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 qualified service technicians should install and service the appliance.
To obtain the name and phone number of your local Hoshizaki Certified 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 qualified 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. Specification 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 fire, follow basic
precautions including the following:
• Only qualified 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 specifications. 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 fire.
• THE APPLIANCE MUST BE GROUNDED: The appliance is equipped with a
NEMA 5-15 three‑prong grounding plug
to reduce the risk of potential shock
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
qualified 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.
• 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 fire. 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, fire, or damage to the appliance.
4
WARNING, continued
• Do not place fingers 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 fingers 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 flammable substances near the
appliance. They might catch fire.
• 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 floor when moving the appliance to prevent damage to the floor.
• 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 floor
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. If the
optional drain pump is not operating properly, water could back up and overflow,
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. If the storage bin drain becomes clogged, water could build up in the
bin and overflow, 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
Top Panel
1. Icemaker
Ice Discharge
Opening
Bin Control
Thermostat
Bulb
Scoop Holder
Slope
Front Panel
Magnet Catch
Control Switch
Door
Front
Power Cord
Louver
C-80BAJ-AD Shown
Top Panel
Inlet Water Valve
Evaporator Condensate
Drain Pan
Evaporator
Assembly
Float Switch
Water Reservoir
Drain Valve
Upper Rear Panel
Bin Control
Gear Motor
Drip
Tray
Power Cord
Compressor
Drier
Rear
Lower Rear Panel
C-80BAJ-AD Shown
7
Gear Motor
Drain Pan
2. Ice Making Assembly
Cutter (motionless)
Evaporator Flange
Seal Bolt
Extruding Head
and Upper
Bearing
Auger
Gear Motor
Cylinder
Insulation
Mechanical Seal
O-Ring
Housing and
Lower Bearing
Socket Head
Cap Screw
with Washer
Spline Coupling
Hex Head
Bolt with
Washer
8
3. Water/Refrigeration Circuit Diagram
Inlet Water Valve
Water Inlet
Evaporator Condensate
Drain Pan (Drip Pan)
Water Level
Float Switch
Evaporator
Assembly
Water Reservoir
Overflow Hose
Evaporator Condensate
Drain Pan (Drip Pan) Hose
Gear
Motor
Evaporator Water
Supply Hose
Drain Valve
Drain Valve Drain Hose
To Bin
Gear Motor Drain Pan Hose
To Drain
Drier
Condenser
Bin Drain Hose
Gear Motor
Drain Pan
Capillary Tube
Condenser
Fan Motor
Suction
Discharge
Compressor
9
10
BC open
Comp de-energized
FM de-energized
GM de-energized
LFS closed
UFS closed
FT resets
Comp continues
FM continues
GM continues
WV de-energized
Legend:
BC-bin control
Comp-compressor
DV-drain valve
DP-drain pump (optional)
FM-fan motor
FT-fill timer (time delay relay)
GM-gear motor
LFS-lower float switch
UFS-upper float switch
WV-inlet water valve
UFS open
FT exceeded
WV continues
Comp de-energized
FM de-energized
GM de-energized
90 sec. FT exceeded
When refill is achieved
(UFS closed) icemaker
restarts at 2. Freeze Cycle.
Low Water Safety
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
1. Bin Full Icemaker Off
UFS open
LFS open
FT starts (90 sec.)
Comp continues
FM continues
GM continues
WV energized
Refill
Maximum 90 sec.
• 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
2. Freeze Cycle
LFS closed
UFS closed
Comp energized
FM energized
GM energized
WV de-energized
1. Startup/Fill Cycle
UFS open
LFS open
WV energized
Control Switch "ON"
Startup
Cycle Steps
C-80BAJ(-DS)(-AD)(-ADDS) Series Sequence Flow Chart
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation Flow Chart
B. Service Diagnosis
WARNING
• This appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• 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 confirming production or
diagnosing low production, see "VIII.A. Specification 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 113 PSIG).
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) Confirm 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).
If 115VAC 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 fills, LFS closes. Nothing happens at this time.
Reservoir continues to fill until UFS closes.
Diagnosis: Check that reservoir fills. If not, check water supply line shut‑off valve, water
filters, 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). If 115VAC is present, confirm that
UFS is open. See "II.D.1. Float Switch Check." If 115VAC is not present and WV is not
energized, check WCR #2 (O) to neutral (W) and #6 (BR) to neutral (W). If 115VAC is
not present at WCR #6 (BR) to neutral (W), check control switch position and continuity.
