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Hoshizaki C-80BAJ, Service Manual

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Hoshizaki C-80BAJ Service Manual Download Page 16

16

Reservoir

Reservoir Cover

Float Switch Assembly

Red (R) 

(upper float switch)

Black (BK) 

(common)

Blue (BU) 

(lower float switch)

Upper Float (blue)

Magnet (towards top)

Magnet (towards top)

Lower Float (white)

Plastic Retainer Clip

Spring Retainer Clip

Fig. 1

Fig. 2

6) Rinse FS assembly thoroughly with clean water and replace in its correct position.
7) Replace the upper rear panel in its correct position.
8) Plug the appliance into the electrical outlet, then move the control switch to the "ICE" 

position to start the automatic icemaking process.

Legend: 

FS–float switch; LFS–lower float switch; UFS–upper float switch

Summary of Contents for C-80BAJ

Page 1: ...Models C 80BAJ C 80BAJ DS C 80BAJ AD C 80BAJ ADDS Self Contained Cubelet Service Manual Number 73219 Issued 12 1 2017 hoshizakiamerica com ...

Page 2: ...erty damage due to improper installation is not covered under warranty Hoshizaki provides this manual primarily to assist qualified service technicians in the service of the appliance 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 1...

Page 3: ...igeration Circuit Service Information 21 B Component Service Information 24 1 Upper Bearing Wear Check 26 2 Removal and Replacement of Extruding Head 27 3 Removal and Replacement of Auger 28 4 Removal and Replacement of Evaporator 29 5 Removal and Replacement of Mechanical Seal and Lower Housing 30 6 Removal and Replacement of Gear Motor 32 V Maintenance 33 A Maintenance Schedule 34 VI Preparing t...

Page 4: ...dependent power supply of proper capacity See the nameplate for electrical specifications Failure to use an independent power supply of proper capacity can result in a tripped breaker blown fuse damage to existing wiring or component failure This could lead to heat generation or fire THE APPLIANCE MUST BE GROUNDED The appliance is equipped with a NEMA 5 15 three prong grounding plug to reduce the ...

Page 5: ...r damage In areas where water damage is a concern install in a contained area with a floor drain Install the appliance in a location that stays above freezing Normal operating ambient temperature must be within 45 F to 100 F 7 C to 38 C If using the optional drain pump HS 5061 test its operation every time the appliance is cleaned and sanitized See II E 2 Drain Pump Check for details If the option...

Page 6: ... ventilation openings in the appliance enclosure or in the built in structure clear of obstruction Do not place objects on top of the appliance The storage bin is for ice use only Do not store anything else in the storage bin ...

Page 7: ...lve Water Reservoir Float Switch Compressor Evaporator Assembly Gear Motor Drier Drip Tray Gear Motor Drain Pan Evaporator Condensate Drain Pan Lower Rear Panel Power Cord Drain Valve Upper Rear Panel Top Panel Ice Discharge Opening Scoop Holder Front Panel Control Switch Louver Bin Control Thermostat Bulb Slope Magnet Catch Door Power Cord Bin Control ...

Page 8: ...lt Gear Motor Spline Coupling Housing and Lower Bearing O Ring Mechanical Seal Cylinder Auger Extruding Head and Upper Bearing Cutter motionless Insulation Socket Head Cap Screw with Washer Hex Head Bolt with Washer Evaporator Flange ...

Page 9: ...r Motor Evaporator Assembly Water Inlet Evaporator Water Supply Hose Capillary Tube Overflow Hose Suction Discharge Inlet Water Valve Drain Valve Drain Hose Evaporator Condensate Drain Pan Drip Pan Hose Evaporator Condensate Drain Pan Drip Pan Gear Motor Drain Pan Bin Drain Hose To Bin Gear Motor Drain Pan Hose To Drain Drain Valve ...

Page 10: ...ries Sequence Flow Chart Startup Shutdown Restart 1 Bin Full Icemaker Off BC open Comp de energized FM de energized GM de energized Legend BC bin control Comp compressor DV drain valve DP drain pump optional FM fan motor FT fill timer time delay relay GM gear motor LFS lower float switch UFS upper float switch WV inlet water valve Optional Drain Pump HS 5061 Drain pump has 115VAC when appliance is...

Page 11: ...ion in 24 hours When confirming production or diagnosing low production see VIII A Specification and Performance Data for typical production information 2 Diagnostic Procedure This diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components Before proceeding check for correct installation proper voltage per appliance nameplate and adequate water pressu...

