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Hoshizaki KMD-460MAJ Service Manual

Modular crescent cuber
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See also: Instruction Manual
Service Manual
Modular Crescent Cuber with
Model
KMD-460MAJ, MWJ
KMD-530MAJ, MWJ, MRJ
hoshizakiamerica.com
Number: 73235
Issued: 2-21-2019
Revised: 9-20-2019

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Summary of Contents for Hoshizaki KMD-460MAJ

  • Page 1 Service Manual Modular Crescent Cuber with Model KMD-460MAJ, MWJ KMD-530MAJ, MWJ, MRJ hoshizakiamerica.com Number: 73235 Issued: 2-21-2019 Revised: 9-20-2019...
  • 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.

  • 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 VI. Preparing the Appliance for Periods of Non-Use ............49 VII. Disposal ......................... 51 VIII. Technical Information ....................52 A. Specification and Performance Data Sheets ............... 52 1. KMD-460MAJ ......................52 2. KMD-460MWJ ....................... 53 3. KMD-530MAJ ......................54 4. KMD-530MWJ ....................... 55 5.

  • 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) Thermostatic Expansion Spray Tubes Valve Wash Valve Water Supply Inlet Inlet Water Hot Gas Valve Valve High-Pressure Switch Condenser Condenser Fan Motor Compressor Drier Drain Valve Control Switch Pump Motor Service Switch Float Switch Control Box...

  • Page 8: Water-Cooled (Mwj)

    2. Water-Cooled (MWJ) Inlet Water Valve Wash Spray Tubes Valve Water Supply Inlet Hot Gas Valve High-Pressure Switch Water Regulator Thermostatic Expansion Valves Condenser Drier Drain Valve Compressor Pump Motor Float Switch Control Box Control Switch Service Switch Bin Control...

  • Page 9: Remote Air-Cooled (Mrj)

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

  • 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 Wash 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 Wash 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 Wash 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 full bin), check BC. Move ice away from BC actuator paddle.
  • 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 5b) Harvest Pump Time (Harvest Assist) – LEDs 1, 3, and 2 are on. 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). When WV de-energizes, LED 4 turns off, X11 relay de-energizes and LED 3 turns on.
  • Page 19 6) Freeze Cycle – LED 1 is on. Comp, PM, and X14 relay continue. FMR, FM, and LLV energize. HGV, X10, and X12 relays de-energize. Appliance is held in freeze by a 5-min. short cycle protection timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle terminates.
  • Page 20 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.
  • Page 21 7) Pump-Out Cycle – LEDs 1, 3, and 2 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 1st Pump-Out Frequency No.
  • Page 22 e) X13 Relay Diagnosis - 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 23: 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 24: Bin Control Check

    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"...
  • Page 25 5) Remove the actuator paddle from the switch mount. See Fig. 2. 6) Wipe down BC with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water. 7) Reassemble BC and replace it in its correct position.

  • Page 26: Float Switch Check And Cleaning

    E. Float Switch Check and Cleaning F/S is used to determine that there is sufficient water in the water tank after the 1-minute fill cycle and after each harvest cycle. F/S 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 27 9) Wipe down F/S assembly's housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Clean the inside of the rubber boot and hose with cleaning solution. Rinse the parts thoroughly with clean water.

  • Page 28: Thermistor Check

    F. Thermistor Check To check thermistor resistance, 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 top and right side panels, then remove the control box cover. 4) Remove the thermistor.

  • Page 29: Switches

    G. 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 30: 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. Main Transformer a) Voltage tap switch not set to proper voltage. b) Coil winding open or shorted, defective. 3.
  • Page 31 2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. See "II.I. Freeze Up Check List," the Hoshizaki America Technician's Pocket Guide, or contact your local distributor for a copy of the freeze-up checklist.
  • Page 32 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 33 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 34: Freeze-Up Check List

    I. 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__________Freeze-Up Date___________ List model and manufacture of bin or dispenser__________________________. Date appliance was last cleaned:__________.

  • Page 35: Controls And Adjustments

    III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KMD 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 36: Control Board Layout

    A. Control Board Layout • Bin Control Switch Closed LED (green) • "OUTPUT TEST" Button • S4 Dip Switch • "ALARM RESET" Button (used to test relays on control board) • Bin Control Switch • K3 (white) Connector Open LED (yellow) Thermistor (harvest control and high temperature safety)

  • Page 37: Led Lights And Audible Alarm Safeties

    Correct green LED lighting sequence is 1, 4, 3, 2. Components (e.g., compressor) cycle during test. Following test, icemaker resumes operation. Dip switches must be adjusted per unit’s service manual or Hoshizaki Technical Support recommendation. S4 dip switch 8 must remain off.

  • Page 38: 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:...

  • Page 39: Harvest Time (S4 Dip Switch 1 & 2)

    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.

  • Page 40: Pump-Out Frequency Control (S4 Dip Switch 5)

    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.

  • Page 41: Harvest Pump Time (Harvest Assist) (S4 Dip Switch 7)

    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.

  • Page 42: Freeze Timer (S4 Dip Switch 9 & 10)

    In this case, see "II.H.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 43: 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 44: 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 45 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 46 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 47: 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 48: 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 49: 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 50 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 51: 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 52: 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. KMD-460MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 10 A ( 5 Min.

  • Page 53: Kmd-460Mwj

    2. KMD-460MWJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.5 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.) 820 (4.16) 810 (3.98) WATER gal./24HR (gal./100 lbs.)

  • Page 54: Kmd-530Maj

    3. KMD-530MAJ Specifications Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 12 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.) 1050 (5.72) 970 (4.65) WATER gal./24HR (gal./100 lbs.)

  • Page 55: Kmd-530Mwj

    4. KMD-530MWJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 14.1 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.) 990 (4.74) 960 (4.47) WATER gal./24HR (gal./100 lbs.)

  • Page 56: Kmd-530Mrj

    5. KMD-530MRJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 12.4 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.) 1120 (6.10) 1020 (4.91) WATER gal./24HR (gal./100 lbs.)

  • Page 57: Wiring Diagram

    B. Wiring Diagram 1. KMD-460M_J and KMD-530M_J...

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