Hoshizaki KMD-901MWH User manual

Hoshizaki
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models
KMD-901MAH
KMD-901MWH
KMD-901MRH
Modular Crescent Cuber
Hoshizaki America, Inc.
SERVICE MANUAL
™
Number: 73154
Issued: 3-28-2008

2
IMPORTANT
Only qualied service technicians should attempt to install, service, or maintain
this icemaker. No service or maintenance should be undertaken until the
technician has thoroughly read this Service Manual. Failure to service and
maintain the equipment in accordance with this manual may adversely affect
safety, performance, and warranty coverage.
HOSHIZAKI provides this manual primarily to assist qualied 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, write, or send an e-mail message to the HOSHIZAKI Technical
Support Department for assistance.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: HOSHIZAKI Technical Support Department
Phone: [phone] Technical Service
[phone]
Fax: [phone]
[phone]
E-mail: [email protected]
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
  •ModelNumber
  •SerialNumber
  •Completeanddetailedexplanationoftheproblem.

3
CONTENTS
I. Specications...................................................................................................................... 5
A. Icemaker ....................................................................................................................... 5
1. KMD-901MAH (air-cooled) ....................................................................................... 5
2. KMD-901MWH (water-cooled) ................................................................................. 6
3. KMD-901MRH (remote air-cooled) .......................................................................... 7
B. Condenser Unit ............................................................................................................. 8
1. URC-9F.................................................................................................................... 8
II. General Information ......................................................................................................... 10
A. Construction................................................................................................................ 10
1. KMD-901MAH (air-cooled) ..................................................................................... 10
2. KMD-901MWH (water-cooled) ................................................................................11
3. KMD-901MRH (remote air-cooled) ........................................................................ 12
B. Sequence of Operation ............................................................................................... 13
1. One Minute Fill Cycle ............................................................................................. 13
2. Initial Harvest Cycle .............................................................................................. 13
3. Freeze Cycle ......................................................................................................... 13
4. Pump-Out Cycle ................................................................................................... 13
5. Normal Harvest Cycle ........................................................................................... 14
C. Control Board .............................................................................................................. 16
1. Control Board Layout ............................................................................................. 17
2. Features................................................................................................................. 18
a) Maximum Water Supply Period – 6 minutes....................................................... 18
b) Harvest Backup Timer and Freeze Timer ........................................................... 18
c) High Temperature Safety .................................................................................... 18
d) Low Water Safety ............................................................................................... 18
e) High Voltage and Low Voltage Cut-outs ............................................................. 18
f) LED Lights and Audible Alarm Safeties ............................................................... 19
3. Controls and Adjustments...................................................................................... 20
a) Default Dip Switch Settings ................................................................................ 20
b) Harvest Timer (S4 dip switch 1 & 2) ................................................................... 20
c) Pump-Out Timer (S4 dip switch 3 & 4)................................................................ 21
d) Pump-Out Frequency Control (S4 dip switch 5 & 6) ........................................... 21
e) S4 Dip Switch 7 & 8 ........................................................................................... 22
f) Freeze Timer (S4 dip switch 9 & 10).................................................................... 22
g) Float Switch Control (S5 dip switch 1 through 5)................................................ 22
4. Control Board Check Procedure ............................................................................ 22
5. Control Board Replacement ................................................................................ 23
D. Harvest Control – Thermistor ...................................................................................... 23
IMPORTANT
This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualied service technicians
should install, service, and maintain the icemaker. Read the warnings
contained in this booklet carefully as they give important information regarding
safety. Please retain this booklet for any further reference that may be
necessary.

