Hoshizaki KM-40C-HC Service Manual Download Page 4

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2. MAINTENANCE ---------------------------------------------------------------------------------- 85

[a] MACHINE AND BIN EXTERIOR --------------------------------------------------------- 85

[b] SCOOP AND STORAGE BIN HANDLE CLEANING/SANITISATION

(DAILY) ----------------------------------------------------------------------------------------- 85

[c] STORAGE BIN INTERIOR CLEANING/SANITISATION (WEEKLY) ------------ 85

[d] AIR FILTER ------------------------------------------------------------------------------------ 86

[e] CONDENSER --------------------------------------------------------------------------------- 86

3. PREPARING THE ICEMAKER FOR LONG STORAGE -------------------------------- 87

Summary of Contents for KM-40C-HC

Page 1: ...KM 40C HC KM 60C HC KM 80C HC SELF CONTAINED CRESCENT CUBER SERVICE MANUAL F158 1120 102921 ...

Page 2: ...14 3 CONTROL BOARD 17 a INPUT OUTPUT LAYOUT 17 b SWITCH OPERATION 18 c MODEL CODE SETTING 19 d USER SETTINGS 19 e SERVICE MODE 21 f 7 SEGMENT DISPLAY 24 g ERROR CODES 25 4 THERMISTOR 29 5 BIN CONTROL 30 a EXPLANATION OF OPERATION 30 b BIN CONTROL CHECK PROCEDURE 30 III TECHNICAL INFORMATION 32 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 32 a KM 40C HC KM 60C HC 32 b KM 80C HC 33 2 WIRING DIAGRAM 34 a ...

Page 3: ...VALVE 59 6 EXPANSION VALVE KM 80C HC ONLY 61 7 FAN MOTOR 63 8 PUMP MOTOR 64 9 WATER VALVE 65 10 DRAIN VALVE 66 11 FLOAT SWITCH 67 a KM 40C HC KM 60C HC 67 b KM 80C HC 68 12 BIN CONTROL SWITCH 70 13 THERMISTOR 72 14 CONTROL BOX 73 a FUSE 73 b FUSE HOLDER 73 c CONTROL BOARD 74 d OPERATION BOARD 74 e SWITCHING REGULATOR 74 f RELAY 75 15 WATER TANK 75 16 CUBE GUIDE 77 17 SEPARATOR 78 18 SPRAY TUBE WAT...

Page 4: ...a MACHINE AND BIN EXTERIOR 85 b SCOOP AND STORAGE BIN HANDLE CLEANING SANITISATION DAILY 85 c STORAGE BIN INTERIOR CLEANING SANITISATION WEEKLY 85 d AIR FILTER 86 e CONDENSER 86 3 PREPARING THE ICEMAKER FOR LONG STORAGE 87 ...

Page 5: ...1 I SPECIFICATIONS 1 DIMENSIONS SPECIFICATIONS Refer to the dimensional drawings available from the Product Literature Search System ...

Page 6: ...r Evaporator Tank Fan Motor Condenser Fuse Control Box Spring Rear Panel Pipe Cover Rear Cover Power Supply Cord Thermistor Drain Valve Water Valve Pump Motor Water Inlet Hose Drain Outlet Hose Drier Compressor Float Switch Bin Control Switch Hinge Slope Scoop Holder Door Stopper Door Gasket With Tank Removed Front Frame ...

Page 7: ...ondenser Fuse Control Box Spring Thermistor Drain Valve Water Valve Front Frame Pump Motor Float Switch Water Inlet Hose Drain Outlet Hose Drier Compressor Rear Panel Pipe Cover Rear Cover Power Supply Cord Tank Slope Scoop Holder Door Stopper Door Gasket Bin Control Switch Hinge With Tank Removed ...

Page 8: ... ICEMAKING COMPARTMENT KM 40C HC KM 60C HC Spray Tube Separator Cube Guide Water Supply Tube With Spray Tube Removed Water Valve Drain Valve Evaporator Pump Motor Float Switch Water Tank Bin Control Switch ...

Page 9: ...5 d ICEMAKING COMPARTMENT KM 80C HC Spray Tube Separator Cube Guide Water Tank Pump Motor Float Switch Water Supply Tube With Spray Tube Removed Evaporator Water Valve Drain Valve Bin Control Switch ...

Page 10: ... Thermistor temp reaches 2 C Freeze cycle operation turned over to F S Minimum freeze time 5 minutes Comp continues HGV energized PM de energized DV energized FM de energized Freeze timer 4 Freeze Cycle 5 Drain Cycle Maximum freeze time freeze timer setting Setting No 4 If F S is open compressor stops and cycle returns to fill cycle Legend Comp compressor DV drain valve FM fan motor F S float swit...

