Hoshizaki DCM-60KE Service Manual
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Hoshizaki DCM-60KE Service Manual

Cubelet ice dispenser
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CUBELET ICE DISPENSER
MODEL
HOSHIZAKI
DCM-60KE
DCM-60KE-P
DCM-120KE
DCM-120KE-P
SERVICE MANUAL
NO.
L009-872
ISSUED: JUN. 1, 2012
REVISED:

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  • Page 1 NO. L009-872 ISSUED: JUN. 1, 2012 REVISED: HOSHIZAKI CUBELET ICE DISPENSER DCM-60KE MODEL DCM-60KE-P DCM-120KE DCM-120KE-P SERVICE MANUAL...

  • Page 2: Table Of Contents

    CONTENTS PAGE I. SPECIFICATIONS -------------------------------------------------------------------------------------- 1 1. DIMENSIONS/SPECIFICATIONS ----------------------------------------------------------------- 1 [a] DCM-60KE (L013: Continental) ---------------------------------------------------------------- 1 [b] DCM-60KE (L013-C101: UK) ------------------------------------------------------------------- 2 [c] DCM-60KE (L013-C201: Oceania) ------------------------------------------------------------ 3 [d] DCM-60KE (L013-C301: China)---------------------------------------------------------------- 4 [e] DCM-60KE (L013-C130: Middle East)-------------------------------------------------------- 5 [f] DCM-60KE-P (L014: Continental) -------------------------------------------------------------- 6...
  • Page 3 [h] RESETTING ERROR LOG ---------------------------------------------------------------------37 [i] REDUCING COMPRESSOR STARTING TIME--------------------------------------------37 [j] RESETTING COMPRESSOR OPERATING HOURS ------------------------------------37 6. ERROR CODES ---------------------------------------------------------------------------------------38 7. PERFORMANCE DATA -----------------------------------------------------------------------------41 [a] DCM-60KE(-P): 50Hz ----------------------------------------------------------------------------41 [b] DCM-60KE(-P): 60Hz ----------------------------------------------------------------------------42 [c] DCM-120KE(-P): 50Hz---------------------------------------------------------------------------43 [d] DCM-120KE(-P): 60Hz --------------------------------------------------------------------------44 IV. SERVICE DIAGNOSIS -----------------------------------------------------------------------------45 1.

  • Page 4: Specifications

    I. SPECIFICATIONS 1. DIMENSIONS/SPECIFICATIONS [a] DCM-60KE (L013: Continental)

  • Page 5: [B] Dcm-60Ke (L013-C101: Uk)

    [b] DCM-60KE (L013-C101: UK)

  • Page 6: [C] Dcm-60Ke (L013-C201: Oceania)

    [c] DCM-60KE (L013-C201: Oceania)

  • Page 7: [D] Dcm-60Ke (L013-C301: China)

    [d] DCM-60KE (L013-C301: China)

  • Page 8: [E] Dcm-60Ke (L013-C130: Middle East)

    [e] DCM-60KE (L013-C130: Middle East)

  • Page 9: [F] Dcm-60Ke-P (L014: Continental)

    [f] DCM-60KE-P (L014: Continental)

  • Page 10: [G] Dcm-60Ke-P (L014-C101: Uk)

    [g] DCM-60KE-P (L014-C101: UK)

  • Page 11: [H] Dcm-60Ke-P (L014-C201: Oceania)

    [h] DCM-60KE-P (L014-C201: Oceania)

  • Page 12: [I] Dcm-60Ke-P (L014-C301: China)

    [i] DCM-60KE-P (L014-C301: China)

  • Page 13: [J] Dcm-60Ke-P (L014-C130: Middle East)

    [j] DCM-60KE-P (L014-C130: Middle East)

  • Page 14: [K] Dcm-120Ke (L009: Continental)

    [k] DCM-120KE (L009: Continental)

  • Page 15: [L] Dcm-120Ke (L009-C101

    [l] DCM-120KE (L009-C101: UK)

  • Page 16: [M] Dcm-120Ke (L009-C201: Oceania)

    [m] DCM-120KE (L009-C201: Oceania)

  • Page 17: [N] Dcm-120Ke (L009-C301: China)

    [n] DCM-120KE (L009-C301: China)

  • Page 18: [O] Dcm-120Ke-P (L010: Continental)

    [o] DCM-120KE-P (L010: Continental)

  • Page 19: [P] Dcm-120Ke-P (L010-C101

    [p] DCM-120KE-P (L010-C101: UK)

  • Page 20: [Q] Dcm-120Ke-P (L010-C201: Oceania)

    [q] DCM-120KE-P (L010-C201: Oceania)

  • Page 21: [R] Dcm-120Ke-P (L010-C301: China)

    [r] DCM-120KE-P (L010-C301: China)

  • Page 22: Construction

    2. CONSTRUCTION Bin Control Shutter Switch Water Dispense Valve Ice Storage Operation Board Control Water Dispense Switch Valve *DCM-60/120KE-P Safety Switch Float Switch Reservoir Front Cover Spout Push Lever *DCM-60/120KE Grille Drain Pan Water Supply Inlet Air Filter...
  • Page 23 Operation Control Box Switch Controller Board Ice Making Switch Expansion Valve Transformer Evaporator Compressor Drier Lever Switch *DCM-60/120KE Fan Motor Flush Water Valve Thermistor Gear Motor Condenser Drain Outlet...

