Hoshizaki C80BAJDS User Manual
Service Manual
Self-Contained Cubelet
Models
C-80BAJ
C-80BAJ-DS
C-80BAJ-AD
C-80BAJ-ADDS
hoshizakiamerica.com
Number: 73219
Issued: 12-1-2017
WARNING
Only qualied service technicians should install and service the appliance.
Toobtain the name and phone number of your local Hoshizaki Certied Service
Representative, visit www.hoshizaki.com. No service should be undertaken until
the technician has thoroughly read this Service Manual. Failure to service and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage and may result in costly water
damage. Proper installation is the responsibility of the installer. Product failure or
property damage due to improper installation is not covered under warranty.
Hoshizaki provides this manual primarily to assist qualied 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
Fax: 1-800-843-1056; (770) 487-3360
E-mail: techsupport@hoshizaki.com
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department
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.
2
IMPORTANT
This manual should be read carefully before the appliance is serviced. Read
the warnings and guidelines contained in this manual carefully as they provide
essential information for the continued safe use, service, and maintenance of the
appliance. Retain this manual for any further reference that may be necessary.
CONTENTS
Important Safety Information ................................................................................................. 4
I. Construction and Water/Refrigeration Circuit Diagram ....................................................... 7
A. Construction .................................................................................................................. 7
1. Icemaker .................................................................................................................. 7
2. Ice Making Assembly ............................................................................................... 8
3. Water/Refrigeration Circuit Diagram ........................................................................ 9
II. Sequence of Operation and Service Diagnosis ............................................................... 10
A. Sequence of Operation Flow Chart ........................................................................... 10
B. Service Diagnosis ........................................................................................................11
1. Ice Production Check ..............................................................................................11
2. Diagnostic Procedure .............................................................................................11
C. Bin Control Check ....................................................................................................... 14
D. Float Switch Check and Cleaning ............................................................................... 15
1. Float Switch Check ................................................................................................ 15
2. Float Switch Cleaning ............................................................................................ 15
E. Optional Drain Pump HS-5061 .................................................................................... 17
1. Overview ................................................................................................................ 17
2. Drain Pump Check ................................................................................................. 17
F. Diagnostic Tables ......................................................................................................... 18
III. Controls and Relays ........................................................................................................ 20
A. Control Switch ............................................................................................................. 20
B. Time Delay Relay ........................................................................................................ 20
C. Water Control Relay .................................................................................................... 20
IV. Refrigeration Circuit and Component Service Information.............................................. 21
A. Refrigeration Circuit Service Information .................................................................... 21
B. Component Service Information .................................................................................. 24
1. Upper Bearing Wear Check .................................................................................. 26
2. Removal and Replacement of Extruding Head ...................................................... 27
3. Removal and Replacement of Auger ..................................................................... 28
4. Removal and Replacement of Evaporator ............................................................. 29
5. Removal and Replacement of Mechanical Seal and Lower Housing ................... 30
6. Removal and Replacement of Gear Motor ............................................................ 32
V. Maintenance .................................................................................................................... 33
A. Maintenance Schedule ................................................................................................ 34
VI. Preparing the Appliance for Periods of Non-Use ............................................................ 35
VII. Disposal ......................................................................................................................... 37
VIII. Technical Information .................................................................................................... 38
A. Specication and Performance Data ........................................................................... 38
B. Wiring Diagrams .......................................................................................................... 39
1. C-80BAJ(-DS)(-AD)(-ADDS) .................................................................................. 39
2. Optional Drain Pump HS-5061 .............................................................................. 40
3
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, damage to the appliance, or damage to property.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
NOTICE Indicates a situation which could result in damage to the
appliance or property.
IMPORTANT Indicates important information about the use and care of the
appliance.
WARNING
The appliance should be destined only to the use for which it has been expressly
conceived. Any other use should be considered improper and therefore dangerous.
The manufacturer cannot be held responsible for injury or damage resulting from
improper, incorrect, and unreasonable use. Failure to service and maintain the
appliance in accordance with this manual will adversely affect safety, performance,
component life, and warranty coverage and may result in costly water damage.