Page 11: ...and PM energizes when the water saver timer starts counting down PM de energizes 5 seconds before the timer finishes counting down When the time is up HGV closes and the freeze cycle starts If F S is open no water in tank at the end of harvest cycle the fill cycle starts In Setting 18 FM energizes when FM operation temperature is reached in the harvest cycle 4 Freeze Cycle Comp continues to run FM...

Page 12: ...it repeats de energizing every component for 20 minutes and energizing PM for 15 minutes When BC stays closed bin empty for 90 seconds the fill cycle starts In the sanitation mode Setting 53 the sanitation control starts in 4 hours after the beginning of bin control BC Operation Freeze Cycle 1 Drain BC open 15 sec or more PM energized DV energized Drain Timer F S open 2 Standby PM de energized DV ...

Page 13: ...he time is up DV closes while PM de energizes to start the fill process 2 Fill Process WV opens and the 2 minute timer starts counting down When the time is up WV closes while PM energizes and the 30 second timer starts counting down When the time is up PM de energizes to start the drain process 3 Drain Process DV opens in 2 seconds while PM energizes to drain the water tank If F S is open no wate...

Page 14: ...s to flush the water circuit with tap water When the time is up PM de energizes 2 Drain Process DV opens in 2 seconds while PM energizes to drain the water tank If F S is open no water in tank the drain timer starts counting down When the time is up DV closes while PM and every component de energize After the end of drain process the original process is resumed Fill Cycle Bin Control Halt Control ...

Page 15: ... PM energizes to supply water and flush the water circuit with tap water When the time is up WV closes and PM de energizes 3 Water Cleaning Process PM energizes in 2 seconds to flush the water circuit with tap water by adjusting the rotation speed Then PM de energizes 10 seconds A high speed 5 seconds D low speed 10 seconds A high speed 5 seconds D low speed 10 seconds A high speed Harvest Cycle F...

Page 16: ...arts counting down When the time is up DV closes while PM de energizes Chemical Cleaning 2 Feed Process When the display shows cln the 15 minute timer starts counting down Feed the water F S open 1 Drain PM energized DV energized PM de energized DV de energized Drain Timer F S closed 15 min Timer 1 PM energized WV de energized WV energized PM de energized WV energized F S open See Timing Chart PM ...

Page 17: ...onds A high speed Drain 5 Drain Process DV opens in 2 seconds while PM energizes to drain the water tank If F S is open no water in tank the drain timer starts counting down When the time is up DV closes while PM de energizes Rinse 6 Rinse Process WV opens If F S is closed water in tank the 2 minute timer starts counting down while PM energizes to supply water and rinse the water circuit with tap ...

Page 18: ...ing down while PM energizes to supply water and flush the water circuit with tap water When the time is up WV closes and PM de energizes 2 Water Cleaning Process PM energizes in 2 seconds to flush the water circuit with tap water by adjusting the rotation speed Then PM de energizes 10 seconds C medium speed 5 seconds D low speed 10 seconds C medium speed 5 seconds D low speed 10 seconds C medium s...

Page 19: ...in Process DV opens in 2 seconds while PM energizes to drain the water tank If F S is open no water in tank the drain timer starts counting down When the time is up DV closes while PM de energizes The above rinse and drain processes 8 and 9 are repeated 4 times Flush 10 Fill Process WV opens If F S is closed water in tank the 2 minute timer starts counting down while PM energizes When the time is ...

Page 20: ...nergized F S open F S closed PM energized Tank Level Timer DV energized WV de energized PM de energized restarted DV de energized TPM energized 1 Feed Timer TPM de energized PM continues DV de energized WV energized F S open PM energized DV energized TPM energized 2 WV de energized F S closed PM energized Water Cleaning 1 Normal rotation 2 Reverse rotation See Timing Chart See Timing Chart F S ope...

Page 21: ...witch Evaporator Thermistor Condenser Thermistor LED Thermistor Option 24V DC Input Relay X3 Fan Motor Relay X2 Water Valve Drain Valve Relay X1 Hot Gas Valve Pump Motor UV LED Option Cleaning System Option Compressor Communication Control Board Input Output Communication Legend Program Install ...

Page 22: ...hows oFF and the unit shuts down 2 When pressed while the display shows oFF the display switches to run and the icemaking operation starts 3 When pressed while the display shows other than run or oFF the display switches to oFF and the unit shuts down after finishing the ongoing process 4 Cleaning Button Up Button 1 When pressed during the icemaking operation or shutdown or with the storage bin fu...

