Hoshizaki JWE-2400CUA-L-25B Service Manual
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Hoshizaki JWE-2400CUA-L-25B Service Manual

Hoshizaki JWE-2400CUA-L-25B Service Manual

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MODEL
HOSHIZAKI
DISHWASHER
JWE-2400CUA-L-25B
JWE-2400CUA-R-25B
SERVICE MANUAL
NO.
J002-794
ISSUED:
APR. 1, 2011
REVISED: SEP. 6, 2011

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Summary of Contents for Hoshizaki JWE-2400CUA-L-25B

  • Page 1 J002-794 ISSUED: APR. 1, 2011 REVISED: SEP. 6, 2011 HOSHIZAKI DISHWASHER JWE-2400CUA-L-25B MODEL JWE-2400CUA-R-25B SERVICE MANUAL...
  • Page 2 Hoshizaki provides this manual primarily to assist qualifi ed service technicians in the maintenance and service of the unit. Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, write, or send an e-mail message to the Hoshizaki Technical Support Department for assistance.

  • Page 3: Table Of Contents

    CONTENTS I. Specifi cations ------------------------------------------------------------------------------------------------ 1 A. Specifi cation Sheet ------------------------------------------------------------------------------------- 1 1. JWE-2400CUA-L-25B ------------------------------------------------------------------------------ 1 2. JWE-2400CUA-R-25B ------------------------------------------------------------------------------ 2 B. Nameplate Rating --------------------------------------------------------------------------------------- 3 C. Dimensions/Connections ------------------------------------------------------------------------------ 4 1. JWE-2400CUA-L-25B ------------------------------------------------------------------------------ 4 2.
  • Page 4 12. Special Modes ---------------------------------------------------------------------------------------22 III. Service Diagnosis ----------------------------------------------------------------------------------------24 A. Diagnostic Procedure ---------------------------------------------------------------------------------24 B. Error Codes ----------------------------------------------------------------------------------------------26 1. Error Code Table ------------------------------------------------------------------------------------26 2. Error Code Log --------------------------------------------------------------------------------------27 3. Error Code Details ----------------------------------------------------------------------------------28 C. Service Flow Charts -----------------------------------------------------------------------------------41 1. Unit Will Not Start -----------------------------------------------------------------------------------41 2.
  • Page 5 Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the unit or property.

  • Page 6: Specifi Cations

    I. Specifi cations A. Specifi cation Sheet 1. JWE-2400CUA-L-25B DISHWASHER SIDE BOOSTER SIDE 2 power supply lines 3 phase 3-wire 208-230V/60Hz (±10%) / AC SUPPLY VOLTAGE 208V : 18.4kVA(51.1A) 208V : 20.6kVA(57.2A) POWER SUPPLY CAPACITY 230V : 22.1kVA(55.5A) 230V : 25.3kVA(63.5A) AMPERAGE Max Running 51.2A...

  • Page 7: Jwe-2400Cua-R-25B

    2. JWE-2400CUA-R-25B DISHWASHER SIDE BOOSTER SIDE 2 power supply lines 3 phase 3-wire 208-230V/60Hz (±10%) / AC SUPPLY VOLTAGE 208V : 18.4kVA(51.1A) 208V : 20.6kVA(57.2A) POWER SUPPLY CAPACITY 230V : 22.1kVA(55.5A) 230V : 25.3kVA(63.5A) AMPERAGE Max Running 51.2A Max Running 63.3A Rated Motor 9.0A STARTING AMPERAGE 26.0A...

  • Page 8: Nameplate Rating

    B. Nameplate Rating For certifi cation marks, see the nameplate on the dishwasher. We reserve the right to make changes in specifi cations and design without prior notice.

  • Page 9: Dimensions/Connections

    C. Dimensions/Connections 1. JWE-2400CUA-L-25B...

  • Page 10: Jwe-2400Cua-R-25B

    2. JWE-2400CUA-R-25B...

  • Page 11: General Information

    II. General Information A. Construction 1. Dishwasher The illustration below shows JWE-2400CUA-L-25B (left-to-right rack fl ow). Operation Panel Emergency Stop Button Vertically Sliding Wash Spray Arm (stationary) Service Panel Rinse Spray Arm (stationary) Rinse Start Switch Conveyor Wash Start Switch...

