Hoshizaki KM-301BAJ Service Manual Download

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No Ice Production - Possible Cause

15. Thermostatic Expansion Valve

a) Bulb loose.
b) Operating erratically.

16. Fan Motor

a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.

17. Water System

a) Water leaks causing short freeze time.

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.

Freeze-Up - Possible Cause

Harvest Cycle

1. Evaporator

a) Scaled up.
b) Damaged.

2. Cube Guides

a) Out of position.
b) Damaged.

3. Spray Tubes and/or Spray

Guides

a) Dirty.
b) Out of position.

4. Water Supply

a) Low water pressure.
b) External water filters clogged.
c) Insufficient water line size.

Minimum 1/4" Nominal ID (6 mm Nominal OD in the EU) copper
water tubing or equivalent.

5. Inlet Water Valve

a) Screen or orifice clogged.
b) Defective.

6. Float Switch

See "II.E. Float Switch Check
and Cleaning"

a) Dirty, sticking.
b) Defective.

7. Refrigerant Charge

a) Low.

8. Control Board

See "III.C. Settings and
Adjustments" and "II.C. Control
Board Check"

a) Harvest timer (S1 dip switch 1 & 2) set too short.

b) Harvest pump timer (S1 dip switch 7) not in factory default position.
c) Defective.

9. Bin Control

See "II.D. Bin Control Check"

a) Actuator does not move freely.

10. Thermistor

See "II.F. Thermistor Check"

a) Loose, disconnected, or defective.

11. Thermostatic Expansion Valve

a) Defective.

12. Hot Gas Valve

a) Closed or restricted.

Summary of Contents for KM-301BAJ

Page 1: ...Models KM 231BAJ KM 301BAJ BWJ Self Contained Crescent Cuber Service Manual Number 73238 Issued 7 23 2019 hoshizakiamerica com ...

Page 2: ...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 1940 770 487 2331 Fa...

Page 3: ...36 3 Pump Out Time Harvest Time During Pump Out S1 dip switch 3 4 36 4 Pump Out Frequency Control S1 dip switch 5 6 37 5 Harvest Pump Time Duration Harvest Assist S1 dip switch 7 8 37 6 Freeze Timer S1 dip switch 9 10 38 7 Pump Out Drain Selector S2 dip switch 1 38 8 Harvest Promotion Control S2 dip switch 2 38 9 Minimum Harvest Time S2 dip switch 3 39 10 Harvest Completion Detection Control S2 di...

Page 4: ...e 46 VI Preparing the Appliance for Periods of Non Use 47 VII Disposal 49 VIII Technical Information 50 A Specification and Performance Data Sheets 50 1 KM 231BAJ 50 2 KM 301BAJ 51 3 KM 301BWJ 52 B Wiring Diagram 53 ...

Page 5: ...roper 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 risk of potential shock haz...

Page 6: ...or when moving the appliance to prevent damage to the floor When making water supply or drain line repairs follow the requirements found in the instruction manual to reduce the risk of costly water damage In areas where water damage is a concern confirm appliance is installed in a contained area with a floor drain Confirm the appliance is in a location that stays above freezing Normal operating am...

Page 7: ...Panel Control Switch Service Switch Water Pump Float Switch Compressor Thermostatic Expansion Valve Fan Motor Hot Gas Valve Cleaning Valve Bin Control Inlet Water Valve Rear Panel Power Supply Cord Right Side Panel Front View Rear View Top Cover Evaporator Separator Water Tank Leg Louver Air Filter Door Front Cover Drain Valve Thermistor Overflow Pipe Separator ...

Page 8: ... Switch Water Pump Compressor Thermostatic Expansion Valve Water Regulating Valve Hot Gas Valve Cleaning Valve Bin Control Inlet Water Valve Rear Panel Power Supply Cord Right Side Panel Front View Rear View Top Cover Evaporator Separator Water Tank Leg Louver Door Front Cover Drain Valve Thermistor Overflow Pipe Separator ...