Page 23: ...ter reset button d USER SETTINGS The settings listed below are adjustable by the user 1 Press and hold the reset button for 3 seconds to enter the user setting mode The display shows one of the setting codes 2 Use the up or down button until the display shows the desired setting code Then press the enter button 3 Use the up or down button to adjust the setting Then press the enter button 4 After f...

Page 24: ...rmal mode cln Sanitation mode nor cln U 54 Fully automated chemical cleaning mode When Setting 45 is set to 1 and cln sanitation mode is selected unit runs one cycle of fully automated chemical cleaning cln U 55 Reset number of chemical doses When res is selected number of chemical doses set by U 49 is reset res U 56 Reset settings Reset all user settings to default dEF U 58 Forced shut down Shut ...

Page 25: ...ap control 1 If bin control trips in freeze cycle harvest cycle begins when minimum freeze cycle time is up If bin control trips in the last 10 seconds of harvest cycle harvest cycle is extended for 30 seconds which repeats every time bin control trips ON OFF 9 Thermistor temperature control 1 If evaporator outlet temperature differs by 4 C or more before and after water saver harvest cycle is ext...

Page 26: ...r during harvest cycle another harvest cycle begins which repeats not more than three times Freeze cycle begins even if bin control does not trip during the third harvest cycle ON OFF 18 Harvest cycle fan motor operation To reduce load in harvest cycle fan motor energizes if control board thermistor reads set point or higher temperature 70 C 30 C 1 C 35 Float switch delay timer end of freeze cycle...

Page 27: ...err 69 Low water shut down If low water is detected in fill cycle unit shuts down for water leak error ON OFF Err Error history Show last ten errors res Fre Freeze cycle time Show freeze cycle time min for last ten cycles res HAr Harvest cycle time Show harvest cycle time min for last ten cycles res EVA Evaporator outlet temperature Show evaporator outlet thermistor temperature res Con Condenser t...

Page 28: ...tation Mode Mode Change Icemaking run Bin Full FUL Shut Down oFF Water Cleaning cln Automated Chemical Cleaning Chemical Cleaning Rinse Drain Fully Automated Chemical Cleaning Water Cleaning Pre feed Feed Chemical Cleaning Rinse Flush Drain ...

Page 29: ...he dot illuminated at the center of the display The dot goes off when the main power supply is turned off and back on Notice The n32 n33 n70 n92 n93 and n99 notices are flashed in the display alternately with the current operating condition while the unit keeps running for n70 with the dot illuminated at the center of the display e g run blank n92 blank run blank n92 blank The notices are reset wh...

Page 30: ...ly Condenser thermistor reads set point or higher temperature at the end of freeze cycle Halt Automatically reset in 10 minutes fill cycle begins E71 Low water With Setting 69 ON float switch fails to close at lower float level four times in a row when checked every minute in fill cycle Shut down Press reset button E73 Evaporator thermistor error Evaporator thermistor circuit is open or shorted fo...

Page 31: ...n circuit Replace Short circuit Replace Connector disconnected Reconnect E40 Control board EEPROM defective Replace E41 Control board EEPROM defective Replace E46 Fan motor Locked Replace Broken fan Replace fan Fan motor relay Coil circuit open Replace Water regulator water cooled model only Low water Check water tap Hot gas valve Opening failure Replace coil or valve Hot gas valve relay Coil circ...

Page 32: ...ard setting Wrong model code setting Correct E71 Water circuit Low water Check water tap Low water pressure Adjust Water valve Closing failure Clean or replace Water valve relay Bad contacts Replace Water tank Disconnected Reconnect E73 Float switch Broken Replace Float sticking Descale Bad contacts Replace E79 Control board thermistor Open circuit Replace Short circuit Replace E81 Condenser therm...

Page 33: ...place Broken fan Replace fan Fan motor relay Coil circuit open Replace n93 Chemical pack Set number of times exceeded Replace n99 Control board Set time exceeded Press reset button after maintenance Starting failure Replace control board 4 THERMISTOR A thermistor semiconductor is used as a harvest control sensor and anti slush sensor The resistance varies depending on the suction line temperatures...

Page 34: ...ontrol is calling for ice proximity switch closed the control board continues icemaking operations When the bin control is activated in the bin full position proximity switch open the control board performs the bin control II 2 b BIN CONTROL and shuts down the unit However to prevent incomplete batches of ice from forming on the evaporator the control board will only shut down the machine during t...

Page 35: ... control leads When calling for ice the bin control proximity switch should be closed If open replace the bin control Activate the bin control actuator press the actuator in check for continuity across the bin control leads The bin control proximity switch should be open If closed replace the bin control 7 Reconnect the 2 pin connector to the CN5 connector pins 1 6 on the control board Allow the m...