  • Page 12: Booster Tank

    Sheathed Heater [H7 - 15] Band Heater 2. Booster Tank Hot Water Outlet Pipe Overfl ow Pipe Top View Thermostat Plate Thermal Protector [TH7 - 12] Inlet Water (heater boil dry protection) Valve [WV] Inlet Pipe Water Level Float Switch [FS1] (downward end) Backup Water Level Float Switch [FS2] (upward end)

  • Page 13: Control Box

    3. Control Box...

  • Page 14: Functions

    B. Functions Upper Rinse Spray Arm 1. Increasing Rinse Water Flow Rate Clean Pipe The rinse water fl ow rate is factory adjusted to 1.90 gal/min (7.2 L/min). To increase the fl ow rate to 3.17 gal/min (12 L/ min), follow the steps below. Hot water supply of at least Lower Rinse 3.44 gal/min (13 L/min) and 113°F (45°C) will be required.

  • Page 15: Ready Cycle (Unit Inactive)

    4. If BT WLF/S fails, BT BUWLF/S assumes control. If BT BUWLF/S remains closed for 1 minute, o1 or o2 error appears in the display. For details, see "III.B. Error Codes." 5. The wash/rinse start switch is inactive during the auto fi ll cycle. 2.

  • Page 16: Table Limit Switch

    BZ–buzzer; CB–control board; DFT–detergent feeder terminals (detergent feeder not provided by Hoshizaki); DS–door switch; ESB–emergency stop button; RFT–rinse aid feeder terminals (rinse aid feeder not provided by Hoshizaki); RPM–rinse pump motor; SP–service panel; SPS–service panel switch; WLSF/ S–water level safety float switch; TLS–table limit switch; WLF/S–water level fl...

  • Page 17: Sequence Of Operation Flow Chart

    D. Sequence of Operation Flow Chart...

  • Page 18: Timing Chart

    E. Timing Chart 1. Auto Fill Cycle Booster Tank...

  • Page 19: Wash Cycle/Rinse Cycle

    2. Wash Cycle/Rinse Cycle...

  • Page 20: Control Board And Operation Board

    F. Control Board and Operation Board • A Hoshizaki exclusive solid-state control board and operation board are employed in all Hoshizaki dishwasher units. • All models are pretested and factory set. NOTICE 1. The control board and operation board are fragile; handle very carefully.

  • Page 21: Control Board Layout

    2. Control Board Layout Inputs and outputs are laid out on the control board as illustrated below. Signal Input XA Connector (6P) Buzzer Output XA Connector (2P) Signal Input XA Connector (10P) Power Input VH Connector (4P) Thermistor Signal Input XA Connector (4P) Power Input VH Connector (6P) CN10...

  • Page 22: Control Board Diagram

    3. Control Board Diagram 200VAC from Transformer Transformer 11V 7.7V 1 (CN1) 4 1 (CN2) 6 [Communication] Booster Tank Heater Operation Panel Board Wash Tank Heater (Shielded Wire) (CN5) Rinse Pump Wash Tank Thermistor Upper Wash Pump Booster Tank Thermistor (CN3) Water Valve (CN7)

  • Page 23: Operation Panel Layout

    4. Operation Panel Layout The operation panel is mounted on top of the unit (wash compartment exit side) and is connected to the CN5 connector on the control board. Up Button Water Temperature Lamps Down Button "AUTO FILL" Lamp Display "READY"...

  • Page 24: Service Menu And Error Log

    c) "READY" Lamp Lights up when the auto fi ll cycle completes and the dishwasher is ready to wash. d) "WASH" Lamp Lights up during washing operation. e) Up Button, Down Button Indicates the total hours of operations in six digits by two digits each time. Example: 123,456 hours are indicated by Press to stop the beep in case of error.
  • Page 25 b) Service Menu Chart Service Factory Item and Details Setting Range Display Menu Default Extended Wash Cycle Time 1 to 99 seconds 1 to 99 (in 10 second steps) Extended Rinse Cycle Time 1 to 99 seconds 1 to 99 (in 1 second steps) Auto Fill Cycle Rinse Time 0 to 99 minutes...

