Hoshizaki DCM-500BAF User manual

NO:
HOSHIZAKI
CUBELET ICE DISPENSER
MODEL DCM-500BAF
DCM-500BWF
DCM-750BAF
DCM-750BWF
SERVICE MANUAL
73071
ISSUED: MAR. 11, 1999
REVISED: DEC.17,2003

2
Only qualified service technicians should attempt to service or maintain this icemaker.
No service or maintenance should be undertaken until the technician has thoroughly
read this Service Manual.
HOSHIZAKI AMERICA, INC.
618Highway74South
PeachtreeCity,GA 30269
Attn: HOSHIZAKITechnicalSupportDepartment
Phone: [phone]TechnicalService
[phone]
Fax: [phone]
NOTE: Toexpediteassistance,allcorrespondence/communicationMUST includethefollowing
information:
• ModelNumber
• SerialNumber
• Completeanddetailedexplanationoftheproblem
IMPORTANT
HOSHIZAKI provides this manual primarily to assist qualified service technicians in the
service and maintenance of the icemaker.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call or write to the HOSHIZAKI Technical Support Department for
assistance.

3
• Please review this manual. It should be read carefully before the ice dispenser is
installed and operated. Only qualified service technicians should install, service and
maintain the ice dispenser. This manual should be made available to the technician
prior to installation, service or maintenance.
CONTENTS PAGE
I. SPECIFICATIONS ............................................................................................................ 5
1. DCM-500BAF (Air-cooled) .......................................................................................... 5
2. DCM-500BWF (Water-cooled) .................................................................................... 6
3. DCM-750BAF (Air-cooled) .......................................................................................... 7
4. DCM-750BWF (Water-cooled) .................................................................................... 8
II. GENERAL INFORMATION .............................................................................................. 9
1. CONSTRUCTION ....................................................................................................... 9
DCM-500BAF, DCM-750BAF ..................................................................................... 9
DCM-500BWF, DCM-750BWF ................................................................................. 10
2. CONTROL BOX LAYOUT......................................................................................... 11
DCM-500BAF, DCM-750BAF ................................................................................... 11
DCM-500BWF, DCM-750BWF ................................................................................. 12
3. CABINET STAND ..................................................................................................... 13
III. TECHNICAL INFORMATION........................................................................................ 16
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT................................................... 16
DCM-500BAF (Air-cooled) ........................................................................................ 16
DCM-500BWF (Water-cooled) .................................................................................. 17
DCM-750BAF (Air-cooled) ........................................................................................ 18
DCM-750BWF (Water-cooled) .................................................................................. 19
2. WIRING DIAGRAM ................................................................................................... 20
DCM-500BAF, DCM-500BWF .................................................................................. 20
DCM-750BAF, DCM-750BWF .................................................................................. 21
3. SEQUENCE OF ELECTRICAL CIRCUIT ................................................................. 22
4. TIMING CHART ........................................................................................................ 36
5. TIMER BOARD ......................................................................................................... 37
6. PERFORMANCE DATA............................................................................................ 41
IV. ADJUSTMENT OF COMPONENTS ............................................................................ 45
ADJUSTMENT OF WATER REGULATING VALVE
- WATER-COOLED MODEL ONLY ............................................................................ 45
V. SERVICE DIAGNOSIS ................................................................................................. 46

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VI. REMOVAL AND REPLACEMENT OF COMPONENTS .............................................. 50
1. SERVICE FOR REFRIGERANT LINES..................................................................... 50
[a] REFRIGERANT RECOVERY ............................................................................. 50
[b] EVACUATION AND RECHARGE [R-404A]........................................................ 50
2. BRAZING .................................................................................................................. 51
3. REMOVAL AND REPLACEMENT OF COMPRESSOR ............................................ 52
4. REMOVAL AND REPLACEMENT OF DRIER........................................................... 53
5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE ................................... 54
6. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE ................... 55
7. REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY......................... 56
8. REMOVAL AND REPLACEMENT OF FAN MOTOR ................................................ 61
9. REMOVAL AND REPLACEMENT OF CONTROL/DISPENSING WATER VALVE 61
10. REMOVAL AND REPLACEMENT OF FLOAT SWITCH ........................................... 62
11. REMOVAL AND REPLACEMENT FLUSH WATER VALVE..................................... 62
12. REMOVAL AND REPLACEMENT OF ELECTRICAL SYSTEM ............................... 63
13. REMOVAL AND REPLACEMENT OF DISPENSING SYSTEM ............................... 64
VII. CLEANING AND MAINTENANCE INSTRUCTIONS.................................................. 66
1. PREPARING THE ICE DISPENSER FOR LONG STORAGE.................................. 66
2. CLEANING INSTRUCTIONS.................................................................................... 68
[a] WATER SYSTEM ............................................................................................... 68
[b] STORAGE BIN.................................................................................................... 70
[c] WATER VALVE................................................................................................... 72
[d] STRAINER.......................................................................................................... 73
3. MAINTENANCE INSTRUCTIONS ............................................................................ 75