Page 9: ...9 Water Supply Pipe Evaporator Water Pump Inlet Water Valve Spray Tube 3 Icemaking Compartment Separator Cube Guide Water Tank Overflow Pipe Drain Valve Cleaning Valve Separator Float Switch Separator ...

Page 10: ...e Spray Tube Fan Condenser Expansion Valve Compressor Access Valve Strainer Hot Gas Valve High Pressure Switch Refrigerant Circuit Water Circuit Discharge Line Insulation Tube Pump Motor Water Tank Drain Drain Valve Cleaning Valve B Water Refrigeration Circuit Diagram 1 Air Cooled Models BAJ ...

Page 11: ...lating Valve Water Supply Water Valve Spray Tube Strainer Hot Gas Valve Float Switch Thermistor Expansion Valve Compressor Access Valve Refrigerant Circuit Water Circuit Discharge Line Pump Motor Water Tank Drain Evaporator Cube Guide Drier Suction Line Insulation Tube Cleaning Valve Drain Valve ...

Page 12: ...ps 2 Harvest Cycle WV time 6 min or the length of harvest minus 30 sec KM 231 or 10 sec KM 301 S1 dip switch 7 whichever is shorter Do not adjust S1 dip switch 7 out of the factory position Max harvest time 20 min Thermistor in control 3 Freeze Cycle Min freeze time 5 min Max freeze time freeze timer setting S1 dip switch 9 10 FS in control 4 Pump Out Cycle Factory set for every 10th cycle S1 dip ...

Page 13: ...WER OK LED flashing FS opens or 5 min timer terminates DV de energizes PM de energizes 3 Icemaker Off Minimum off time 90 sec minimum 90 sec off timer terminates before the appliance can restart 4 Ice Level Lowered Icemaker starts at 1 1 Minute Fill Cycle BC closed BC actuator paddle disengaged Red POWER OK LED on solid To 1 1 Minute Fill Cycle Legend BC bin control DV drain valve FS float switch ...

Page 14: ...h Settings Note When checking high voltage 115VAC always choose a white W neutral wire to establish a good neutral connection 1 Remove the louver Move the control switch to the OFF position then unplug the appliance from the electrical outlet Clear any ice from BC 1 Sequence and Component Diagnosis 3 Power On Plug the appliance into the electrical outlet Move the control switch to the ICE position...

Page 15: ...present and WV does not energize check for 115VAC at WV If 115VAC is present check coil continuity If open replace WV If the water tank fills but the appliance fails to start harvest Comp energized check for open FS See II E Float Switch Check and Cleaning If FS is closed and CB fails to start the harvest cycle after 1 min replace CB 5a Initial Harvest Cycle LEDs 5 6 and 8 are on WV continues Comp...

Page 16: ...VAC at the control switch terminal 4 DBU and 5 BK If 115VAC is present replace control switch If contacts are closed and 115VAC is present between control switch terminal 5 BK and neutral W check PM capacitor and motor winding continuity 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 ...

Page 17: ...HGV Diagnosis If WV is energized check for 115VAC at CB K5 4 O to neutral W If 115VAC is present after PM energizes in harvest cycle replace CB If 115VAC is not present replace WV bypassing If HGV did not de energize at the end of harvest check for 115VAC at CB K5 2 V to neutral W If 115VAC is present and LED 6 is off replace CB If 115VAC is not present replace HGV bypassing d PM Diagnosis Confirm...

Page 18: ... Data Sheets i Short Freeze Cycle Diagnosis Confirm water tank fills and overflows during 1 min fill and harvest cycles If not check water supply filters shut off valve WV screen If water tank empties before 5 min timer terminates and freeze cycle is short check that DV is not leaking by or energized water flowing through DV If DV is leaking by remove and clean DV replace as needed If water tank i...

Page 19: ...eck for 115VAC at control switch 4 DBU to neutral W If 115VAC is not present confirm 115VAC at control switch 5 BK to neutral W If 115VAC is present at control switch 5 BK and not at control switch 4 DBU replace control switch If 115VAC is present at control switch 4 DBU and PM is de energized check PM capacitor motor winding wiring connections and impeller for binding e DV Diagnosis Check for 115...

