Hoshizaki KML-325MAJ Service Manual
  1. Manuals
  2. Brands
  3. Hoshizaki Manuals
  4. Air Conditioner
  5. KML-325MAJ
  6. Service manual

Hoshizaki KML-325MAJ Service Manual

Hide thumbs Also See for KML-325MAJ:
Table of Contents

Advertisement

Quick Links

Service Manual
Modular Crescent Cuber with
Models
KML-325MAJ, MWJ
KML-500MAJ, MWJ
KML-700MAJ, MWJ, MRJ
hoshizakiamerica.com
Number: 73249
Issued: 5-27-2021

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KML-325MAJ and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hoshizaki KML-325MAJ

Summary of Contents for Hoshizaki KML-325MAJ

  • Page 1 Service Manual Modular Crescent Cuber with Models KML-325MAJ, MWJ KML-500MAJ, MWJ KML-700MAJ, MWJ, MRJ Number: 73249 Issued: 5-27-2021 hoshizakiamerica.com...
  • Page 2 WARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and...

  • 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 Icemaker for Periods of Non-Use ............. 48 VII. Disposal ......................... 50 VIII. Technical Information ....................51 A. Specification and Performance Data Sheets ............... 51 1. KML-325MAJ ......................51 2. KML-325MWJ ......................52 3. KML-500MAJ ......................53 4. KML-500MWJ ......................54 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) Spray Tubes Drain Valve Water Supply Inlet Cleaning Valve Inlet Water Valve Thermostatic Expansion Valve Condenser Water Pump Fan Motor Control Box High-Pressure Switch Float Switch Control Switch Drier Compressor Mode Switch Liquid Line Valve...

  • Page 8: Water-Cooled (Mwj)

    2. Water-Cooled (MWJ) Water Supply Inlet Spray Tubes Water Regulating Valve Drain Valve Cleaning Valve Condenser Inlet Water Valve High-Pressure Switch Thermostatic Expansion Valve Control Box Thermostatic Bin Control Water Pump Drier Float Switch Control Switch Compressor Mode Switch Liquid Line Valve Bin Control Bulb Holder NSF Plate Bin Control Bracket...

  • Page 9: Remote Air-Cooled (Mrj)

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

  • Page 10: Water/Refrigeration Circuit Diagram

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

  • Page 11: Water-Cooled Models (Mwj)

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

  • Page 12: Remote Models (Mrj)

    3. Remote Models (MRJ) Remote Condenser Headmaster (C.P.R.) High-Pressure Switch Spray Tubes Inlet Water Valve Evaporator Water Supply Inlet Drier Receiver Cleaning Valve Liquid Line Valve Heat Exchanger Drain Valve Thermistor Suction Line Hot Gas Valve Water Pump Float Switch Discharge Line Strainer Compressor...

  • 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 Auxiliary Code L-1 and Later 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.
  • Page 16 1. Sequence and Component Diagnosis 3) Power On: Turn on the power supply, 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 missing or loose jumper on CB K4 (4A4883G01)), check that the jumper is securely in place.
  • Page 17 5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV continues. Comp, FMR, 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 &...
  • Page 18 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.
  • Page 19 d) PM Diagnosis: Confirm water is flowing over evaporator from PM and not WV. If PM de-energizes once freeze begins, check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized, check PM capacitor and motor winding continuity.
  • Page 20 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 1st Pump-Out Frequency No.
  • Page 21 2. Shutdown Diagnosis When the appliance is running, hold ice in contact with the thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. BC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations.

  • 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 4) To verify voltage output from CB to the components, slide the CB K1 connector out far enough to allow multimeter lead contact. With the icemaker in the cycle to be tested, check output voltage from the corresponding pin on CB K1 connector to a neutral (W wire).

  • Page 24: Bin Control Check

    D. Bin Control Check BC 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), BC opens and shuts down the appliance even if the ice storage bin is empty. When BC is set in the prohibited range, the appliance operates continuously even if the ice storage bin is filled with ice.

  • Page 25: Float Switch Check And Cleaning

    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.
  • Page 26 Retainer Rod 5) Wipe down FS assembly's 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. 6) Reassemble FS assembly and replace it in its correct position.

  • Page 27: Thermistor Check

    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 move the top and right side panels. 4) Remove the thermistor from the refrigerant tubing. See Fig. 5. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.

  • Page 28: Switches

    G. Switches Two control switches are used to control operation. These switches are referred to as the "CONTROL" switch and the "MODE" switch and are located on the control box. 1. Control Switch The control switch has three positions: "OFF" for power and pump off, "ON" for power on, and "PUMP"...

  • Page 29: 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 30 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 31 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 32 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 33: 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 34: 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 35: Control Board Layout

    A. Control Board Layout Control Board • "OUTPUT TEST" Button (black or blue) (used to test relays on control board) • S4 Dip Switch • "ALARM RESET" Button (white) • K3 (white) Connector • Bin Control Switch (5VDC) BC OPEN/CLOSED Thermistor LED (yellow) (harvest control and high...

  • Page 36: Led Lights And Audible Alarm Safeties

    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 5 turn on and sequence from initial startup as listed in the table below.

  • Page 37: 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.

  • Page 38: 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 39: 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 40: Harvest Pump Time (Harvest Assist) (S4 Dip Switch 7)

    In this case, see "II.H.2. 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 41: Float Switch Selector (S5 Dip Switch 1)

    9. Float Switch Selector (S5 dip switch 1) NOTICE Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly. This dip switch setting allows use of this control board in single and dual float switch models.

  • Page 42: Anti-Slush (S5 Dip Switch 5)

    12. Anti-Slush (S5 dip switch 5) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside the factory default setting may result in damage to the appliance. This dip switch setting provides anti-slush control during the freeze cycle. When the evaporator temperature reaches 36°F (2.2°C) the control board reads a 5.8 kΩ...

  • Page 43: 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 44 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 45 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 46: 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 47: Maintenance

    V. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. Consult with your local Hoshizaki Certified Service Representative about maintenance service. 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 48: Preparing The Icemaker For Periods Of Non-Use

    VI. Preparing the Icemaker for Periods of Non-Use NOTICE • When storing the icemaker 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 leave the control switch in the "PUMP"...
  • Page 49 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, top, and right side panels. 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 50: 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 51: 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. KML-325MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.4 A (5 Min.

  • Page 52: 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) WATER gal./24HR (gal./100 lbs.)

  • Page 53: Kml-500Maj

    3. KML-500MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.9 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 54: 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 55: Kml-700Maj

    5. KML-700MAJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 14.9 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.) 1250 (4.90) 1140 (4.15) WATER gal./24HR (gal./100 lbs.)

  • Page 56: Kml-700Mwj

    6. KML-700MWJ Specification AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 11.9 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.) 1040 (3.79) 1050 (3.79) WATER gal./24HR (gal./100 lbs.) 129 (19.5)

  • Page 57: Kml-700Mrj

    7. KML-700MRJ Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 13.7 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.) 1250 (4.90) 1130 (4.14) WATER gal./24HR (gal./100 lbs.) 101 (16.4) 223 (33.9)

  • Page 58: Wiring Diagram

    B. Wiring Diagram 1. KML-325M_J, KML-500M_J, KML-700M_J Auxillary Code: L-1 and Later...

This manual is also suitable for:

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

Table of Contents