To reduce the risk of death, electric shock, serious injury, or re, follow basic
precautions including the following:
• Only qualied service technicians should install and service the appliance.
• The appliance must be installed in accordance with applicable national, state, and
local codes and regulations.
• The appliance requires an independent power supply of proper capacity. See the
nameplate for electrical specications. 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 re.
• THE APPLIANCE MUST BE GROUNDED: The appliance is equipped with a
NEMA5-15 three-prong grounding plug
hazards. It must be plugged into a properly grounded, independent 3-prong wall
outlet. If the outlet is a 2-prong outlet, it is your personal responsibility to have a
qualied electrician replace it with a properly grounded, independent 3-prong wall
outlet. Do not remove the ground prong from the power cord and do not use an
adapter plug. Failure to properly ground the appliance could result in death or serious
injury.
• Do not use an extension cord.
• To reduce the risk of electric shock, do not touch the control switch or plug with damp
hands. Make sure the control switch is in the "OFF" position before plugging in or
unplugging the appliance.
to reduce the risk of potential shock
• Do not use an appliance with a damaged power cord. The power cord should not
be altered, jerked, bundled, weighed down, pinched, or tangled. Such actions could
result in electric shock or re. To unplug the appliance, be sure to pull the plug, not
the cord, and do not jerk the cord.
• Do not make any alterations to the appliance. Alterations could result in electric
shock, injury, re, or damage to the appliance.
4
WARNING, continued
• Do not place ngers or any other objects into the ice discharge opening.
• The appliance is not intended for use by persons (including children) with reduced
physical, sensory, or mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction concerning use of the
appliance by a person responsible for their safety.
• Young children should be properly supervised around the appliance.
• Do not climb, stand, or hang on the appliance or appliance door or allow children or
animals to do so. Serious injury could occur or the appliance could be damaged.
• Be careful not to pinch ngers when opening and closing the door. Be careful when
opening and closing the door when children are in the area.
• Do not use combustible spray or place volatile or ammable substances near the
appliance. They might catch re.
• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance
could cause harm to individuals or damage to the appliance.
NOTICE
• Protect the oor when moving the appliance to prevent damage to the oor.
• Follow the water supply, drain connection, and maintenance instructions carefully to
reduce the risk of costly water damage.
• In areas where water damage is a concern, install in a contained area with a oor
drain.
• Install the appliance in a location that stays above freezing. Normal operating
ambient temperature must be within 45°F to 100°F (7°C to 38°C).
• If using the optional drain pump (HS-5061), test its operation every time the
appliance is cleaned and sanitized. See "II.E.2. Drain Pump Check" for details. Ifthe
optional drain pump is not operating properly, water could back up and overow,
leading to costly water damage.
• If water collects in the bin and will not drain, turn off the appliance and close the
water supply line shut-off valve. Locate and resolve the issue.
• To help ensure that the storage bin drain remains clear, follow the storage bin drain
instructions in the instruction manual once every 3 months or as often as necessary
for conditions. Ifthe storage bin drain becomes clogged, water could build up in the
bin and overow, leading to costly water damage.
• If water seeps from the base of the appliance, turn off the appliance and close the
water supply line shut-off valve. Locate and resolve the issue. Failure to do so could
lead to costly water damage.
• Do not leave the appliance on during extended periods of non-use, extended
absences, or in sub-freezing temperatures. To properly prepare the appliance for
these occasions, follow the instructions in "VI. Preparing the Appliance for Periods of
Non-Use."
5
NOTICE, continued
• Keep ventilation openings, in the appliance enclosure or in the built-in structure, clear
of obstruction.
• Do not place objects on top of the appliance.
• The storage bin is for ice use only. Do not store anything else in the storage bin.
