Hoshizaki KML "F" SERIES Service Manual Download

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HOSHIZAKI

MODULAR CRESCENT CUBER

SERVICE MANUAL

KML “F” SERIES
KML “H” SERIES

MODELS

NO.:
ISSUED:
REVISED:

AUG. 18, 1999

JAN. 13, 2004

73085

Summary of Contents for KML "F" SERIES

Page 1: ...HOSHIZAKI MODULAR CRESCENT CUBER SERVICE MANUAL KML F SERIES KML H SERIES MODELS NO ISSUED REVISED AUG 18 1999 JAN 13 2004 73085...

Page 2: ...0 233 1940TechnicalService 770 487 2331 Fax 770 487 3360 NOTE Toexpediteassistance allcorrespondence communicationMUST includethefollowing information Model Number Serial Number Completeanddetailedexp...

Page 3: ...L00001D through M10530B 16 12 KML 450MWH Beginning Serial M20531D 17 13 KML 600MAF Air cooled 18 14 KML 600MWF Water cooled 19 15 KML 600MRF Remote air cooled 20 16 KML 600MAH Air cooled 21 17 KML 60...

Page 4: ...L00200G 56 h KML 450MAH Beginning Serial L20951H ending Serial M12770F KML 450MWH Beginning Serial L10201H ending Serial M20710F 57 i KML 450MAH Beginning Serial M22771G KML 450MWH Beginning Serial M...

Page 5: ...SSOR 91 4 REMOVAL AND REPLACEMENT OF DRIER 92 5 REMOVAL AND REPLACEMENT OF EXPANSION VALVE 93 6 REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND LINE VALVE 94 7 REMOVAL AND REPLACEMENT OF EVAPORATOR 96 8...

Page 6: ...6 I SPECIFICATIONS 1 KML 250MAH...

Page 7: ...7 2 KML 250MWH...

Page 8: ...8 3 KML 350MAF...

Page 9: ...9 4 KML 350MWF...

Page 10: ...10 5 KML 350MAH...

Page 11: ...11 6 KML 350MWH Beginning serial L00001J ending Serial M20060C...

Page 12: ...12 7 KML 350MWH Beginning serial M30061E...

Page 13: ...13 8 KML 450MAF...

Page 14: ...14 9 KML 450MWF...

Page 15: ...15 10 KML 450MAH...

Page 16: ...16 11 KML 450MWH Beginning Serial L00001D ending Serial M10530B...

Page 17: ...17 12 KML 450MWH Beginning Serial M20531D...

Page 18: ...18 13 KML 600MAF...

Page 19: ...19 14 KML 600MWF...

Page 20: ...20 15 KML 600MRF...

Page 21: ...21 16 KML 600MAH...

Page 22: ...22 17 KML 600MWH Beginning Serial L00001D ending Serial M10115C...

Page 23: ...23 18 KML 600MWH Beginning Serial M10121E...

Page 24: ...24 19 KML 600MRH...

Page 25: ...25 20 CONDENSER UNIT URC 7F Unit mm inches...

Page 26: ...26 SPECIFICATIONS URC 7F...

Page 27: ...MAH Spray Tubes Water Supply Inlet Junction Box Condenser Condenser Fan Motor Control Box Drier Hot Gas Valve Compressor Float Switch Water Pump Bin Control Thermostat except models with Mechanical Bi...

Page 28: ...bes Water Supply Inlet Junction Box Control Box Drier Hot Gas Valve Compressor Water Regulator Float Switch Water Pump Bin Control Thermostat except models with Mechanical Bin Control Control Switch E...

Page 29: ...ondenser Fan Motor Control Box Drier Hot Gas Valve Compressor Float Switch Control Switch Water Pump Expansion Valve c KML 600MAF KML 600MAH Bin Control Thermostat except models with Mechanical Bin Co...

Page 30: ...Water Regulator Control Box Drier Hot Gas Valve Float Switch Control Switch Water Pump Expansion Valve Compressor Water Supply Inlet Bin Control Thermostat except models with Mechanical Bin Control M...