  • Page 26: Temperature Display

    8. Temperature Display • Indicates the average water temperature read by the wash tank or booster tank thermistor. Indicates water temperature selected by the water temperature lamps beside the display. The factory default setting is to indicate wash water temperature and rinse water temperature alternately every 5 seconds.

  • Page 27: Operation Time Display

    11. Operation Time Display To indicate the total hours of operation in the display, press the up button on the operation panel. The number appears from the hundred-thousands place by two digits each for 1 second. The maximum number is 999,999 hours, and the display does not change for the higher numbers.
  • Page 28 4) Set service menu item 19 to ON to stop the beep when the "ON/OFF" button is switched off but to resume fl ashing "Ch" when the "ON/OFF" button is switched back on unless the wash water tank is refi lled (factory default: OFF). Press the emergency stop button or turn off the external power supply to stop both the beep and "Ch"...

  • Page 29: Service Diagnosis

    III. Service Diagnosis WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fi re. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices.
  • Page 30 It is recommended to conduct this sequence check in the auto fi ll cycle after draining the wash tank and booster tank. See “II.C. Sequence of Operation” for further details. 1) Use the “ON/OFF” button on the operation panel to turn off the unit. 2) Pull out the overfl...

  • Page 31: Error Codes

    B. Error Codes In the event of operation outside of normal parameters, the control board identifi es the issue with an error code. For further service information, see "III.C. Service Flow Charts." 1. Error Code Table Error Problem Operation Reset Code Wash Tank Auto Fill Error Whole unit...

  • Page 32: Error Code Log

    Error Problem Operation Reset Code Booster Tank Thermistor Error (open) Normal After replacing failed component, (Booster tank alarm resets. Thermistor senses abnormal temperature heaters off) (at or below -6°F (-21°C)). ROM/RAM Error Whole unit After replacing control board, alarm stops resets.

  • Page 33: Error Code Details

    3. Error Code Details a) Auto Fill Error (A1) • If the water level sensor in the wash tank is not closed at the end of the auto fi ll cycle, the unit shuts down, "A1" appears in the display, and the buzzer sounds. •...
  • Page 34 Continue Sticking (with float in Check and clean. See Booster Tank Water “ON” position). “III.D. Float Switch Level Float Switch Check and Cleaning.” Defective (with internal Replace. contacts in “ON” position).
  • Page 35 b) Booster Tank Auto Fill Error (A2) • In the auto fi ll cycle, if the booster tank water level fl oat switch does not close within 10 minutes (or 20 minutes in "READY" mode) after the cycle starts, the unit shuts down, "A2" appears in the display, and the buzzer sounds.
  • Page 36 c) Wash Tank Water Level Error (A3) • If the water level in the wash tank goes below the water level sensor in "READY" mode or during operation, the supplementary fi ll cycle starts, "A3" appears in the display, the "AUTO FILL"...
  • Page 37 d) Booster Tank Water Level Error 1 (Booster Tank Water Level Float Switch Closed) (o1) • If both the booster tank water level fl oat switch and the booster tank backup water level fl oat switch have remained closed for 1 minute, the booster tank heaters de-energize, "o1" appears in the display, and the buzzer sounds.
  • Page 38 e) Booster Tank Water Level Error 2 (Booster Tank Water Level Float Switch Open) (o2) • If the booster tank water level fl oat switch is open and the booster tank backup water level fl oat switch has remained closed for 1 minute, the booster tank heaters de-energize, "o2" appears in the display, and the buzzer sounds.
  • Page 39 f) Wash Tank Thermistor Error (H1, H2) • If the wash tank thermistor senses a temperature at or above 231°F (111°C) (2.4kΩ), the thermistor leads are considered shorted and the wash tank heaters de-energize, "H1" appears in the display, and the buzzer sounds. •...
  • Page 40 g) Booster Tank Thermistor Error (H3, H4) • If the booster tank thermistor senses a temperature at or above 231°F (111°C) (2.4kΩ), the thermistor leads are considered shorted and the booster tank heaters de-energize, "H3" appears in the display, and the buzzer sounds. •...
  • Page 41 h) ROM/RAM Error (H5) • If a ROM/RAM error is detected, the unit shuts down, "H5" appears in the display, and the buzzer sounds. • After replacing the failed component, the alarm resets. • See the chart below for possible causes and remedies. Operation Code Error...
  • Page 42 j) Conveyor Overload or Table Limit Error 1 (L1) • If the inverter sends an overload signal or the table limit switch closes, the unit shuts down, "L1" appears in the display, and the buzzer sounds. • After removing the jammed rack or the cause of the overload (the table limit switch opens or the inverter stops sending the overload signal), the alarm resets after 3 seconds, and the unit is ready to resume operation.
  • Page 43 k) Conveyor Overload or Table Limit Error 2 (L2) • If the unit shuts down with "L1" in the display and restarts in 3 seconds after the cause of the overload is removed, and the inverter sends another overload signal within 3 seconds after the conveyor moves, the unit completely shuts down, "L2"...
  • Page 44 l) Booster Tank Error (b1) • If the booster tank error input contacts stay open for more than 2 seconds, "b1" appears in the display, and the buzzer sounds. • If the booster tank error input contacts stay closed for more than 2 seconds, the alarm resets.
  • Page 45 m) Booster Tank Water Level Safety Error (b2) • If the booster tank water level safety fl oat switch opens after the booster tank water level fl oat switch closes, the unit shuts down, "b2" appears in the display, and the buzzer sounds. •...