Page 36: ... a KM 40C HC KM 60C HC Pump Motor Water Tank Compressor Water Circuit Refrigeration Circuit Drain Valve Drain Outlet Hot Gas Valve Accumulator Insulation Drier Capillary Tube Evaporator Fan Condenser Spray Tube Water Valve Water Inlet Float Switch Thermistor Insulation ...

Page 37: ... Motor Water Tank Compressor Water Circuit Refrigeration Circuit Drain Valve Drain Outlet Hot Gas Valve Drier Expansion Valve Evaporator Fan Condenser Spray Tube Water Valve Water Inlet Float Switch Thermistor Thermistor ...

Page 38: ...34 2 WIRING DIAGRAM a KM 40C HC KM 60C HC ...

Page 39: ...35 b KM 80C HC ...

Page 40: ... Reverse Rotation 5 sec sec BS 0 1800 sec sec BS 0 1800 sec UV LED ON OFF PUMP MOTOR AUTO CLEANING KIT Basic Control run 7 SEGMENT DISPLAY ON OFF BIN CONTROL SWITCH ON OFF FLOAT SWITCH ON OFF WATER VALVE ON OFF DRAIN VALVE ON OFF CLEANING VALVE HOT GAS VALVE ON OFF B D C PUMP MOTOR ON C B ON or OFF BS C D C OFF C D COMPRESSOR ON OFF FAN MOTOR ON ON or OFF BS OFF RESET ON OFF THERMISTOR 9 C 1 C ICE...

Page 41: ...igh 0 20 sec Low none BS High Low 0 240 sec Max 6 min BS High Low 0 120 sec 30 sec BS 0 120 sec Max 5min 15 sec 90 sec 30 sec BS 5 120 sec 5 sec sec BS 0 1800 sec FREEZE BIN FULL FILL HARVEST CYCLE AFTER BIN FILL FREEZE CYCLE HARVEST CYCLE ON or OFF BS C B D C C D FUL run Bin Control run 5ºC BS 2 10ºC BS 5 50ºC ...

Page 42: ...se Rotation D FUL A D BIN FULL FILL HARVEST CYCLE AFTER BIN FILL C A D PART NAME BIN FULL CLEANING BIN FULL BIN FULL CLEANING 1 C ICE STOP ON OFF CLEANING ON OFF COMPRESSOR ON OFF FAN MOTOR ON RESET ON OFF THERMISTOR 9 C D OFF PUMP MOTOR ON HOT GAS VALVE ON OFF ON OFF CLEANING VALVE ON OFF OFF BIN CONTROL SWITCH ON OFF FLOAT SWITCH ON WATER VALVE ON OFF OFF DRAIN VALVE 7 SEGMENT DISPLAY FUL run PU...

Page 43: ...S 0 1200 sec CLEANING FREEZE CYCLE HARVEST CYCLE PART NAME COMPRESSOR ON OFF ON OFF RESET ON OFF ICE STOP ON OFF OFF PUMP MOTOR ON FAN MOTOR ON THERMISTOR 9 C 1 C OFF HOT GAS VALVE ON OFF C C B D ON OFF DRAIN VALVE ON OFF BIN CONTROL SWITCH ON OFF ON or OFF BS 7 SEGMENT DISPLAY FLOAT SWITCH ON OFF PUMP MOTOR AUTO CLEANING KIT WATER VALVE STOP run A 30 sec D C FILL HARVEST CYCLE AFTER BIN FILL D ru...

Page 44: ... 5 min Max 5 min Normal Rotation OFF Reverse Rotation CLEANING STOP cln STOP oFF A D CLEANING run D Fill 1 C 7 SEGMENT DISPLAY PUMP MOTOR AUTO CLEANING KIT UV LED ON OFF FLOAT SWITCH ON OFF CLEANING VALVE ON OFF BIN CONTROL SWITCH ON OFF WATER VALVE ON OFF DRAIN VALVE ON OFF HOT GAS VALVE ON OFF PUMP MOTOR OFF OFF ON OFF FAN MOTOR ON RESET ON OFF THERMISTOR 9 C COMPRESSOR PART NAME ICE STOP ON OFF...