Page 31: ...ver Tank Control Box Drier Hot Gas Valve Float Switch Control Switch Water Pump Expansion Valve Compressor Water Supply Inlet Hot Gas Valve Bin Control Thermostat except models with Mechanical Bin Con...

Page 32: ...e board or the back of the board to prevent damage to the board 4 Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the Thermistor white Float...

Page 33: ...out water the mechanical seal can fail To prevent this type of failure the Controller Board checks the position of the Float Switch at the end of the initial one minute water fill cycle and at the end...

Page 34: ...ergizes Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge or inefficient compressor To manually reset the above safeties depress white alarm reset button w...

Page 35: ...white wire supplied to the K1 connector If there is a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain ener gize...

Page 36: ...t 5 minutes in freeze cycle Ready to complete freeze cycle when Float Switch circuit opens 4 Defrost Timer stops counting Defrost cycle is completed and freeze cycle starts IMPORTANT Board never accep...

Page 37: ...NT Water Valve opening is limited to 6 minutes 5 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when Float Switch circuit opens 4 Defrost Timer stops counting Defrost cycle i...

Page 38: ...minutes 4 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when Float Switch circuit opens 3 Defrost Timer stops counting Defrost cycle is completed and freeze cycle starts IMP...

Page 39: ...imum defrost time Switch Nos 5 and 6 Used for adjustment of the Drain Counter The Pump Motor drains the Water Tank at the frequency determined by the Drain Counter FOR MODELS WITH MECHANICAL BIN CONTR...

Page 40: ...emove the Thermistor See V 11 REMOVAL AND REPLACEMENT OF THERMISTOR iii Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes iv Check for a resistance between T...

Page 41: ...in the Water Tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a pump drain more often the Drain Counter can be adjusted as shown in the tabl...

Page 42: ...thin 10 seconds after ice contacts the Bin Control Thermostat Bulb SETTING FREQUENCY Dip Switch Dip Switch No 5 No 6 OFF OFF every cycle ON OFF every 2 cycles OFF ON every 5 cycles ON ON every 10 cycl...

Page 43: ...a 1 5 k 3 5 k resistor to the Connector K3 pins 1 and 2 and energize the unit After the 1 minute 5 second water supply cycle and the 2 minute 10 second defrost cycle the unit should start the freeze...

Page 44: ...to the pump in all three positions 1 Drain The KML series utilizes a pump out drain system When the Service Switch is active and placed in the left position power is supplied to the pump and the Drai...

Page 45: ...o the control board to shut down the unit iii When the bin control is in the normal position bin is not full a 7 9 K reading is sent to the control board to continue operation 2 During operation the c...

Page 46: ...l related issues are resolved ii Dip switch No 7 should be in the on position If the switch is in the off position the controller board will not receive input from the bin control iii Move the lever t...

Page 47: ...47 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a KML 250MAH KML 350MAF KML 350MAH KML 450MAF KML 450MAH KML 600MAF KML 600MAH...

Page 48: ...48 b KML 250MWH KML 350MWF KML 350MWH KML 450MWF KML 450MWH KML 600MWF KML 600MWH...

Page 49: ...49 c KML 600MRF KML 600MRH...

Page 50: ...ning Serial L00001E ending Serial M10460F KML 250MWH Beginning Serial L10001K ending Serial M10090D Note KML 250MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 250MWH Pressure Switch C...

Page 51: ...KML 250MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG b KML 250MAH Beginning Serial M20461G KML 250MWH Beginning Serial M20091G KML 250MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21...

Page 52: ...52 c KML 350MAF and KML 350MWF Note KML 350MAF Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 350MWF Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG...

Page 53: ...al L00001L ending Serial M10290F KML 350MWH Beginning Serial L00001J ending Serial M30080F Note KML 350MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 350MWH Pressure Switch Cut out 38...

Page 54: ...350MAH Beginning Serial M20291G KML 350MWH Beginning Serial M40081G Note KML 350MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 350MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21...

Page 55: ...55 Note KML 450MAF Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG f KML 450MAF and KML 450MWF KML 450MWF Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG...