  • Page 46: Service Flow Charts

    C. Service Flow Charts 1. Unit Will Not Start Unit will not start Problem Possible Cause Remedy Off, blown fuse, or Turn on, replace, or Main Power Supply tripped or defective check and reset. Call circuit breaker. electrician if breaker trips repeatedly.
  • Page 47 Continue Open coil winding. Replace. Transformer Loose connections or Check continuity and Wiring to Control Board open. repair or replace. In alarm. See “III.B. Error Control Board Codes.” Defective. Replace.

  • Page 48: Dishes Not Clean

    2. Dishes Not Clean Dishes not clean Problem Possible Cause Remedy Clogged with foreign Clean. Low Wash Pump matter. Output Voltage drop. Remove cause. Vapor lock due to Clean tank filter. clogged tank filter. Vapor lock due to use Stop using neutral of neutral cleaner.
  • Page 49 Continue No supply. See “III.C.5. No or Detergent Inadequate Detergent/Rinse Aid Supply.” Insufficient supply. Refill or adjust detergent feeder. Unspecified detergent Use specified used. detergent only. Dirty. Drain wash tank and Wash Tank Water supply fresh hot water. Temperature too low. Raise setting or see “Heater Not Energized”.

  • Page 50: Inadequate Rinse

    3. Inadequate Rinse Inadequate rinse Problem Possible Cause Remedy Clean. Clogged with foreign Low Rinse Pump matter. Output Rinse water line Clean. scaled. Voltage drop. Remove cause. Rinse pump defective. Replace. Clogged. Clean. Rinse Spray Arms Out of position. Set in position. Low pump output.

  • Page 51: Dishwasher Will Not Start Wash/Rinse Cycle

    4. Dishwasher Will Not Start Wash/Rinse Cycle Dishwasher will not start wash/rinse cycle Problem Possible Cause Remedy Protector tripped. Wait until wash pump Wash Pump Inoperative cools. Locked with foreign Remove obstacles. matter. Controller input/output Check input/output error. and repair or replace. Magnetic contactor Replace.

  • Page 52: No Or Inadequate Detergent/Rinse Aid Supply

    5. No or Inadequate Detergent/Rinse Aid Supply No or inadequate detergent/rinse aid supply Problem Possible Cause Remedy Empty. Refill. Detergent/Rinse Aid Clogged or kinked. Clean or straighten. Supply Line (Injector, Vinyl Hose, Strainer) Air in line. Purge air. Supply volume too Set to proper volume.