  • Page 24: Maintenance And Cleaning Instructions

    II. MAINTENANCE AND CLEANING INSTRUCTIONS IMPORTANT 1. This ice dispenser must be maintained individually, referring to the instruction manual and labels provided with the ice dispenser. 2. To achieve optimum ice dispenser performance, the following parts need periodic inspection and maintenance: Extruding head (upper bearing) Housing (lower bearing) Mechanical seal...

  • Page 25: Gear Motor

    Note: The water leakage will exceed the above amount with scale/dirt build up or damage on the mating surface. Replace the mechanical seal when the water leakage exceeds 0.5 mL/h. 3. GEAR MOTOR After the following hours of operation, check the gear motor for excessive noise caused by increased torque or deterioration of mechanical parts.

  • Page 26: Control Water Valve And Water Dispense Valve

    6. CONTROL WATER VALVE AND WATER DISPENSE VALVE 1) Unplug the ice dispenser. 2) Close the water supply tap. 3) Disconnect the fitting from the valve. 4) Clean the filter packing using a brush. 5) Replace the filter packing and fitting in their correct positions. 6) Open the water supply tap.

  • Page 27: Cleaning Of Water System

    7. CLEANING OF WATER SYSTEM WARNING 1. HOSHIZAKI recommends cleaning this unit at least twice a year. More frequent cleaning, however, may be required in some existing water conditions. 2. Do not touch the operation switch and ice making switch with damp hands.
  • Page 28 3) Press the drain switch on the control panel. The display illuminates “DRAIN” during the 1 minute drain cycle. 4) Unplug the ice dispenser. 5) Remove the top panel and storage bin cover. 6) Pour the cleaning solution carefully into the opening in the center of the storage bin (top of the evaporator) to an overflow level (surplus solution will be seen overflowing into the drain pan).
  • Page 29 17) Wait for 10 minutes. During this time, use a clean cloth and some of the remaining solution to wipe the inside of the storage bin and the bin cover. (Do not fit the agitator or the drip ring.) 18) Refit the storage bin cover, and loosely fit the machine’s top panel. 19) Plug in the ice dispenser to make ice with the sanitising solution.

  • Page 30: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT Control Water Valve Storage Bin Float Switch Water Reservoir Supply Inlet Freezer (Evaporator) Expansion Valve Water Dispense Valve Flush Water Valve Gear Motor Drier Condenser Compressor Thermistor Water Circuit Refrigerant Circuit...

  • Page 31: Wiring Diagram

    2. WIRING DIAGRAM...

  • Page 32: Icemaking Mechanism

    3. ICEMAKING MECHANISM Bin Control Switch Storage Bin Cover Bracket - Solenoid Inside Cover Solenoid Balance Plate (B) Ice Storage Bin Agitator Shutter Assembly Drip Ring Insulation Ice Chute O-ring Evaporator Top Cover Auger Extruding Head Sealing Bolt Evaporator Mechanical Seal Water Supply Pipe Housing O-ring...

  • Page 33: [A] Evaporator (Casing)

    [a] EVAPORATOR (CASING) The evaporator consists of a stainless steel icemaking cylinder coiled with a refrigeration pipe and wrapped together with a polyurethane foam insulation material. Water coming from the inlet into the evaporator will be frozen into ice. The ice spout is located on top of the evaporator.

  • Page 34: [H] Sealing Bolt

    [h] SEALING BOLT Sometimes the icemaking operation may produce white solids on the drip pan. They are deposits of silica and calcium contents in the icemaking water leaking from the sealing bolt. The bolt is provided with retaining and sealing functions, which may be reduced by the load and vibration during a freeze cycle.

  • Page 35: Electric Circuit

    Compressor starts * Low ice bin level Low ice bin level (Freeze cycle starts) DCM-60KE: 400g less ice than bin full DCM-120KE: 800g less ice than bin full (Microprocessor calculates amount of ice Gear motor stops melt and dispensed)

  • Page 36: [B] Timing Chart

    [b] TIMING CHART...