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I. SPECIFICATIONS
1. DCM-500BAF (Air-cooled)
AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 7.9 RLA 51 LRA
GEAR MOTOR 120 V 1.6 FLA 1/6 HP
FAN MOTOR 120 V 0.6 FLA 30W
AGITATING MOTOR 120 V 0.9 FLA 55 W
DISPENSING MOTOR 120 V 0.9 FLA 55 W
OTHERS 120 V 0.2 A
MAXIMUM FUSE SIZE 20 A
MAX. HACR BREAKER (USA ONLY) 20 A
MAX. CIRC. BREAKER (CANADA ONLY) 20 A
MINIMUM CIRCUIT AMPACITY 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER24HR. Temp.(°F)507090
lbs./day ( kg/day ) 70 *525 (243) 510 (231) 485 (220)
Reference without *marks 80 461 (209) 438 (199) 416 (189)
90 396 (179) *385 (175) 358 (162)
100 340 (154) 323 (147) *304 (138)
SHAPE OF ICE Cubelet (Compressed Flake Ice)
ICE QUALITY Approx. 90%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACITY 40 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1055 (6.6) 985 (4.4)
POTABLE WATER 46 (11.9) 64 (11.9)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" (661 x 571 x 1016 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 251 lbs. ( 114 kg ), Shipping 276 lbs. ( 125 kg )
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT x2
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model R43C1E-CAA-219
CONDENSER Air-cooled, Fin and tube type
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A,
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Auto-reset Thermal Protector
Manual reset Circuit Breaker or Fuse
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES -SUPPLIED Spare Fuse
-REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
DRAWING NO. (DIMENSION) 340147S--
1 lb. 4.1 oz.
(
570
g)
We reserve the right to make changes in specifications and design without prior notice.

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2. DCM-500BWF (Water-cooled)
AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 7.9 RLA 51 LRA
GEAR MOTOR 120 V 1.6 FLA 1/6 HP
AGITATING MOTOR 120 V 0.9 FLA 55 W
DISPENSING MOTOR 120 V 0.9 FLA 55 W
OTHERS 120 V 0.2 A
MAXIMUM FUSE SIZE 20 A
MAX. HACR BREAKER (USA ONLY) 20 A
MAX. CIRC. BREAKER (CANADA ONLY) 20 A
MINIMUM CIRCUIT AMPACITY 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *545 (247) 526 (239) 515 (233)
Reference without *marks 80 503 (228) 493 (223) 482 (219)
90 471 (214) *465 (211) 451 (205)
100 441 (200) 432 (196) *400 (181)
SHAPE OF ICE Cubelet (Compressed Flake Ice)
ICE QUALITY Approx. 90%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACITY 40 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 930 (4.8) 985 (4.0)
POTABLE WATER 56 (12) 65 (12)
WATER-COOLED CONDENSER 465 (100) 285 (52)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" (661 x 571 x 1016 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 245 lbs. ( 111 kg ), Shipping 269 lbs. ( 122 kg )
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT x2 Condenser Outlet 3/8" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL Automatic Water Regulator
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model R43C1E-CAA-219
CONDENSER Water-cooled, Double Tube Type
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A,
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Auto-reset Thermal Protector
Manual-reset Circuit Breaker or Fuse
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES -SUPPLIED Spare Fuse
-REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104-127 V
AMBIENT TEMP. 45-100° F
WATER SUPPLY TEMP. 45-90° F
WATER SUPPLY PRESSURE 10-113 PSIG
DRAWING NO. (DIMENSION) 340148S--
13.4 oz. (380g)
We reserve the right to make changes in specifications and design without prior notice.