Page 12: ...le Complete Check that UFS closes when reservoir is full If not check FS See II D 1 Float Switch Check 8 Freeze Cycle UFS closes and energizes WCR WCR allows TDR to energize then TDR energizes GM FM and CR CR then energizes Comp WV de energizes Ice production starts 4 to 6 minutes after Comp energizes depending on ambient and water conditions WCR Diagnosis Confirm WCR energizes If not confirm UFS ...

Page 13: ...energizes If not see II D 1 Float Switch Check Once WCR de energizes confirm WV energizes If not check for 115VAC at WCR 2 O to neutral W If 115VAC is not present replace WCR If 115VAC is present check WV solenoid continuity Replace as needed Confirm UFS closes and WCR energizes within 90 sec of WV energizing If not confirm that water supply is on Once UFS closes WCR energizes energizing TDR and r...

Page 14: ...et and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations To check BC follow the steps below 1 Turn off the power supply 2 Move the control switch to the OFF position 3 Clear any ice away from BC bulb 4 Remove the upper rear panel and disconnect BC wires from BC switch 5 Hold your hand around the bulb to warm it up 6 Ch...

Page 15: ... FS check UFS and LFS again Replace if necessary 10 Reconnect FS wires to the appropriate appliance wires Black BK to black BK red R to brown BR and blue BU to blue BU 11 Replace upper rear panel in its correct position 12 Plug the appliance into the electrical outlet then move the control switch to the ICE position to start the automatic icemaking process Legend FS float switch LFS lower float sw...

Page 16: ...stic Retainer Clip Spring Retainer Clip Fig 1 Fig 2 6 Rinse FS assembly thoroughly with clean water and replace in its correct position 7 Replace the upper rear panel in its correct position 8 Plug the appliance into the electrical outlet then move the control switch to the ICE position to start the automatic icemaking process Legend FS float switch LFS lower float switch UFS upper float switch ...

Page 17: ... the OFF position 1 Move the control switch to the OFF position then unplug the appliance from the electrical outlet WARNING To reduce the risk of electric shock do not touch the control switch or plug with damp hands 2 Remove all ice from the storage bin 3 Plug the appliance back in 4 Slowly pour 24 to 30 oz 710 to 890 ml of water over the storage bin drain hole in the storage bin 5 If water pump...

Page 18: ... and not allowing water valve to energize See II D 1 Float Switch Check b Defective 7 Inlet Water Valve a Screen or orifice clogged b Defective 8 Float Switch See II D Float Switch Check and Cleaning a Float does not move freely b Defective Freeze Cycle 1 Water Control Relay a Defective 2 Time Delay Relay a Defective 3 Gear Motor a Gear motor external protector 2 4 3 0A tripped b Gear motor intern...

Page 19: ...upply a Water supply off or improper water pressure 7 to 113 PSIG b External water filters clogged 4 Water Control Relay a Defective 5 Time Delay Relay a Defective Shutdown 1 Bin Control Thermostat Assembly with integrated heater a Open with bin filled with ice b Out of position c Out of adjustment See II C Bin Control Check d Bad contacts e Bad thermostat heater ...

Page 20: ... P Time delay relay contacts close between time delay relay 8 BR and time delay relay 9 W R energizing the gear motor fan motor and compressor When the lower float switch opens the water control relay de energizes de energizing the time delay relay A 90 sec low water safety timer starts Once the upper float switch closes the water control relay energizes energizing the time delay relay The time de...

Page 21: ...essurized air for leak testing NOTICE Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Do not leave the system open for longer than 15 min when replacing or servicing parts The Polyol Ester POE oils used in R 134a applications can absorb moisture quickly Therefore it is important to prevent moisture from entering the system w...

Page 22: ...ng an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG Do not use R 134a as a mixture with pressurized air for leak testing 3 Evacuation and Recharge R 134a 1 Attach a vacuum pump to the system Be sure the high side charging hose is connected to the field installed high side access valve IMPORTANT The vacuum level and vacuum pump may be the same as those for current...

Page 23: ... service cylinder then place it on the scales Open the high side valve on the gauge manifold 7 Allow the system to charge with liquid until the proper charge weight is met 8 Close the high side valve on the gauge manifold then close the refrigerant access valve if applicable Disconnect the gauge manifold hose 9 Cap the refrigerant access valve to prevent a possible leak ...

Page 24: ...ocker to seal bolt threads Tighten down the new seal bolts to a torque of 11 1 ft lb 15 N m Compressor Install a new drier and PTC relay Upper and Lower Bearings Inspect the upper bearing for wear See IV B 1 Upper Bearing Wear Check Replace if necessary When replacing the upper bearing it is advised to also change the lower bearing at the same time Evaporator Install a new drier Inspect the mechan...

