Float Switch Cleaning

    Be careful not to bend the retainer rod excessively when removing it. See Fig. 1. 6) Wipe down FS housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water.

  • Page 27: Thermistor Check

    G. 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.

  • Page 28: Diagnostic Tables

    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. Thermostatic Bin Control a) Engaged with bin filled with ice. See "II.D. Bin Control Check" b) Ambient temperature too cool.
  • Page 29 Water leaks causing short freeze time. 2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. See the Hoshizaki America Technician's Pocket Guide or contact your local distributor for a copy of the freeze-up checklist. Freeze-Up - Possible Cause Harvest Cycle 1.
  • Page 30 Freeze-Up - Possible Cause Freeze Cycle 1. Evaporator a) Scaled up. b) Damaged. 2. Spray Tubes and/or Spray a) Dirty. Guides b) Out of position. 3. Refrigerant Charge a) Low. 4. Control Board a) Freeze timer (S4 dip switch 9 & 10) set incorrectly. See "II.C.
  • Page 31 Low Ice Production - Possible Cause Long Freeze Cycle 1. Evaporator a) Scaled up, dirty. 2. Float Switch a) Scaled up, dirty. See "II.E. Float Switch Check b) Float sticking. and Cleaning" c) Defective switch. 3. Inlet Water Valve a) Leaking by. 4.

  • Page 32: Controls And Adjustments

    III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KML 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.

  • Page 33: Control Board Layout

    A. Control Board Layout "J" Control Board • Bin Control Switch Closed LED (green) • "OUTPUT TEST" Button • "ALARM RESET" Button (on continuously (used to test relays on control board) in thermostatic bin • S4 Dip Switch control application) •...

  • Page 34: Led Lights And Audible Alarm Safeties

    B. LED Lights and Audible Alarm Safeties At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red "POWER OK" LED indicates proper control voltage and remains on unless a control voltage problem occurs.

  • Page 35: Settings And Adjustments

    Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting decreases 24-hour production.

  • Page 36: Pump-Out Timer (S4 Dip Switch 3 & 4)

    3. Pump-Out Timer (S4 dip switch 3 & 4) NOTICE Do not adjust 3 off and 4 on. Drain valve does not energize in this setting. When a pump-out is called for, the pump motor stops for 2 sec. After 2 sec. the drain valve and pump motor energize.

  • Page 37: Harvest Pump Time (S4 Dip Switch 6)

    5. Harvest Pump Time (S4 dip switch 6) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the appliance. The harvest pump time starts with 50 sec. left to go in the harvest time (S4 dip switches 1 &...

  • Page 38: Factory Use (S4 Dip Switch 8)

    In this case, see "II.G.3. Low Ice Production" for possible solutions. The freeze timer is factory set and no adjustment is required. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations.

  • Page 39: Minimum Harvest Time (S5 Dip Switch 4)

    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 Minimum Harvest Timer No. 4 120 sec. 70 sec.

  • Page 40: Refrigeration Circuit And Component Service Information

    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"...
  • Page 41 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.
  • Page 42 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 AHRI Standard 700 (latest edition) be used.

  • Page 43: Component Service Information

    • The thermistor should be at the 12 o'clock position on the tube. • Smoothly fill the recessed area of the thermistor holder with high thermal conductive type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound 10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu Silicones), or equivalent are recommended.

  • Page 44: Maintenance

    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 •...

  • Page 45: Preparing The Appliance For Periods Of Non-Use

    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. • The pump motor is energized continuously when the control switch is in the "SERVICE"...
  • Page 46 3. On water-cooled model, remove the water from the water-cooled condenser: 1) Make sure the power supply is off, then remove the front panel and right side panel. 2) Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve.

  • Page 47: Disposal

    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.

  • Page 48: Technical Information

    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.

  • Page 49: Kml-325Mwj

    2. KML-325MWJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.4 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 670 (4.51) 690 (4.31)

  • Page 50: Kml-500Maj

    3. KML-500MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.6 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 930 (5.55) 850 (4.64) WATER gal./24HR (gal./100 lbs.)

  • Page 51: Kml-500Mwj

    4. KML-500MWJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.6 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 930 (4.33) 890 (3.93) WATER gal./24HR (gal./100 lbs.) 82 (16.0)

  • Page 52: Kml-700Maj

    5. KML-700MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 14.2 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1230 (5.16) 1120 (4.10) WATER gal./24HR (gal./100 lbs.) 92 (16.0)

  • Page 53: Kml-700Mwj

    6. KML-700MWJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 12.6 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1100 (3.61) 1070 (3.40) WATER gal./24HR (gal./100 lbs.) 117 (16.0)

  • Page 54: Kml-700Mrj

    7. KML-700MRJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 16.0 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1260 (4.70) 1170 (3.78) WATER gal./24HR (gal./100 lbs.) 103 (16.0)

  • Page 55: Wiring Diagram

    B. Wiring Diagram 1. KML-325M_J, KML-500M_J, KML-700M_J...

This manual is also suitable for:

Kml-325majKml-500majKml-500mwjKml-700majKml-700mwjKml-700mrj

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