Page 45: ... Reverse Rotation 300 sec BS 0 1200 sec OFF THERMISTOR B C HARVEST CYCLE CLEANING PART NAME ICE STOP ON D D FILL HARVEST CYCLE INITIAL C A A A D FREEZE CYCLE 7 SEGMENT DISPLAY DRAIN VALVE OFF PUMP MOTOR FAN MOTOR ON FLOAT SWITCH 10 sec HOT GAS VALVE ON OFF OFF ON 10 sec 10 sec ON OFF ON OFF BIN CONTROL SWITCH ON 9 C 1 C COMPRESSOR ON OFF WATER VALVE OFF OFF ON OFF OFF CLEANING VALVE ON RESET ON PU...

Page 46: ... 20 sec Low none BS High Low 0 240 sec 120 sec Max 6 min BS High Low 0 120 sec 30 sec BS 0 120 sec 30 sec BS 0 120 sec Max 5 min Max 5 min 30 sec BS 5 120 sec 300 sec BS 0 1200 sec run cln FREEZE CYCLE FILL HARVEST CYCLE INITIAL HARVEST CYCLE CLEANING D ON or OFF BS B D C C C 10 sec 10 sec 10 sec run D A A A A 5ºC BS 2 10ºC ...

Page 47: ...ax 5 min Max 5 min Max 5 min Max 5 min Max 5 min Normal Rotation OFF Reverse Rotation CLEANING FILL HARVEST CYCLE AFTER BIN FILL ICE STOP ON OFF PART NAME HARVEST CYCLE STOP CLEANING ON OFF RESET ON OFF THERMISTOR 9 C 1 C COMPRESSOR ON OFF FAN MOTOR ON ON or OFF BS OFF PUMP MOTOR ON C OFF D A D C D C D C D A D A D A D A D C 30 sec HOT GAS VALVE ON OFF WATER VALVE ON OFF DRAIN VALVE ON OFF CLEANING...

Page 48: ... 360 sec OFF Reverse Rotation flash D 7 SEGMENT DISPLAY run BIN CONTROL SWITCH ON OFF FLOAT SWITCH PUMP MOTOR AUTO CLEANING KIT UV LED ON OFF ON OFF DRAIN VALVE ON OFF CLEANING VALVE ON OFF HOT GAS VALVE ON OFF WATER VALVE ON OFF 10 sec 10 sec 10 sec D A D D A D A D A D A 2 2V C D C D C D A A A A D PUMP MOTOR ON B D C C OFF COMPRESSOR ON OFF FAN MOTOR ON ON or OFF BS OFF RESET ON OFF THERMISTOR 9 ...

Page 49: ...1 1 1 1 1 30 sec BS 0 120 sec Max 5 min Max 5 min Max 5 min Max 5min Max 5 min Max 5 min Max 5 min Max 5 min 5 sec flash A run run 10 sec 10 sec 10 sec A D A D D C A D A D A D A A A A D D C D HARVEST CYCLE INITIAL FULLY AUTOMATED CHEMICAL CLEANING CYCLE Starts when cln is selected by U 54 or after number of cycles set by U 50 is completed Fill HARVEST CYCLE INITIAL CLEANING CYCLE SANITATION CYCLE ...

Page 50: ...the compressor is still energized and the hot gas valve opens 4 In 5 seconds the compressor de energizes the hot gas valve closes and the fan motor energizes When set to 1 DC Setting 19 1 AC or 1 DC the fan motor runs at the speed set by the fan speed control DC high speed Setting 23 0 to 5V 5 In 5 seconds the fan motor de energizes and the pump motor energizes The pump motor runs at the speed A s...

Page 51: ... high temperature safety operates 1 Check for power off in freeze cycle and replace g Water Supply Line 1 Water supply off and water supply cycle does not finish 1 Check and get recommended pressure Check for water supply h Inlet Water Valve 1 Mesh filter or orifice gets clogged and water supply cycle does not finish 1 Clean Replace if necessary 2 Coil winding opened 2 Replace 3 Wiring to water va...

Page 52: ...circuit and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature and verify cause f Control Board 1 Defective 1 Check and replace g Condenser Air Filter 1 Clogged with dirt and dust 1 Clean and unclog h Condenser Thermistor KM 80C HC only 1 Dirty air filter or condenser 1 Clean 2 Ambient temperature too warm 2 Reduce ambient temperature 3 Refrigerant overcharged 3 Recharge 4 Fan ...

Page 53: ...ive or bound impeller 5 Replace and clean e Control Board 1 Defective 1 Check and replace f Drain Valve 1 Leaking by 1 Clean or replace g Float Switch 1 Dirty or erratic operation 1 Clean or replace h Switching Regulator 1 Defective 1 Check and replace 6 Fan motor will not start or is not operating a Fan Motor 1 Motor winding opened 1 Replace 2 Bearing worn out 2 Replace 3 Wiring to fan motor 3 Ch...