Page 20: ...T secondary circuit CT output is 10 5VAC at 115VAC primary input If the secondary circuit has proper voltage and the red LED is off replace CB If the secondary circuit does not have proper voltage check CT primary circuit Check for 115VAC at CB K3 connector pin 1 P to neutral W for 115VAC Always choose a white W neutral wire to establish a good neutral connection when checking voltages For additio...

Page 21: ...tor and water tank and press and hold the actuator paddle check for continuity across the wires of BC connector When the actuator paddle is engaged BC switch is open If closed check that the actuator paddle is not restricted Clean if necessary See II D 2 Bin Control Cleaning If BC switch still reads closed replace BC 9 Reconnect the BC connector to CB K1 connector and resecure in the protective pl...

Page 22: ...ompletely 2 After all of the water has drained move the control switch to the OFF position then unplug the icemaker from the electrical outlet 3 Clear any ice away from BC 4 Disconnect the overflow pipe then remove the 2 water tank thumbscrews Remove the water tank See Fig 1 5 Remove one of the bin control thumbscrews then loosen the other bin control thumbscrew and then slide the bin control asse...

Page 23: ...e control switch to the OFF position Move the service switch to the DRAIN position then move the control switch to the SERVICE position Allow the water tank to drain completely 2 After all of the water has drained move the control switch to the OFF position then unplug the icemaker from the electrical outlet 3 Remove the control box mounting screws and lower the control box access CB 4 Disconnect ...

Page 24: ...o drain completely 2 After all of the water has drained move the control switch to the OFF position then unplug the icemaker from the electrical outlet 3 Remove the top and upper rear panels 4 Locate FS on the compressor base See Fig 3 Remove the screw securing FS to the compressor base and lift FS from the icemaker 5 Remove the retainer clip from FS shaft then remove the float Be careful not to d...

Page 25: ...eads Normal range is 4 7 to 6 2 kΩ If outside the normal range replace the thermistor See IV B Component Service Information If within the normal range continue to the next step 8 Replace the thermistor in its correct position See IV B Component Service Information 9 Reconnect the thermistor connector to CB connector and re secure in the protective plastic cover 10 Replace the top panel in its cor...

Page 26: ...mp in all three positions 2 When the control switch is in the OFF position or in the ICE position the service switch has no power and can be left in any position a DRAIN This model utilizes a pump out drain system When the service switch is active and placed in the DRAIN position power is supplied to the pump service relay and drain valve b CIRCULATE When the service switch is active and placed in...

Page 27: ...n Control Check a Tripped with bin filled with ice b Actuator does not move freely c Defective 8 Water Supply a Water supply off or improper water pressure b External water filters clogged 9 Inlet Water Valve a Screen or orifice clogged b Coil winding open c Water valve open in freeze cycle 10 Float Switch See II E Float Switch Check and Cleaning a Float does not move freely b Defective 11 Compres...

Page 28: ...nd or Spray Guides a Dirty b Out of position 4 Water Supply a Low water pressure b External water filters clogged c Insufficient water line size Minimum 1 4 Nominal ID 6 mm Nominal OD in the EU copper water tubing or equivalent 5 Inlet Water Valve a Screen or orifice clogged b Defective 6 Float Switch See II E Float Switch Check and Cleaning a Dirty sticking b Defective 7 Refrigerant Charge a Low ...

Page 29: ...ive 3 Low Ice Production Low Ice Production Possible Cause Long Harvest Cycle 1 Evaporator a Scaled up 2 Spray Tubes and or Spray Guides a Dirty b Out of position 3 Refrigerant Charge a Low 4 Water Supply a Low water pressure b External water filters clogged c Insufficient water line size Minimum 1 4 Nominal ID 6 mm Nominal OD in the EU water tubing or equivalent d Too cold 5 Control Board See II ...