Page 56: ...al L00101C ending Serial L00950G KML 450MWH Beginning Serial L00001D ending Serial L00200G Note KML 450MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 450MWH Pressure Switch Cut out 38...

Page 57: ...al L20951H ending Serial M12770F KML 450MWH Beginning Serial L10201H ending Serial M20710F Note KML 450MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 450MWH Pressure Switch Cut out 38...

Page 58: ...450MAH Beginning Serial M22771G KML 450MWH Beginning Serial M30711G Note KML 450MAH Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG KML 450MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21...

Page 59: ...59 21 3 0 21 3 0 Note KML 600MWF Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG KML 600MAF MRF Pressure Switch Cut out 412 5 PSIG Cut in 327 21 3 PSIG j KML 600MAF KML 600MWF and KML 600MRF...

Page 60: ...F KML 600MWH Beginning Serial L00001D ending Serial L00080E KML 600MRH Beginning Serial L00001F ending Serial L00050F Note KML 600MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG KML 600MAH...

Page 61: ...G KML 600MWH Beginning Serial L10081K ending Serial M10140E KML 600MRH Beginning Serial L10051H ending Serial M10350E Note KML 600MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG KML 600MAH...

Page 62: ...al M2_ _ _ _ _ KML 600MWH Beginning Serial M20141F KML 600MRH Beginning Serial M20331E Note KML 600MWH Pressure Switch Cut out 384 PSIG Cut in 284 5 21 3 PSIG KML 600MAH MRH Pressure Switch Cut out 41...

Page 63: ...ost Cycle When Control Sw is turned OFF Pressure Sw is OFF Thermistor Temp exceeds t1 or Bin Control is in full position during first 5 minutes of freeze cycle for mechanical bin control only 3 To Def...

Page 64: ...20 min 1 The Pump Motor waits for 2 seconds before starting a drain cycle See II 2 d CONTROLS AND ADJUSTMENTS 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II 2 d CO...

Page 65: ...65 4 PERFORMANCE DATA a KML 250MAH...

Page 66: ...66 b KML 250MWH...

Page 67: ...67 c KML 350MAF...

Page 68: ...68 d KML 350MWF...

Page 69: ...69 e KML 350MAH...

Page 70: ...70 f KML 350MWH Serial L00001J through M20060C...

Page 71: ...71 g KML 350MWH Beginning Serial M30061E...

Page 72: ...72 h KML 450MAF...

Page 73: ...73 i KML 450MWF...

Page 74: ...74 j KML 450MAH...

Page 75: ...75 k KML 450MWH Serial L00001D through M10530B...

Page 76: ...76 l KML 450MWH Beginning Serial M20531D...

Page 77: ...77 m KML 600MAF...

Page 78: ...78 n KML 600MWF...

Page 79: ...79 o KML 600MRF...

Page 80: ...80 p KML 600MAH...

Page 81: ...81 q KML 600MWH Serial L00001D through Serial M10115C...

Page 82: ...82 r KML 600MWH Beginning Serial M10121E...

Page 83: ...83 s KML 600MRH...

Page 84: ...ce f Transformer 1 Thermal fuse blown out 1 Replace or coil winding opened g Wiring to 1 Loose connections or 1 Check for continuity and Controller Board open replace h Thermistor 1 Leads short circui...

Page 85: ...odel only 5 Fan not operating Except 5 See chart 1 6 water cooled model 6 Refrigerant line or 6 Clean and replace Drier components plugged c Water Regulator 1 Set too high 1 Adjust lower d Overload Pr...

Page 86: ...r open and replace 4 Defective or bound impeller 5 CLEAN e Controller Board 1 Defective 1 See II 2 e CHECKING CONTROLLER BOARD 6 Fan Motor will a Fan Motor 1 Motor winding opened 1 Replace not start o...

Page 87: ...Board 1 Defrost Timer is set too 1 Adjust longer referring short to II 2 d CONTROLS AND ADJUSTMENT 2 Defrost Timer 2 Defective 2 See II 2 e CHECKING CONTROLLER BOARD 3 Others a Spray Tube 1 Clogged 1...