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3.DCM-750BAF (Air-cooled)
AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 11.1 RLA 60 LRA
GEAR MOTOR 120 V 3 FL
A
1/4 HP
FAN MOTOR 120 V 0.85 FL
A
1/15 HP
AGITATING MOTOR 120 V 1.8 FLA (Total) 110 W
DISPENSING MOTOR 120 V 0.9 FL
A
55 W
OTHER 120 V 0.6
A
MAXIMUM FUSE SIZE 20 A
MAX. HACR BREAKER (USA ONLY) 20 A
MAX. CIRC. BREAKER (CANADA ONLY) 20 A
MINIMUM CIRCUIT AMPACITY 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 * 803 (364) 770 (349) 726 (329)
Reference without *marks 80 684 (310) 645 (293) 608 (276)
90 573 (260) * 567 (257) 509 (231)
100 480 (218) 452 (205) * 423 (192)
SHAPE OF ICE Cubelet (Compressed Flake Ice)
ICE QUALIT
Y
Approx. 90%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACIT
Y
95 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1481 (6.3) 1449 (4.3)
POTABLE WATER 68 (12) 96 (12)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 34-1/16" x 28-1/2" x 48-1/16" (865 x 723 x 1221 mm)
EXTERIOR FINISH Stainless Steel; Galvanized Steel (Rear)
WEIGHT Net 375 lbs. ( 170 kg ), Shipping 405 lbs. ( 184 kg )
CONNECTIONS - ELECTRIC Permanent Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Drain Pan 3/4" FPT
Bin Drain 3/4" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model RS55C1E-PAA
CONDENSER Air-cooled, Fin and tube type
EVAPORATOR Copper Tube on Cylinde
r
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 1 lb. 7.1 oz. (660 g)
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Rela
y
COMPRESSOR PROTECTION Auto-reset Overload Protecto
r
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Time
r
ACCESSORIES - SUPPLIED Spare Fuse
- REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
DRAWING NO. (DIMENSIONS) 340969---
We reserve the right to make changes in specifications and design without prior notice.

8
4. DCM-750BWF (Water-cooled)
AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 10 RL
A
60 LRA
GEAR MOTOR 120 V 3 FL
A
1/4 HP
AGITATING MOTOR 120 V 1.8 FLA (Total) 110 W
DISPENSING MOTOR 120 V 0.9 FL
A
55 W
OTHER 120 V 0.6
A
MAXIMUM FUSE SIZE 20
A
MAX. HACR BREAKER (USA ONLY) 20
A
MAX. CIRC. BREAKER (CANADA ONLY) 20
A
MINIMUM CIRCUIT AMPACIT
Y
20
A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 * 879 (399) 851 (386) 830 (376)
Reference without *marks 80 809 (367) 789 (358) 770 (349)
90 751 (341) * 746 (338) 714 (324)
100 697 (316) 679 (308) * 628 (285)
SHAPE OF ICE Cubelet (Compressed Flake Ice)
ICE QUALIT
Y
Approx. 90%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACIT
Y
95 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1349 (4.3) 1348 (3.7)
POTABLE WATER 89 (12) 105 (12)
WATER - COOLED CONDENSER 624 (83.7) 421 (47.9)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 34-1/16" x 28-1/2" x 48-1/16" (865 x 723 x 1221 mm)
EXTERIOR FINISH Stainless Steel; Galvanized Steel (Rear)
WEIGHT Net 375 lbs. ( 170 kg ), Shipping 405 lbs. ( 184 kg )
CONNECTIONS - ELECTRIC Permanent Connection
- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2" FPT
- DRAIN Drain Pan 3/4" FPT Condenser Outlet 1/2" FPT
Bin Drain 3/4" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL Water Regulating Valve
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model RS55C1E-PA
A
CONDENSER Water-cooled, Double tube type
EVAPORATOR Copper Tube on Cylinde
r
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 1 lb. 1.7 oz. (500 g)
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Rela
y
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES - SUPPLIED Spare Fuse
- REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V
AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG
DRAWING NO. (DIMENSIONS) 340970---
We reserve the right to make changes in specifications and design without prior notice.

9
II. GENERAL INFORMATION
1. CONSTRUCTION
DCM-500BAF, DCM-750BAF

10
DCM-500BWF, DCM-750BWF