Page 30: ...b Float sticking c Defective switch 3 Inlet Water Valve a Leaking by 4 Hot Gas Valve a Erratic or open 5 Condenser a Clogged 6 Control Board See II C Control Board Check a Float switch connection loose K5 b Defective 7 Refrigerant Charge a Low 8 Thermostatic Expansion Valve a Bulb loose b Defective 9 Compressor a Inefficient or off 10 Pump Motor a RPM too slow ...

Page 31: ...31 I Freeze Up Check List ...

Page 32: ...le very carefully The control board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the icemaker when handling or replacing the control board Do not touch the electronic devices on the control board or the back of the control board Do not short out power supply to test for voltage Always replace the whole c...

Page 33: ...ivated Relay LEDs 6 indicate which relays are energized as listed below LED 5 X1 Relay Compressor Comp Fan Motor Remote FMR LED 4 X6 Relay Drain Valve DV LED 8 X4 Relay Inlet Water Valve WV WV1 on units with 2 inlet water valves K7 Connector Transformer K3 Connector Power Relay LED 7 X3 Relay Pump Motor PM LED 6 X2 Relay Hot Gas Valve HGV Fan Motor FM FM off when LED on LED 9 X5 Relay Inlet Water ...

Page 34: ...eep High Evaporator Temp temperature 127 F 53 C Check for harvest problem stuck HGV or relay hot water entering unit or shorted thermistor 2 Beep Harvest Backup Timer harvest 20 min for two cycles in a row Check thermistor open HGV not opening TXV leaking by low charge inefficient Comp or WRV leaking by 3 Beep Freeze Timer freeze freeze timer setting for two cycles in a row Check FS stuck closed u...

Page 35: ...F ON ON ON OFF ON OFF S2 Dip Switch Do Not Adjust Dip Switch No 1 2 3 4 5 6 KM 231BAJ ON OFF OFF OFF OFF OFF KM 301BAJ ON OFF OFF OFF OFF OFF KM 301BWJ ON OFF OFF OFF OFF OFF Do not adjust the S2 dip switch These must be left in the factory default position or the appliance will not operate properly Freeze Timer 9 10 Pump Out Frequency Control 5 6 Pump Out Time 3 4 Harvest Time 1 2 Harvest Pump Ti...

Page 36: ...very cycle thereafter S1 Dip Switch Setting Time sec No 1 No 2 OFF OFF 60 ON OFF 90 OFF ON 120 ON ON 180 3 Pump Out Time Harvest Time During Pump Out S1 dip switch 3 4 When a pump out is called for the pump motor stops for 2 seconds then the pump motor and drain valve energize Water is removed from the bottom of the water tank and sent down the drain The pump out drains the water tank for the time...

Page 37: ...tion Harvest Assist S1 dip switch 7 8 NOTICE Factory set for proper operation Do not adjust Adjustment outside of the factory default setting may result in damage to the appliance The harvest pump timer allows the water valve to close and the pump motor to circulate water in the tank during the final part of harvest The water valve is open during harvest for a maximum of 6 minutes or the length of...

Page 38: ... pump motor energizes pump out or stays off drain after a 2 second delay at the beginning of the pump out cycle or at shutdown Regardless of the pump out drain selector setting the drain valve energizes after a 2 second delay at the beginning of the pump out cycle or at shutdown When the pump out drain selector is set to pump out the pump motor takes water from the tank and forces it through the d...

Page 39: ...he appliance It is deactivated on the KM 231BAJ and KM 301BAJ BWJ When activated this control determines whether ice remains on the evaporator at the end of a harvest cycle and at the beginning of a freeze cycle If ice drops and activates the bin control switch in the last 10 seconds of a harvest cycle the control determines that ice still remains on the evaporator and extends the harvest cycle fo...

Page 40: ... between the temperature at the beginning of a freeze cycle and the minimum temperature after 30 seconds in the freeze cycle is 2 5kΩ or more and less than 3 5kΩ the next harvest cycle is extended for 30 seconds If the above conditions occur in succession the number of occurrence times 30 seconds will be added to the harvest cycle time If the above temperature difference is 3 5kΩ or more the freez...