Page 88: ...r 1 Replace surfaces 3 Ice in storage a Bin Drain 1 Plugged 1 Clean bin often melts PROBLEM POSSIBLE CAUSE REMEDY 1 Small Cube a Ice Cube Guide 1 Out of position 1 Place in position Circulated water f...

Page 89: ...side and one on the high side line Using proper refrigerant practices recover the refrigerant from the Access Valves and store it in an approved container Do not discharge the refrigerant into the atm...

Page 90: ...Hoses and Service Manifold 10 Cap the Access Valves to prevent a possible leak 2 BRAZING DANGER 1 Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 2 Ref...

Page 91: ...ower supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Terminal Cover on the Compressor and disconnect the Compressor Wiring 5 Remove the Discharg...

Page 92: ...using nitrogen gas 140 PSIG and soap bubbles 7 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remot...

Page 93: ...azing equipment 6 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating...

Page 94: ...refrigerant and store it in an approved container 4 Remove the screw and the Solenoid 5 Disconnect the Hot Gas Valve or Line Valve using brazing equipment 6 Installthenewvalve WARNING Always protect...

Page 95: ...ng enough lead length to reconnect using closed end connectors 11 Connect the new Solenoid leads 12 Attach the Solenoid to the valve body and secure it with a screw 13 Replace the panels in their corr...

Page 96: ...is 5 Remove the Insulation Tube and disconnect the Evaporator Inlet Tubing at the Tee next to the Expansion Valve 6 Lift up the Evaporator and disconnect the Evaporator Outlet Tubing 7 Install the new...

Page 97: ...5 Disconnect the Capillary Tube at the Condenser outlet using brazing equipment 6 Disconnect the Flare connections of the valve 7 Remove the screws and the valve from the Bracket 8 Install the new va...

Page 98: ...e system Or prepare a thermometer to check for the condenser drain temperature 2 Rotate the adjustment screw by using a flat blade screwdriver so that the pressure gauge shows 270 PSIG or the thermome...

Page 99: ...off the stub on the dome to release the dome charge 5 Disconnect the C P R using brazing equipment 6 Install the new C P R Use nitrogen gas at the pressure of 3 4 PSIG when brazing the C P R WARNING...

Page 100: ...ol Box Cover 4 Disconnect the Thermistor leads from the K3 Connector on the Controller Board 5 Remove the Plastic Cable Ties Foam Insulation Thermistor Holder and Thermistor See Fig 2 6 Scrape away th...

Page 101: ...replacing a Fan Motor with defective winding it is recommended that a new capacitor be installed 1 Turnoffthepowersupply 2 Remove the panels 3 Remove the Junction Box Cover from the remote condenser u...

Page 102: ...ng the Clamp 5 Remove the Bracket from the unit 6 Remove the Fitting Nut and Water Valve 7 Disconnect the Terminals from the Water Valve 8 Install the new Water Valve and replace the removed parts in...

Page 103: ...verse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply 14 REMOVAL AND REPLACEMENT OF PUMP MOTOR 1 Turn off the power supply 2 Remove the Fron...

Page 104: ...per ambient temperature is resumed When the icemaker is not used for two or three days it is sufficient to only move the Control Switch to the OFF position unless the icemaker will be at sub freezing...

Page 105: ...o the ICE position 8 Replace the Front Panel and turn on the power supply 9 Blow the potable water line out using compressed air or carbon dioxide 3 Drain the Potable Water Tank 1 Turn off the power s...

Page 106: ...g water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves for safe handling of the cleaning and sanitizing sol...

Page 107: ...ng process 13 Turn off the power supply after 30 minutes 14 Remove the Front Panel 15 Move the Service Switch to the DRAIN position 16 Replace the Front Panel and turn on the power supply for 2 minute...

Page 108: ...e Front Panel 9 Move the Service Switch to the DRAIN position 10 Replace the Front Panel and turn on the power supply for 2 minutes 11 Turn off the power supply 12 Remove the Front Panel 13 Repeat the...

Page 109: ...horoughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Air Filter Air cooled model only A plastic mesh air filter removes dirt or dust from the air and keeps the Co...

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