  • Page 53: Wash Tank Water Not Draining

    7. Wash Tank Water Not Draining Wash tank water not draining Problem Possible Cause Remedy Clogged. Unclog. Drain Hose Pinched. Correct. Raised. Correct. Clogged. Unclog. Drain Pipe (Overflow Pipe)

  • Page 54: Float Switch Check And Cleaning

    3) Use a soft brush to remove scale or soil on the fl oat switches, or wipe down the fl oat switches with a mixture of 1 part of Hoshizaki “Scale Away” and 25 parts of warm water. 4) Rinse the parts thoroughly with clean water.

  • Page 55: Thermistor Check

    E. Thermistor Check If the error code “H1” “H2” “H3” or “H4” or an abnormal temperature [above 231°F (111° C) or below -6°F (-21°C)] appears in the display, or the wash tank water boils, check the thermistor(s) according to the procedure below. If replacement is required, see “IV.H. Removal and Replacement of Thermistor.”...

  • Page 56: Removal And Replacement Of Components

    IV. Removal and Replacement of Components WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fi re. 2. Use the “ON/OFF” button on the operation panel to turn off the unit, then turn off the dishwasher and booster tank power supplies.

  • Page 57: Removal And Replacement Of Rinse Pump Motor

    4) The rinse pump motor is located at the rear right side of the machine compartment (JWE-2400CUA-L-25B) or located behind the control box and at the rear left side of the machine compartment (JWE-2400CUA-R-25B). 5) Remove the fan motor in front of the rinse pump motor.
  • Page 58 3. Be sure to use new O-rings and gaskets. Be careful of the direction of the U-packing for the suction inlet pipe. 12) Make a trial run, and check for water leaks. Rinse Pump Motor [JWE-2400CUA-L-25B] * For JWE-2400CUA-R-25B, fan motor and rinse pump motor are located behind control box U-Packing...
  • Page 59 [JWE-2400CUA-L-25B] * View without rinse pump motor Booster Tank Band Discharge Pipe Rinse Pump Motor Suction Inlet Rinse Pump Motor Flexible Tube Band Booster Tank Discharge Pipe Rinse Pump Motor Suction Inlet Flexible Tube...

  • Page 60: Removal And Replacement Of Gear Motor

    2) Remove the front panel. 3) The gear motor is located behind the control box and at the rear left side of the machine compartment (JWE-2400CUA-L-25B) or located at the rear right side of the machine compartment (JWE-2400CUA-R-25B). 4) Disconnect the gear motor wiring at the closed end connectors.

  • Page 61: Removal And Replacement Of Conveyor

    E. Removal and Replacement of Conveyor 1) Remove the 4 bolts (2 at rear, 2 at both sides) securing the rear rack rail. 2) Hold the conveyor, and lift off the rear rack rail. Slider 3) Take out the conveyor. 4) Remove the left and right frames from the conveyor.

  • Page 62: Removal And Replacement Of Crankshaft

    F. Removal and Replacement of Crankshaft To remove: 1) Remove the front panel. 2) Remove the conveyor. 3) Loosen the 6 hexagon socket set screws for the stopper and the coupling. 4) Lift off the crank together with the shaft. 5) Loosen the screw securing the crank to release the crank from the shaft.

  • Page 63: Removal And Replacement Of Control Box

    G. Removal and Replacement of Control Box WARNING Do not touch the live parts during a trial run or servicing operations. NOTICE Be careful not to damage the wiring when handling the control box. 1) Use the “ON/OFF” button on the operation panel to turn off the unit, then turn off the dishwasher and booster tank power supplies.

  • Page 64: Removal And Replacement Of Control Board Or Operation Board

    2) Remove the front panel. 3) Slide out the control box. 4) Remove the plastic bag covering the thermistor connector, then disconnect the thermistor connector. If replacing the wash tank thermistor, disconnect the leads from the wash tank electrode. If replacing the booster tank thermistor, disconnect the closed end connectors for the booster tank water level fl...

  • Page 65: Operation Board

    3) Disconnect the control board connectors from the control board. 4) Slide out the control board. 5) Install the new control board. 6) To replace, reverse the above procedure. 2. Operation Board 1) Use the “ON/OFF” button on the operation panel to turn off the unit, then turn off the dishwasher and booster tank power supplies.