  • Page 37: Operation Board

    5. OPERATION BOARD [a] DISPLAYING COMPRESSOR OPERATING HOURS 1) Press and hold the lock switch. 2) After 3 seconds, the display shows the compressor operating hours. Note: The display shows the compressor operating hours in six digits divided into three parts (two digits for 2 seconds each time).

  • Page 38: [C] Displaying Model Number

    By using the freeze cycle time, approximate ice production capacity can be calculated. Ice production capacity (kg/d) = 24,000 / cycle time (sec) * If the automatic drain pan flush is activated, the cycle time becomes longer because the drain pan is flushed at the same time as water is supplied to the reservoir. [c] DISPLAYING MODEL NUMBER 1) Press and hold the lock switch.

  • Page 39: [E] Displaying Controller Board Software Version

    [e] DISPLAYING CONTROLLER BOARD SOFTWARE VERSION 1) Press and hold the lock switch. 2) After 3 seconds, the display shows the compressor operating hours. 3) While still holding down the lock switch, press the drain switch three times. 4) The display shows the software version of controller board. Note: The display shows the software version divided in three parts.

  • Page 40: [H] Resetting Error Log

    6) The display shows ongoing error. Note: 1. The display shows up to eight errors from the latest error. 2. If there is no error log, the display shows “- -”. 3. Ongoing errors appear from the smallest error code, not from the latest error. [h] RESETTING ERROR LOG Operation SW 1) Press and hold the lock switch and portion control switch together, and turn on the...

  • Page 41: Error Codes

    6. ERROR CODES Interlock Errors Code Error Condition Operation Reset Check/Repair Water leak from Service call lamp water circuit blinks. (reservoir, inlet Power supply, Icemaking c0 error occurs 2 times in a E0 blinks. hose, outlet hose, Turn OFF - Water Leak row.
  • Page 42 Service call lamp supply cycles reaches in a blinks. row: Power supply, Bin Control EL blinks. DCM-60KE(-P) 12 times Turn OFF - Bin control switch Switch Error Whole unit stops. DCM-120KE(-P) 24 times Turn ON Dispensing not...
  • Page 43 Dispensing not minutes. ambient controller board. available. temperature Interval between reservoir water supplies exceeds: Water leak from water circuit DCM-60KE(-P) Whole unit stops, (reservoir, inlet Low Ice 1st freeze cycle 40 minutes then Error record hose, outlet hose, Production 2nd cycle or later 20 minutes automatically only.

  • Page 44: Performance Data

    7. PERFORMANCE DATA [a] DCM-60KE(-P): 50Hz 0.07 0.06 0.05 0.04 0.03 0.02 1.60 1.55 1.50 1.45 1.40 1.35 1400 1200 1000 The horizontal axis shows the ambient temperature It refers to data of at/wt=10/10, 21/15, 32/21...

  • Page 45: [B] Dcm-60Ke(-P): 60Hz

    [b] DCM-60KE(-P): 60Hz 0.07 0.06 0.05 0.04 0.03 0.02 1.60 1.55 1.50 1.45 1.40 1.35 1400 1200 1000 The horizontal axis shows the ambient temperature It refers to data of at/wt=10/10, 21/15, 32/21...

  • Page 46: [C] Dcm-120Ke(-P): 50Hz

    [c] DCM-120KE(-P): 50Hz 0.14 0.13 0.12 0.11 0.10 0.09 0.08 0.07 2.95 12.5 2.90 12.0 2.85 11.5 11.0 2.80 10.5 2.75 10.0 2.70 1400 1200 1000 The horizontal axis shows the ambient temperature It refers to data of at/wt=10/10, 21/15, 32/21...

  • Page 47: [D] Dcm-120Ke(-P): 60Hz

    [d] DCM-120KE(-P): 60Hz 0.14 0.13 0.12 0.11 0.10 0.09 0.08 0.07 2.75 14.5 2.70 14.0 2.65 13.5 13.0 2.60 12.5 2.55 12.0 2.50 1400 1200 1000 The horizontal axis shows the ambient temperature It refers to data of at/wt=10/10, 21/15, 32/21...

  • Page 48: Service Diagnosis

    IV. SERVICE DIAGNOSIS Display error records by operating the operation board (see “III. 5. [g] DISPLAYING ERROR LOG AND ONGOING ERROR”). Check for a possible cause and service the unit. 1. NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The ice a) Power supply 1.
  • Page 49 PROBLEM POSSIBLE CAUSE REMEDY [3] (Continued) d) Condenser 1. Dirty condenser fins. 1. Clean. thermistor 2. Ambient temperature 2. Check for recommended too warm. temperature. 3. Fan not rotating. 3. Replace. 4. Condenser water 4. Check and get recommended pressure too low or off. pressure.