Page 54: ...ragm does not close 2 Check for water leaks with icemaker off Replace if necessary d Ambient and or water temperature 1 Too cool 1 Increase temperature e Thermistor 1 Out of position or loose attachment 1 See V 13 THERMISTOR f Control Board 1 Harvest timer is set too short 1 Adjust longer referring to II 3 e SERVICE MODE 2 Defective 2 Check and replace 3 Other a Spray Tubes 1 Clogged 1 Clean 2 Out...

Page 55: ...ine and inlet water valve 5 ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY 1 Small cubes a Cube Guide Water Tank 1 Out of position Circulated water falls into bin 1 Check that cube guide is properly installed on water tank and tank is fixed securely with snaps b See chart 2 5 and check water supply line inlet water valve water system pump motor and control board c Drain Valve 1 Dirty 1 Clean 2 Cloudy ...

Page 56: ...tion 6 Magnet disconnected from detector 6 Place in position b Control Board 1 Defective 1 Check and replace 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not move freely 3 Replace c Compressor 1 Bearings worn out or cylinder valve broken 1 Replace 2 Mounting pad out of position or loo...

Page 57: ...orbs a lot of moisture If an ice maker charged with R290 has possibly drawn in air the drier must be replaced Be sure to use a drier designed for R290 3 Handling of Handy Flux R290 Brazing is needed to connect the refrigeration circuit pipes It is no problem to use the same handy flux that has been used for the current refrigerants However its entrance into the refrigerant circuit should be avoide...

Page 58: ...ure 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 R290 to suddenly react with oxygen and explode Be sure to use nitrogen to prevent explosion b REFRIGERANT RECOVERY WARNING Do not recover the R290 refrigerant in a refrigerant recovery cylinder for R404A or R134a The R290 refrigera...

Page 59: ...rant charging cylinder to accurately weigh in the liquid charge Remember to purge any air from the charging hose See the nameplate for the required refrigerant charge 6 Open the high side valve on the gauge manifold and accurately measure in the liquid charge Close the valve on the charging cylinder before closing the high side manifold valve Any remaining liquid in the line can be charged into th...

Page 60: ...en 5 Discharge the pressurized nitrogen and recover the refrigeration circuit to atmospheric pressure 6 Repeat 4 and 5 above Use a gas detector at the open end of refrigeration circuit to detect any gas left inside the circuit 7 Evacuate the refrigeration circuit for 30 minutes to remove any gas left inside the circuit WARNING Remove the R290 refrigerant from the unit in an area well ventilated an...

Page 61: ...mpressor and disconnect solderless terminals 5 Disconnect the discharge and suction pipes using brazing equipment 6 Remove the hold down bolts washers and rubber grommets 7 Slide and remove the compressor Unpack the new compressor package 8 Attach the rubber grommets of the previous compressor 9 Clean the suction and discharge pipes with an abrasive cloth paper 10 Place the compressor in position ...

Page 62: ...refrigerant and store it in a proper container if required by an applicable law see V 1 b REFRIGERANT RECOVERY 4 Remove the drier holder if any and pull the drier toward you for easy service 5 Remove the drier using brazing equipment 6 Braze or solder the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 0 2 0 3 bar when brazing tubing...

Page 63: ...tem is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the icemaker 2 Remove the louver and rear cover 3 Recover the refrigerant and store it in a proper container if required by an applicable law see V 1 b REFRIGERANT RECOVERY 4 Disconnect the hot gas valve leads 5 Remove the screw and the solenoid coil 6 Remove the valve and drier using brazing ...

Page 64: ...ze with the valve body exceeding 135 C 8 Install the new drier see V 4 DRIER 9 Check for leaks using nitrogen gas 10 bar and soap bubbles 10 Evacuate the system and charge it with refrigerant see V 1 d EVACUATION AND RECHARGE 11 Attach the solenoid coil to the valve body and secure it with the screw 12 Connect the lead wires 13 Refit the panels in their correct positions 14 Plug in the icemaker ...

Page 65: ...mp cloths or similar 5 Remove the insulation hose from the expansion valve sensor bulb and remove the bulb 6 Remove the drier using brazing equipment 7 Braze in the new expansion valve Protect the body of the valve from excessive heat and use nitrogen at a pressure of 0 2 0 3 bar when brazing 8 Braze or solder the new drier see V 4 DRIER 9 Check for leaks using nitrogen gas 10 bar and soap bubbles...

Page 66: ...emovable Bulb Insulation Hose Expansion Valve Remove band from bulb with a screwdriver Wrap this part with a damp cloth to prevent overheating Bulb Expansion valve is brazed at these two points While brazing remove insulation hoses from pipes and keep brazing equipment away from other parts to prevent burning ...