6
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Icemaker
Ice Discharge
Opening
Scoop Holder
Front Panel
Control Switch
Slope
Power Cord
Top Panel
Front
C-80BAJ-AD Shown
Bin Control
Thermostat
Bulb
Magnet Catch
Door
Louver
Upper Rear Panel
Power Cord
Top Panel
Inlet Water Valve
Evaporator Condensate
Drain Pan
Float Switch
Water Reservoir
Drain Valve
Lower Rear Panel
Bin Control
Drip
Tra y
Compressor
Drier
Rear
C-80BAJ-AD Shown
Evaporator
Assembly
Gear Motor
Gear Motor
Drain Pan
7
2. Ice Making Assembly
Cutter (motionless)
Seal Bolt
Extruding Head
and Upper
Bearing
Auger
Cylinder
Mechanical Seal
O-Ring
Evaporator Flange
Gear Motor
Insulation
Housing and
Lower Bearing
Spline Coupling
Hex Head
Bolt with
Washer
Socket Head
Cap Screw
with Washer
8
3. Water/Refrigeration Circuit Diagram
Water Inlet
Float Switch
Water Reservoir
Overow Hose
Evaporator Condensate
Drain Pan (Drip Pan) Hose
Evaporator Water
Supply Hose
Drain Valve
Drain Valve Drain Hose
Gear Motor Drain Pan Hose
Inlet Water Valve
Water Level
To Bin
Evaporator Condensate
Drain Pan (Drip Pan)
Evaporator
Assembly
Gear
Motor
Bin Drain Hose
Gear Motor
Drain Pan
To Drain
Condenser
Condenser
Fan Motor
Discharge
Drier
Compressor
9
Capillary Tube
Suction
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation Flow Chart
UFS open
FT exceeded
WV continues
Comp de-energized
FM de-energized
GM de-energized
Legend:
BC-bin control
Comp-compressor
DV-drain valve
DP-drain pump (optional)
FM-fan motor
FT-ll timer (time delay relay)
GM-gear motor
LFS-lower oat switch
UFS-upper oat switch
WV-inlet water valve
2. Freeze Cycle
Low Water Safety
When rell is achieved
(UFS closed) icemaker
Rell
restarts at 2. Freeze Cycle.
Maximum 90 sec.
90 sec. FT exceeded
LFS closed
UFS closed
UFS open
LFS open
FT resets
Comp continues
FM continues
GM continues
FT starts (90 sec.)
Comp continues
FM continues
GM continues
WV de-energized
WV energized
Restart is based on position of UFS
a. If UFS is closed, restart begins at 2. Freeze Cycle
b. If UFS is open, restart begins at 1. Startup/Fill Cycle
2. Icemaker Restart
BC closed
LFS closed
UFS closed
Comp energized
FM energized
GM energized
WV de-energized
1. Startup/Fill Cycle
UFS open
LFS open
C-80BAJ(-DS)(-AD)(-ADDS) Series Sequence Flow Chart
Startup
Control Switch "ON"
WV energized
Cycle Steps
1. Bin Full Icemaker Off
BC open
Comp de-energized
FM de-energized
GM de-energized
• Optional Drain Pump HS-5061
Drain pump has 115VAC when appliance is plugged into electrical outlet.
115VAC remains at drain pump until appliance is unplugged from the electrical outlet.
• Control Switch in the "DRAIN" Position
When the control switch is in the "DRAIN" position, 115VAC is supplied to the drain valve.
Shutdown & Restart
10
B. Service Diagnosis
WARNING
• This appliance should be diagnosed and repaired only by qualied service
personnel to reduce the risk of death, electric shock, serious injury, or re.
• Risk of electric shock. Use extreme caution and exercise safe electrical practices.
• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after the appliance is serviced. Make sure that none have fallen
into the storage bin.
• Make sure all food zones in the appliance and storage bin are clean after service.
• After service, make sure that there are no wires pinched between the panels and
icemaker. Make sure you do not damage or pinch the water supply line, drain line,
or power cord.
1. Ice Production Check
To check production, prepare a bucket or pan to catch the ice and a set of scales to
weigh the ice. After the appliance has operated for 10 to 20 minutes, catch the ice
production for 10 minutes. Weigh the ice to establish the batch weight. Multiply the
batch weight by 144 for the total production in 24 hours. When conrming production or
diagnosing low production, see "VIII.A. Specication and Performance Data" for typical
production information.
2. Diagnostic Procedure
This diagnostic procedure is a sequence check that allows you to diagnose the electrical
system and components. Before proceeding, check for correct installation, proper voltage
per appliance nameplate, and adequate water pressure (7 to 113PSIG).