Also check wire connections to WCR. If 115VAC 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. If not, 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. WV de‑energizes. Ice
production starts 4 to 6 minutes after Comp energizes depending on ambient and water
conditions.
WCR Diagnosis: Confirm WCR energizes. If not, confirm 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.
Also check wire connections to FS and WCR. If 115VAC is present, check that WV
de‑energized. If not, check for 0VAC at WCR #2 (O) to neutral (W). If 115VAC 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: Confirm
115VAC at TDR #2 (BR) and TDR #5 (P) to TDR #3 (W). If 115VAC 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.
12
GM Diagnosis: Check that GM energizes. If not, check for 115VAC at GM. If 115VAC is
not present, check GM external protector on front of control box. If tripped, reset.
If it does not reset, replace GM external protector. Once reset, if GM does not energize,
check GM windings (internal protector) and GM capacitor. If GM starts but the auger
does not turn, check coupling between auger and GM. FM Diagnosis: Check that FM
energizes. If not, check for 115VAC at FM red (R) wire to neutral (W). If 115VAC is not
present, check wiring connections from TDR and GM. If 115VAC is present and FM is
not energized, check FM windings and fan blade for binding.
CR/Comp Diagnosis: Check for 115VAC at CR #8 (R) to neutral (W). If 115VAC is
not present, check wiring connections from TDR and GM. If 115VAC is present, check
for 115VAC at CR #3 (BR) and CR #5 (R) to neutral (W). If 115VAC is present on CR
#3 (BR) and not at CR #5 (R), replace CR. If 115VAC is present at CR #5 (R), check
Comp PTC and Comp winding.
9) Refill/Low Water Safety–As ice is produced, the water level in the reservoir drops. UFS
opens, nothing happens at this time. LFS opens and refill begins, WCR de‑energizes,
TDR de-energizes, FT (90 sec.) starts, WV energizes. Comp, FM, and GM continue.
LFS closes, nothing happens at this time. UFS closes, WCR energizes, TDR energizes,
and FT resets. WV de-energizes. If FT terminates before UFS closes, Comp, CR, FM,
and GM de‑energize and WV remains energized until UFS closes.
Refill Diagnosis: Check that WCR de-energizes. If not, see "II.D.1. Float Switch
Check." Once WCR de-energizes, confirm WV energizes. If not, check for 115VAC
at WCR #2 (O) to neutral (W). If 115VAC is not present, replace WCR. If 115VAC is
present, check WV solenoid continuity. Replace as needed. Confirm UFS closes and
WCR energizes within 90 sec. of WV energizing. If not, confirm that water supply is on.
Once UFS closes, WCR energizes, energizing TDR and resetting FT. If FT is exceeded,
Comp, FM, and GM de-energize. Check that TDR energizes after WCR energizes.
Check for 115VAC at TDR #5 (P) to neutral (W). If 115VAC is not present at TDR #5 (P)
to neutral (W), confirm WCR status. If 115VAC is present at TDR #5 (P) to neutral (W),
and Comp, CR, FM, and GM de‑energized, replace TDR.
FT Diagnosis (90 sec. low water safety): If UFS does not close within 90 sec. of LFS
opening, FT terminates and TDR de‑energizes GM, FM, CR, and Comp. Components
remain off until UFS closes. If components continue longer than 90 sec. with UFS open,
replace TDR. If GM and FM de-energize but Comp continues, check CR contacts for
sticking. Replace as needed.
10) Shutdown (bin full)–When the appliance is running, hold ice in contact with the
thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. BC is
factory set, and generally no adjustment is required. However, adjustment may be
needed in some conditions, particularly at higher altitude locations. See "II.C. Bin
Control Check.".
Legend: BC–bin control; Comp–compressor; CR–compressor relay; FM–fan motor;
FS–float switch; FT–fill timer; GM–gear motor; LFS–lower float switch; PTC–start
relay; ST–shutdown timer; TDR–time delay relay; UFS–upper float switch;
WCR–water control relay; WV–inlet water valve
13
C. Bin Control Check
BC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb,
regardless of the cycle at activation.
NOTICE
When the ambient temperature is below 45°F (7°C), BC opens and shuts down
the appliance even if the ice storage bin is empty. When BC is set in the prohibited
range, the appliance operates continuously even if the ice storage bin is filled with
ice. Setting in the prohibited range may result in appliance and property damage.