Page 67: ...uring the fan motor bracket and pull out the fan motor in the arrow direction To prevent deformation do not hit the fan on the condenser or other parts 5 Install the new fan motor in the reverse order of the removal procedure 6 Refit the louver in its correct position 7 Plug in the icemaker Condenser Fan Motor Fan Motor Bracket Screw ...

Page 68: ...mp motor discharge outlet and pull off the silicone hose 6 Remove the screw securing the pump motor Shift the case to the back or side to release it from the stopper and lift off the pump motor Tie 7 Install the new motor in the reverse order of the removal procedure 8 Plug in the icemaker and check for leaks 9 Refit the panels in their correct positions Stopper Screw 1 Slide to back or side 2 Lif...

Page 69: ...ve to receive water coming out 7 Turn the inlet nut in the arrow direction to remove it from the water valve 8 Remove the two mounting screws 9 Install the new valve in the reverse order of the removal procedure 10 Tighten the inlet nut to a torque of 7 85 N m 5 to prevent water leaks 11 Open the water supply tap 12 Plug in the icemaker 13 Check for leaks 14 Refit the panels in their correct posit...

Page 70: ...t the two hose clamps 7 Disconnect the hoses from the drain valve Put a towel under the drain valve to receive any water coming out and prevent it from splashing out 8 Remove the mounting screw 9 Install the new valve in the reverse order of the removal procedure 10 Open the water supply tap 11 Plug in the icemaker 12 Check for leaks 13 Refit the panels in their correct positions Hose Clamp Mounti...

Page 71: ...he lead wire from the grommet through the slit 4 Remove the water tank see V 15 WATER TANK 5 Remove the screw securing the float switch 6 Install the new float switch in the reverse order of the removal procedure 7 Refit the panels in their correct positions 8 Plug in the icemaker Slit Mounting Screw Float Switch Attach to three arrowed surfaces when fixing with screw Grommet ...

Page 72: ...rward 2 to unhook the float switch 5 Remove the screw securing the float switch to the bracket 6 Attach the new float switch to the rail of the bracket Secure them with the screw by fitting the round end of the slot to the screw hole Pump Motor Float Switch Hook A Hook B Float Switch Bracket Screw Pinch Pull Rail Round end of slot Secure here with screw When fitted properly top ends of bracket and...

Page 73: ...wn into the mounting hole and hook it in position as shown To ensure proper operation be sure to fit the hook A under the mounting hole 8 Refit the removed parts in the reverse order of the removal procedure 9 Plug in the icemaker ...

Page 74: ...move the top panel and unscrew the rear panel 3 Disconnect the connector of the bin control switch lead black covered with a silicone hose and remove the lead wire from the grommet 4 Remove the water tank see V 15 WATER TANK The bin control switch is located as shown below when viewed from the front 5 Pull down and remove the lead wire from the retainer on the right side of the bin control switch ...

Page 75: ... in stopper A 8 To remove the bin switch plate slightly warp both sides and pull the shaft toward you Top View Slightly warp Pull toward you 9 Refit the removed parts in the reverse order of the removal procedure Be sure to put the lead wire back in the retainer on the bracket 10 Plug in the icemaker ...

Page 76: ...ess Do not use any sealant other than the above 8 Attach the new thermistor in position on the suction pipe and press down the thermistor holder over the thermistor Be careful not to damage the thermistor lead Cover the parts with the insulation and secure them with the ties Keep the thermistor inside the thermistor holder After the thermistor holder is fitted do not pull the thermistor lead to mo...

Page 77: ...ly make sure that the harness is not pinched between the parts a FUSE 1 Use a phillips head screwdriver to remove the fuse holder cap and take out the fuse 2 Install the new fuse in the reverse order of the removal procedure b FUSE HOLDER 1 Disconnect the tab terminal and remove the nut securing the fuse holder 2 Install the new fuse holder in the reverse order of the removal procedure Screw Contr...

Page 78: ... the new operation board in the reverse order of the removal procedure 4 When reconnecting the connectors do not push them too hard The operation board may be damaged e SWITCHING REGULATOR 1 Disconnect all the connectors 2 Remove the mounting screw see Detail A 3 Release the switching regulator from the three board supports 4 Install the new switching regulator in the reverse order of the removal ...

Page 79: ...the removal procedure 4 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label 15 WATER TANK 1 Unplug the icemaker Remove all ice from the storage bin 2 Drain out the water tank by pulling off the overflow pipe from the water tank bottom Cube Guide Water Tank Tube Overflow Pipe Pull ...