4
E. Bin Control .................................................................................................................. 24
1. Explanation of Operation........................................................................................ 24
2. Bin Control Check Procedure ................................................................................ 24
III. Technical Information ...................................................................................................... 25
A. Water Circuit and Refrigeration Circuit ........................................................................ 25
1. KMD-901MAH (air-cooled) ..................................................................................... 25
2. KMD-901MWH (water-cooled) ............................................................................... 26
3. KMD-901MRH (remote air-cooled) ........................................................................ 27
B. Wiring Diagrams.......................................................................................................... 28
1. KMD-901MAH and KMD-901MWH ........................................................................ 28
2. KMD-901MRH ....................................................................................................... 29
C. Performance Data ....................................................................................................... 30
1. KMD-901MAH (air-cooled) ..................................................................................... 30
2. KMD-901MWH (water-cooled) ............................................................................... 31
3. KMD-901MRH (remote air-cooled) ........................................................................ 32
IV. Service Diagnosis ........................................................................................................... 33
A. 10-Minute Diagnostic Procedure ................................................................................ 33
B. Diagnostic Charts........................................................................................................ 34
1. No Ice Production................................................................................................... 34
2. Evaporator is Frozen Up ........................................................................................ 38
3. Low Ice Production ................................................................................................ 39
4. Abnormal Ice ......................................................................................................... 39
5. Other...................................................................................................................... 40
V. Removal and Replacement of Components .................................................................... 41
A. Service for Refrigerant Lines....................................................................................... 41
1. Refrigerant Recovery ............................................................................................. 41
2. Brazing .................................................................................................................. 41
3. Evacuation and Recharge (R-404A)...................................................................... 42
B. Removal and Replacement of Compressor................................................................. 43
C. Removal and Replacement of Expansion Valve.......................................................... 44
D. Removal and Replacement of Hot Gas Valve or Line Valve ....................................... 45
E. Removal and Replacement of Evaporator................................................................... 46
F. Removal and Replacement of Water Regulating Valve - Water-Cooled Model Only .... 46
G. Adjustment of Water Regulating Valve - Water-Cooled Model Only ............................ 47
H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)
- Remote Air-Cooled Model Only............................................................................... 48
I. Removal and Replacement of Thermistor .................................................................... 49
J. Removal and Replacement of Fan Motor..................................................................... 50
K. Removal and Replacement of Inlet Water Valve or Drain Valve .................................. 50
L. Removal and Replacement of Pump Motor................................................................. 51
M. Removal and Replacement of Bin Control.................................................................. 52
VI. Cleaning and Maintenance............................................................................................. 53
A. Cleaning and Sanitizing Instructions ........................................................................... 53
1. Cleaning Procedure................................................................................................ 54
2. Sanitizing Procedure - Following Cleaning Procedure ........................................... 55
B. Maintenance................................................................................................................ 56
C. Preparing the Icemaker for Long Storage ................................................................... 57

5
I. Specications
A. Icemaker
1. KMD-901MAH (air-cooled)
Note: We reserve the right to make changes in specications and design without prior
notice.
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V)
AMPERAGE 10.8 A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 20 A
MAXIMUM FUSE SIZE 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *890 (404) 864 (392) 803 (364)
Reference without *marks 80 870 (395) 830 (376) 754 (342)
90 864 (392) *801 (363) 730 (331)
100 843 (382) 784 (356) 665 (302)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 11.6 lbs. (5.3 kg) 624pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1940(5.8) 1810(4.9)
WATER gal./24HR (gal./100 lbs.) 160(20.0) 372(41.8)
EXTERIOR DIMENSIONS (WxDxH) 42" x 24-5/8" x 28" (1067 x 625 x 713 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 240 lbs. (109 kg), Shipping 278 lbs. (126 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
5/8" OD Tube
CUBE CONTROL SYSTEM Float Switch
HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Lever Switch and Timer
COMPRESSOR Hermetic, Model CS12K6E-PFV-237
CONDENSER Air-Cooled , Fin and tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 4 lb. 3 oz. (1900g)
DESIGN PRESSURE High 467PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )
COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A
-REQUIRED Ice Dispenser or Ice Storage Bin
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

6
2. KMD-901MWH (water-cooled)
Note: We reserve the right to make changes in specications and design without prior
notice.
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V)
AMPERAGE 7.8A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 20 A
MAXIMUM FUSE SIZE 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *876 (397) 874 (397) 831 (377)
Reference without *marks 80 875 (397) 872 (396) 805 (365)
90 874 (397) *870 (395) 812 (368)
100 852 (386) 856 (388) 759 (344)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 12.3 lbs. (5.6 kg) 624pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1520(4.2) 1480(4.1)
WATER gal./24HR (gal./100 lbs.) 213(24.5) 351(40.1)
WATER COOLED CONDENSER 1088(125) 593(68)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 30" x 24-5/8" x 28" (762 x 625 x 713 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 219 lbs. (99 kg), Shipping 251 lbs. (114 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT Cond. Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT Cond. Outlet 3/8" FPT
5/8" OD Tube
CUBE CONTROL SYSTEM Float Switch
HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe
COOLING WATER CONTROL Pressure Regulator
BIN CONTROL SYSTEM Mechanical Lever Switch and Timer
COMPRESSOR Hermetic, Model CS10K6E-PFV-237
CONDENSER Water-cooled, Tube in tube type
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R404A, 2 lb. 3.3 oz. (1000g)
DESIGN PRESSURE High 427PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )
COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A
-REQUIRED Ice Dispenser or Ice Storage Bin
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