  • Page 50: Low Ice Production

    2. LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] Low ice a) Refrigerant line 1. Gas leaks. 1. See 1 - [5] - a). production 2. Refrigerant line 2. Replace the clogged clogged. component. 3. Overcharged. 3. Recharge. b) High-side 1.

  • Page 51: Others

    4. OTHERS PROBLEM POSSIBLE CAUSE REMEDY [1] Abnormal noise a) Fan motor 1. Bearing worn out. 1. Replace. (condenser unit) 2. Fan blade deformed. 2. Replace fan blade. 3. Fan blade does not 3. Replace. move freely. b) Compressor 1. Bearings worn out, or 1.

  • Page 52: Removal And Replacement

    V. REMOVAL AND REPLACEMENT 1. FRONT COVER [a] REMOVAL 1) Remove the top panel. 2) Remove the two screws at the top of the front cover and the screw at the back of the ice spout. 3) Pull the top of the front cover forward. (Hooks are provided at the bottom of the front cover.) Hook...
  • Page 53 4) Disconnect the two connectors. 5) Lift off the front cover.

  • Page 54: [B] Replacement

    [b] REPLACEMENT 1) Replace the removed parts in the reverse order of which they were removed. Note: 1. Before installing the front cover, put the water pipe through the front cover. Water Pipe 2. Hook the bottom of the front cover as shown below, and push it in hard.

  • Page 55: Service For Refrigerant Lines

    2. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R134A] The compressor must not be opened more than 15 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, except when they use the same lubricant.

  • Page 56: [B] Refrigerant Recovery

    8) Refrigerant Leak Check Refrigerant leaks can be detected by charging the unit with a little refrigerant, raising the pressure with nitrogen and using an electronic detector. Do not use air or oxygen instead of nitrogen for this purpose, or rise in pressure as well as in temperature may cause R134A to suddenly react with oxygen and explode.

  • Page 57: Brazing

    3. BRAZING DANGER 1. Refrigerant R134A itself is not flammable, explosive and poisonous. However, when exposed to an open flame, R134A creates phosgene gas, hazardous in large amounts. 2. Always recover the refrigerant and store it in a proper container, if required by an applicable law.

  • Page 58: Drier

    10) Place the compressor in position, and secure it using the bolts and washers. 11) Remove plugs from the discharge, suction and access pipes. 12) Braze the access, suction and discharge pipes (Do not change this order) with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar. 13) Install the new drier (See "5.

  • Page 59: Expansion Valve

    6. EXPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the drier capacity and freezes up at the expansion valve. Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made.

  • Page 60: Fan Motor

    7. FAN MOTOR 1) Unplug the ice dispenser. 2) Remove the cabinet. 3) Disconnect the lead wires at their connection. 4) Take out the fan motor with its bracket from the unit. Remove 4 screws. Remove fan motor from unit. 5) Remove the fan motor from the fan motor bracket.
  • Page 61 Note: Replacing the bearing needs a fitting tool. If it is not available, replace the whole extruding head. AUGER 9) Lift out the auger. Check the top and bottom areas in contact with the bearings. If the surface is scratched or pitted, replace the auger. Check the blade edge of the auger. If it is scratched or worn where it has contacted the evaporator, replace it.

  • Page 62: Control Water Valve And Water Dispense Valve

    18) Remove the four bolts and lift the housing clear of the gear motor. Check the bearing inside the housing. If it is worn or scratched, replace it using a fitting tool. Carefully ease out the lower part of the mechanical seal before replacing the bearing. Note: If a fitting tool is not available, replace the whole lower housing complete with bearing.

  • Page 63: Flush Water Valve

    6) Install the new valve. 7) Assemble the removed parts in the reverse order of which they were removed. 8) Open the water supply tap. 9) Plug in the ice dispenser. 10) Check for water leaks. 11) Refit the panels in their correct position. 10.

  • Page 64: Controller Board

    11. CONTROLLER BOARD IMPORTANT A single type controller board is supplied as a service board. Some modifications and adjustment will be required to fit the ice dispenser models. Do not repair any parts and electronic devices on the controller board in the field. Replace the whole board with a new service board.

  • Page 65: Bin Control Switch Assembly

    6) Install the new bin control switch assembly. 7) Assemble the removed parts in the reverse order of which they ware removed. 8) Plug in the ice dispenser, and check that the bin control switch works normally. DCM-60KE(-P) DCM-120KE(-P) Bin Control Switch...

  • Page 66: Storage Bin Assembly

    13. STORAGE BIN ASSEMBLY 1) Move the ice making switch to the “OFF” position. 2) Press the push lever or dispense switch to dispense ice, and remove all ice from the storage bin. 3) Press the drain switch on the control panel. The display illuminates “DRAIN” during the 1 minute drain cycle.

This manual is also suitable for:

Dcm-120keDcm-120ke-pDcm-60ke-p

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