Page 80: ...d from the square holes the rear part of the water tank dotted circle below is also unhooked Hold the water tank with both hands 5 Tilt the right side of the water tank and pull it toward you Do not hit the pump motor or float switch Slightly twist the left side of the water tank inward and pull it toward you Water Tank Snap Pump Motor Float Switch Right Side Left Side ...

Page 81: ...al procedure left right top rear 8 Plug in the icemaker Bracket Rail 16 CUBE GUIDE 1 Remove the water tank see V 15 WATER TANK 2 Lift off the cube guide out of the water tank 3 To refit the cube guide fit the notches on both sides to the stoppers in the water tank 4 The unit is provided with two or three cube guides quantity varies depending on model Be sure to locate the vertical flanges on both ...

Page 82: ... the separator in the reverse order of the removal procedure Check that the separator is fit correctly on the shaft and can swing like a pendulum 5 Plug in the icemaker 18 SPRAY TUBE WATER SUPPLY PIPE SPRAY GUIDE 1 Unplug the icemaker Remove the top panel 2 Push the tabs on both sides to release the spray tube 3 Remove the end of the spray tube from the bracket 4 Pinch and lower the hose clamp and...

Page 83: ...water supply pipe Pull off the spray guide from the evaporator plate 7 Refit the removed parts in the reverse order of the removal procedure Check for water leaks IMPORTANT Fit the spray guide securely and tightly on the evaporator fin Otherwise cloudy or irregular ice cubes or performance reduction may be caused 8 Plug in the icemaker Spray Tube Hose Clamp Spray Guide Water Supply Pipe Tab Black ...

Page 84: ...g 3 Open the door 4 Lift up the center of the slope warp it and release it from the shaft on both sides 5 Remove the two mounting bolts securing the door to the hinges 6 Remove the door from the hinges Pull the door stopper and hook together out of the icemaker 7 Refit the removed parts in the reverse order of the removal procedure Door Louver Hook Door Spring Slope Door Stopper ...

Page 85: ...ear of the icemaker and remove the top panel 2 Remove the two screws and take off the front frame 3 Refit the removed parts in the reverse order of the removal procedure Hook the top of the front frame on the top panel Top Panel Front Frame Hook here Screw Screw ...

Page 86: ...ways wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 4 For safety and maximum effectiveness use cleaning and sanitizing solutions immediately after dilution a ICEMAKING WATER SYSTEM CAUTION Wear protective equipment e g protective glasses when using the citric acid or sodium hypochlorite solution The solution may spout out and splash int...

Page 87: ...t the automated chemical cleaning 7 The unit resumes the original state when the cleaning is over 8 Dilute 11 ml of 5 25 sodium hypochlorite solution with 3 litres of water for sanitising 9 Repeat the above steps 3 to 7 b PARTS 1 Disconnect the overflow pipe from the water tank Next remove the water tank by pressing down on the snaps on the brackets L and R and pulling the tank towards you slightl...

Page 88: ...M 40C HC 2 pcs KM 60C HC 3 pcs KM 80C HC 3 pcs Snap Bracket L Snap both ends Evaporator Pump Motor Bracket R Float Switch Cube Guide Water Tank This illustration shows KM 40C 60C HC The float switch location is different for KM 80C HC behind the pump motor Push Bin Control Switch Hold here and pull toward you ...

Page 89: ...se thoroughly and shake to remove surplus liquid Note Using a cloth to dry may re contaminate 3 Use a neutral cleaner to wash the storage bin handle Rinse thoroughly 4 Soak a clean cloth with the sanitising solution and wipe the handle Use fresh water and a clean cloth to rinse dry c STORAGE BIN INTERIOR CLEANING SANITISATION WEEKLY 1 Open the storage bin door and remove all ice 2 Remove the scoop...

Page 90: ...ILTER Plastic mesh air filters remove dirt or dust from the air and keep the condenser from getting clogged If the filters get clogged the icemaker s performance will be reduced Remove and clean the air filter s at least twice per month 1 Remove the air filter Note Do not put your hand inside the machine compartment 2 Clean the air filter by using a vacuum cleaner When severely clogged use warm wa...

Page 91: ...maker will be at sub freezing temperatures a Remove the water from the potable water supply line 1 Press the ON OFF button to start the halt control 2 Unplug the icemaker 3 Close the water supply tap and remove the inlet hose 4 Remove all ice from the storage bin and clean the bin b Drain the potable water tank 1 Turn off the power supply at the breaker box 2 Disconnect the overflow pipe from the ...

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Hoshizaki KM-40C-HC, Service Manual

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