Page 25: ... Outlet Hose Connection Spout Socket Head Cap Screw with Washer Socket Head Cap Screw with Washer Evaporator Condensate Drain Pan Evaporator Assembly Seal Bolts Inspect for leakage around seal bolts Tighten 11 1 ft lb 15 N m or replace as necessary Seal bolts must be replaced once removed because seal material is one time use only If new seal bolts do not have preapplied threadlocker apply Loctite...

Page 26: ... Fig 6 Check several locations around the auger shaft If the gauge goes between the shaft and the bearing at any point or if the bearing is scratched or cracked both the top bearing in the extruding head and the lower bearing in the housing should be replaced Instructions for removing the extruding head and housing are located later in this procedure Note Replacing the bearing requires a bearing p...

Page 27: ...t section towards storage bin front of machine 12 If new seal bolts do not have preapplied threadlocker apply Loctite 243 or equivalent threadlocker to seal bolts Tighten new seal bolts to a torque of 11 1 ft lb 15 N m 13 Tighten down the cutter 14 Secure the packing and spout in their correct positions 15 Open the water supply line shut off valve 16 Plug the appliance into the electrical outlet t...

Page 28: ...lower parts of the mechanical seal should be replaced Instructions for removing the mechanical seal are located later in this procedure 11 Remove the mechanical seal from the old auger and place it on the new auger 12 Install the new auger 13 Replace the extruding head with cutter and evaporator flange in their correct positions Confirm the cutter is tight See Fig 7 14 If new seal bolts do not hav...

Page 29: ...e mechanical seal should come out with it 10 Disconnect the reservoir outlet hose from the evaporator 11 Remove the evaporator condensate drain pan 12 Install a temporary tap line valve on the high side then recover the refrigerant and store it in an approved container 13 Disconnect the inlet and outlet tubing 14 Remove the socket head cap screws securing the evaporator to the lower housing 15 Lif...

Page 30: ...o the ICE position to start the automatic icemaking process 29 Once the appliance starts to produce ice allow it to run for another 30 minutes Check for water leaks 30 After 30 minutes move the control switch to the OFF position Unplug the appliance from the electrical outlet 31 Pour warm water into the storage bin and melt the ice Clean the storage bin liner using a neutral cleaner Rinse thorough...

Page 31: ... a bearing press adaptor If one is not available replace the entire extruding head and housing 16 Mount the lower housing onto the gear motor then install the O ring onto the lower housing 17 Install the lower part of the mechanical seal onto the lower housing 18 Lower the evaporator down and secure it to the lower housing 19 Install the auger assembly with the upper part of the mechanical seal at...

Page 32: ...ove the bolts securing the gear motor 9 Disconnect the gear motor wires then remove the gear motor 10 Attach the spline coupling from the old gear motor to the new gear motor 11 Install the new gear motor 12 Lower the evaporator onto the gear motor Secure the lower housing to the gear motor 13 Reconnect the electrical wires 14 Open the water supply line shut off valve 15 Plug the appliance into th...

Page 33: ...the control switch to the OFF position Unplug the appliance from the electrical outlet to prevent the power supply from being turned back on inadvertently CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after any maintenance is done to the appliance Make sure that none have fallen into the storage bin Do not place fingers or any other objects into the ice disch...

Page 34: ...anual Evaporator Condensate Drain Pan and Gear Motor Drain Pan Wipe down with clean cloth and warm water Extruding Head Seal Bolts Inspect for leakage around seal bolts Tighten see torque value below or replace as necessary Seal bolts must be replaced once removed because seal material is one time use only If new seal bolts do not have preapplied threadlocker apply Loctite 243 or equivalent thread...

Page 35: ...ply line shut off valve then open the water supply line drain valve 3 Allow the line to drain by gravity 4 Move the control switch to the DRAIN position 5 Allow the water system to drain for 1 min 6 Attach a compressed air or carbon dioxide supply to the water supply line drain valve 7 Move the control switch to the ICE position 8 Blow the water supply line out using the compressed air or carbon d...

Page 36: ...upply 16 Move the control switch to the OFF position then unplug the appliance from the electrical outlet 17 Reconnect the reservoir outlet hose to the reservoir then secure with the clamp Make sure all hoses are connected and secure 18 Replace the rear panel in its correct position 19 Clean the storage bin by using a neutral cleaner Rinse thoroughly after cleaning ...

Page 37: ...posal 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 38: ...38 VIII Technical Information A Specification and Performance Data 1 C 80BAJ DS AD ADDS DATA PENDING ...

Page 39: ...39 B Wiring Diagrams 1 C 80BAJ DS AD ADDS ...

Page 40: ...40 2 Optional Drain Pump HS 5061 To Icemaker ...

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