  • Page 66: Removal And Replacement Of Heater

    J. Removal and Replacement of Heater When replacing the wash tank heater or the booster tank heater, remove the nuts using a 7/8" crowfoot wrench. When replacing the booster tank heater, move the clean dishtable above the booster tank before following the procedure below. 1) Use the “ON/OFF”...

  • Page 67: Removal And Replacement Of Float Switch

    * The illustration shows the boster tank heater Heater Bolt Band Cross-section: band fi tting Washer Heater Square Hole Band K. Removal and Replacement of Float Switch When replacing the fl oat switch, move the clean dishtable above the booster tank before following the procedure below.

  • Page 68: Removal And Replacement Of Thermostat

    L. Removal and Replacement of Thermostat NOTICE Always use the recommended sealant (high thermal conductive type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 or equivalent. When replacing the thermostat in the wash water tank or the booster tank, remove the thermostat, clear any remaining sealant from the tank walls, apply a proper amount of the above recommended sealant to the new thermostat bulb, then install the new thermostat in its correct position.

  • Page 69: Cleaning And Maintenance Instructions

    V. Cleaning and Maintenance Instructions A. Daily Maintenance IMPORTANT Be sure to clean the dishwasher after closing time every day. It is diffi cult to remove heavy soils left overnight. In high temperature conditions, food scraps will rot and affect sanitary operation. 1) Remove the three curtains at the entrance, center, and exit of the wash compartment.
  • Page 70 6) To remove the lower rinse spray arm, push down the rising part to unhook, pull off the end of the pipe towards you, then take it out from between the rack rails. 7) Remove the separators. 8) Take out scraps from the removed tank filters, drain pipe and separators, and wash them clean with a scouring pad.
  • Page 71 11) Clean the wash compartment. Remove any scraps from inside the wash compartment and wash tank. Use a scouring pad to wash off heavy soils. Remove any silverware left inside the wash compartment. Silverware 12) Check the pump filters inside the wash tank. If they are clogged, clean them with a scouring pad.
  • Page 72 17) To replace the upper wash spray arm, hold it with the nozzles facing down, and insert the joint into the pipe located at the back of the wash compartment. Lift up the front, then securely hook in the square hole. Hook 18) To replace the lower wash spray arm, hold both sides with the nozzles facing up, and put it under the rack...
  • Page 73 20) To replace the lower rinse spray arm, put it between the rack rails, insert the end of the pipe into the joint, then turn and hook the front. Ring 21) Install the curtain (L) in the wash compartment. Curtain Rod (longer) 22) Install the curtains (S) at the entrance and exit of the wash compartment.

  • Page 74: Weekly Maintenance

    Even if there is no problem with its use, a product out of warranty may have a risk of electric shock, fi re, or water leak due to insulation degradation or aging of the electrical parts. Ask an authorized Hoshizaki service company for the following inspections (charged): • Dust and dirt build-up or water leak inside the unit •...

  • Page 75: Descaling (As Required)

    D. Descaling (As Required) Use a descaler according to the supplier’s instructions. WARNING 1. Carefully follow any instructions provided with the descaler. 2. Always wear liquid-proof gloves and goggles to prevent the descaler from coming into contact with skin or eyes. 3.
  • Page 76 1) Press the “ON/OFF” button on the operation panel. The display and lamps go off. 2) Turn off the water heater. 3) Turn off the gas and water supplies. IMPORTANT To operate the water heater, follow its instruction manual. Service Panel 4) Open the service panel.

  • Page 77: Long Storage, Relocation, Disposal, Transfer

    Hoshizaki service company. WARNING 1. When restarting the unit after long storage, contact an authorized Hoshizaki service company. To prevent electric shock, do not restart the unit by yourself. 2. In case of relocation, contact an authorized Hoshizaki service company.

  • Page 78: Technical Information

    (not provided by Hoshizaki) into the wash tank. • The rinse aid is fed by the rinse aid feeder (not provided by Hoshizaki) into the rinse water line and sprayed from the upper and lower rinse spray arms into the wash...

  • Page 79: Wiring Diagram

    B. Wiring Diagram...

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