Note: • When checking high voltage (115VAC), always choose a white (W) neutral wire to
establish a good neutral connection.
• Time Delay Relay: 90 sec. low water safety circuit. Controlled by LFS and UFS
and water control relay.
• Optional drain pump (HS-5061) has 115VAC power supply as soon as the
appliance is plugged into the electrical outlet.
1) Conrm the appliance is plugged into the electrical outlet, supply voltage is correct per
nameplate.
2) Move the control switch to the "DRAIN" position. DV Diagnosis: If DV does not
energize, check for 115VAC at control switch terminal #3 (W/DBU) to neutral (W).
If115VAC is not present, check control switch continuity, optional drain pump connector/
jumper and safety switch, and power supply. If 115VAC is present, check DV coil
continuity. Replace as needed. If optional drain pump is installed, see "II.E. Optional
Drain Pump HS-5061."
11
3) After all of the water has drained, move the control switch to the "OFF" position, then
unplug the appliance.
4) Remove the front panel, louver, and upper and lower rear panels.
5) Remove the screws securing the control box, then gently pull out the control box and
secure it in a safe position. Remove the control box cover.
6) Plug the appliance back into the electrical outlet.
7) Startup/Fill Cycle–Move the control switch to the "ICE" position. With LFS and
UFS open, WV energizes. Reservoir lls, LFS closes. Nothing happens at this time.
Reservoir continues to ll until UFS closes.
Diagnosis: Check that reservoir lls. If not, check water supply line shut-off valve, water
lters, and WV screen. Next, check for 115VAC at WV. If 115VAC is not present at WV,
check for 115VAC at WCR #8 (BK) to WCR #7 (W). If115VAC is present, conrm that
UFS is open. See "II.D.1. Float Switch Check." If115VAC is not present and WV is not
energized, check WCR #2(O) to neutral(W) and #6 (BR) to neutral (W). If115VAC is
not present at WCR #6 (BR) to neutral (W), check control switch position and continuity.
Also check wire connections to WCR. If115VAC is present at WCR #6(BR) to neutral
(W) and not present at WCR #2(O) to neutral (W), replace WCR. If 115VAC is present
at WCR #2 (O) to neutral (W), check WV solenoid continuity. If open, replace WV.
Fill Cycle Complete: Check that UFS closes when reservoir is full. Ifnot, check FS.
See "II.D.1. Float Switch Check."
8) Freeze Cycle–UFS closes and energizes WCR. WCR allows TDR to energize, then
TDR energizes GM, FM, and CR. CR then energizes Comp. WVde-energizes. Ice
production starts 4 to 6minutes after Comp energizes depending on ambient and water
conditions.
WCR Diagnosis:Conrm WCR energizes. If not, conrm UFS is closed.
See"II.D.1.Float Switch Check." With UFS closed, check for 115VAC at WCR #8 (BK)
to WCR #7(W). If 115VAC is not present, check control switch position and continuity.
Alsocheck wire connections to FS and WCR. If115VAC is present, check that WV
de-energized. If not, check for 0VAC at WCR #2(O) to neutral (W). If115VAC is present,
replace WCR. Next, check for 115VAC at WCR #5 (BR) to neutral (W) and WCR #3(P)
to neutral (W). If 115VAC is not present at WCR #5 (BR) to neutral (W), check control
switch position and continuity. Also check wire connections to WCR. If 115VAC is
present at WCR #5 (BR) to neutral (W) and not at WCR #3 (P) to neutral (W), WCR
is not energized or contacts are sticking. Replace WCR. If 115VAC is present at WCR
#3(P) to neutral (W), WCR is good and TDR energizes. TDR Diagnosis: Conrm
115VAC at TDR #2 (BR) and TDR#5 (P) to TDR #3(W). If115VAC is present at TDR
#2(BR) and not at TDR #5(P), see WCR Diagnosis above. If 115VAC is present at TDR
#2 (BR) and TDR #5(P) to TDR #3 (W) and GM does not start, check for 115VAC at
TDR #8(BR) and TDR #9(W/R) to neutral (W). If 115VAC is present at TDR #8 (BR)
and not at TDR #9 (W/R), replace TDR.
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