7
3. KMD-901MRH (remote air-cooled)
Note: We reserve the right to make changes in specications and design without prior
notice.
AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V)
AMPERAGE 10.0A ( 5 Min. Freeze AT 104°F / WT 80°F)
MINIMUM CIRCUIT AMPACITY 20 A
MAXIMUM FUSE SIZE 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 *848 (385) 827 (375) 768 (348)
Reference without *marks 80 832 (377) 798 (362) 723 (328)
90 827 (375) *775 (352) 705 (320)
100 805 (365) 759 (344) 641 (291)
SHAPE OF ICE Crescent Cube
ICE PRODUCTION PER CYCLE 12 lbs. (5.4 kg) 624pcs.
APPROXIMATE STORAGE CAPACITY N/A
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 1710(5.3) 1600(4.5)
WATER gal./24HR (gal./100 lbs.) 155(20.0) 383(45.2)
EXTERIOR DIMENSIONS (WxDxH) 30" x 24-5/8" x 28" (762 x 625 x 713 mm)
EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)
WEIGHT Net 226 lbs. (103 kg), Shipping 258 lbs. (117 kg)
CONNECTIONS - ELECTRIC Permanent - Connection
- WATER SUPPLY Inlet 1/2" FPT
- DRAIN Outlet 3/4" FPT
5/8" OD Tube
CUBE CONTROL SYSTEM Float Switch
HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer
ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Lever Switch and Timer
COMPRESSOR Hermetic, Model CS10K6E-PFV-279
CONDENSER Air-Cooled Remote, Condenser Unit URC-9F
EVAPORATOR Vertical type, Stainless Steel and Copper
REFRIGERANT CONTROL Thermostatic Expansion Valve
Condensing Pressure Regulator on URC-9F
REFRIGERANT CHARGE R404A, 9 lbs. 14.7 oz. (4500g)
(Icemaker 5 lbs. 15.9 oz. Cond. Unit 3 lbs. 14.8 oz.)
DESIGN PRESSURE High 467PSIG, Low 230PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )
COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch
ACCESSORIES -SUPPLIED N/A
-REQUIRED Ice Dispenser or Ice Storage Bin, Remote Condenser Unit
OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V
AMBIENT TEMP. 45 -100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 10 - 113 PSIG

8
B. Condenser Unit
1. URC-9F
Unit: mm [inches]

9
AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker)
FAN MOTOR 115 V Total 1.3FLA 65W
EXTERIOR DIMENSIONS (WxDxH) 32-3/16" x 15-11/16" x 21-15/16" (817 x 398 x 558 mm)
DIMENSIONS INCLUDING LEGS (WxDxH) 34-5/16" x 18-1/8" x 36-15/16" (871 x 460 x 938 mm)
EXTERIOR FINISH Galvanized Steel
WEIGHT Net 81 lbs. ( 37 kg ) Shipping 92 lbs. ( 42 kg )
CONNECTIONS - ELECTRIC Permanent - Connection
- REFRIGERANT Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)
Liquid Line 5/8"-18 UNF Fitting (#6 AEROQUIP)
CONDENSER Air-cooled, Fin and tube type
FAN MOTOR PROTECTION Thermal Protection
REFRIGERANT CONTROL Condensing Pressure Regulator
REFRIGERANT CHARGE R-404A 3 lbs. 14.8 oz. (1780g)
DESIGN PRESSURE High 467 PSIG
OPERATING CONDITIONS VOLTAGE RANGE 104 ~ 127 V
AMBIENT TEMP. -20 ~ 122 °F
ACCESSORIES -SUPPLIED Leg 2 pcs
Hex. Head Bolt w/Washer 8 x 16 8 pcs
Hex. Nut 8 8 pcs
Note: We reserve the right to make changes in specications and design without prior
notice.

10
II. General Information
A. Construction
1. KMD-901MAH (air-cooled)
Control Box
Spray
Tubes
Float Switch
Water Pump
Compressor
Bin Control
Drier
Condenser
Fan Motor
Condenser
Junction Box
Hot Gas Valve
Water Supply Inlet
Expansion Valves
Line Valve
Drain Valve
Inlet Water Valve