Page 41: ...r and de energizes the water pump for 10 sec then energizes the water pump for the duration of freeze time Enabled ON When the evaporator temperature reaches 50 F 10 C the control board reads a 3 9kΩ signal from the thermistor and de energizes the water pump for 10 sec and energize it for 50 secs repeatedly When 34 F 1 C is reached a 5 9 kΩ signal causes the control board to de energize the pump m...

Page 42: ...tem if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG Do not use R 404A as a mixture with pressurized 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 PO...

Page 43: ...n made Install the new drier with the arrow on the drier in the direction of the refrigerant flow When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 2 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the p...

Page 44: ...ractionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the 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 If necessary add any remaining charge to the system through the low side NOTICE To prevent compressor dama...

Page 45: ...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 Secure the thermistor with the holder then insulate it Be very careful to prevent damage to the leads C Water Regulating Valve Adjustment water cooled model The water regulating valve is factory set and generally no ...

Page 46: ...h with warm water and neutral cleaner if dirty Monthly External Water Filters Check for proper pressure and change if necessary Icemaker Exterior Wipe down with a clean soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up Clean any chlorine staining rust colored spots using a non abrasive cleanser Icemaker Exterior Wipe down with a clean soft cloth Use a damp c...

Page 47: ... have elapsed Move the control switch to the ICE position 6 Blow the icemaker water supply line out using the compressed air or carbon dioxide supply 7 Close the icemaker water supply line drain valve 2 Remove the water from the water tank 1 Move the service switch to the DRAIN position then move the control switch to the SERVICE position Allow the water tank to drain completely 2 After all of the...

Page 48: ... the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 6 Close the drain valve s 7 Replace the right side panel and front panel in their correct positions ...

Page 49: ...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 50: ... 100 38 189 86 141 64 98 44 70 21 80 27 90 32 watts 100 38 70 21 58 0 22 51 0 19 45 0 17 80 27 52 0 20 42 0 16 39 0 15 90 32 51 0 19 35 0 13 30 0 11 gal day m3 day 100 38 42 0 16 34 0 13 26 0 10 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 223 15 7 243 17 1 260 18 2 80 27 238 16 7 268 18 9 280 19 7 90 32 243 17 1 290 20 4 304 21 4 PSIG kg cm 2 G 100 38 243 17 1 293 20 6 317 22 3...

Page 51: ... 18 41 0 16 gal day m3 day 100 38 55 0 21 45 0 17 36 0 14 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 219 15 4 234 16 4 249 17 5 80 27 230 16 2 254 17 8 266 18 7 90 32 234 16 4 270 19 0 284 19 9 PSIG kg cm2 G 100 38 235 16 5 273 19 2 296 20 8 70 21 45 3 2 46 3 2 48 3 4 80 27 46 3 2 47 3 3 49 3 5 90 32 46 3 2 48 3 4 50 3 5 PSIG kg cm2 G 100 38 46 3 3 48 3 4 52 3 7 4 200 BTU h AT...

Page 52: ...7 204 0 77 90 32 190 0 72 265 1 00 249 0 94 gal day m3 day 100 38 218 0 82 261 0 99 234 0 89 70 21 80 27 90 32 min 100 38 70 21 80 27 90 32 min 100 38 70 21 289 20 3 286 20 1 287 20 2 80 27 287 20 2 283 19 9 287 20 1 90 32 286 20 1 280 19 7 283 19 9 PSIG kg cm2 G 100 38 288 20 3 281 19 7 285 20 0 70 21 49 3 4 49 3 5 39 2 8 80 27 49 3 5 50 3 5 34 2 4 90 32 49 3 5 50 3 5 36 2 6 PSIG kg cm2 G 100 38 ...

Page 53: ...AJ and KM 301BWJ Models KM 301BAJ Model EXTERNAL PROTECTOR B Wiring Diagram 1 KM 231BAJ KM 301BAJ KM 301BWJ High Pressure Switch Air Cooled Model Water Cooled Model Cut out 412 22 PSIG 384 22 PSIG Cut in 327 22 PSIG 284 22 PSIG 0 0 ...

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