BC is factory set, and generally no adjustment is required. However, adjustment may be
needed in some conditions, particularly at higher altitude locations.
To check BC, follow the steps below.
1) Turn off the power supply.
2) Move the control switch to the "OFF" position.
3) Clear any ice away from BC bulb.
4) Remove the upper rear panel and disconnect BC wires from BC switch.
5) Hold your hand around the bulb to warm it up.
6) Check for continuity across BC switch. If closed, continue to step 8. If open, adjust or
replace BC.
7) With the multimeter test leads still in place, hold ice on BC bulb to lower the
temperature. Within 10 sec., BC switch should open. If it remains closed, adjust or
replace BC.
Legend: BC–bin control
14
D. Float Switch Check and Cleaning
1. Float Switch Check
1) Move the control switch to the "DRAIN" position.
2) Remove the upper rear panel.
3) Allow the water system to drain for 1 min.
4) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
5) Remove bell connectors from FS black (BK), blue (BU), and red (R) wires.
Check continuity between black (BK) (common) and red (R) (UFS) and between black
(BK) (common) and blue (BU) (LFS). If both are open, continue to step 6. If either are
closed, follow the steps in "II.D.2. Float Switch Cleaning." After cleaning FS, check UFS
and LFS again. Replace if necessary.
6) Cap the FS appliance wires. Black (BK), red (R), and blue (BU).
7) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position.
8) Once the reservoir overflows, move the control switch to the "OFF" position, then unplug
the appliance from the electrical outlet.
9) Check continuity between black (BK) (common) and red (R) (UFS), and between black
(BK) (common) and blue (BU) (LFS). If either are open, follow the steps in "II.D.2. Float
Switch Cleaning." After cleaning FS, check UFS and LFS again. Replace if necessary.
10) Reconnect FS wires to the appropriate appliance wires. Black (BK) to black (BK), red
(R) to brown (BR), and blue (BU) to blue (BU).
11) Replace upper rear panel in its correct position.
12) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
Legend: FS–float switch; LFS–lower float switch; UFS–upper float switch
2. Float Switch Cleaning
Depending on local water conditions, scale may build up on FS. Scale on FS can cause
inconsistent operation of UFS and LFS. In this case, FS should be cleaned and checked.
1) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
2) Remove the upper rear panel.
3) Remove FS assembly from the reservoir cover.
4) Wipe down FS assembly with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts
warm water. Rinse the assembly thoroughly with clean water.
5) While not necessary, the floats can be removed from the shaft during cleaning. If you
remove them, note that the blue float is on top (UFS) and the white float is on bottom
(LFS). See Fig. 2. The floats must be installed with the magnets inside them towards the
top of the switch. Installing the floats upside down will affect the timing of FS operation.
15
6) Rinse FS assembly thoroughly with clean water and replace in its correct position.
7) Replace the upper rear panel in its correct position.
8) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
Legend: FS–float switch; LFS–lower float switch; UFS–upper float switch
Float Switch Assembly
Reservoir Cover
Reservoir
Fig. 1
Red (R)
(upper float switch)
Black (BK)
(common)
Blue (BU)
(lower float switch)
Magnet (towards top)
Upper Float (blue)
Spring Retainer Clip
Magnet (towards top)
Lower Float (white)
Plastic Retainer Clip
Fig. 2
16
E. Optional Drain Pump HS-5061
1. Overview
As ice melts, water drains from the storage bin into DP. LFS closes. Nothing happens
at this time. UFS closes, DP energizes and pumps out the water. UFS opens, nothing
happens at this time. LFS opens, DP de-energizes. If water cannot be pumped out of
DP due to a blocked discharge hose, bad check valve, or bad DP motor, water level
continues to rise and SFS closes. DP continues and appliance de-energizes. Power is
supplied to DP motor as long as LFS is closed. For schematic, see "VIII.B.2. Optional
Drain Pump HS-5061."
NOTICE
• If you remove DP from the appliance, be sure to follow all instructions below.
Failure to do so may result in costly water damage.
• DP has an internal check valve. Do not install an external check valve.
Legend: DP–drain pump; LFS–lower float switch; SFS–safety float switch; UFS–upper float
switch
2. Drain Pump Check
When the optional DP (HS-5061) is installed, test its operation at least twice a year as
outlined below. Note that 115VAC is at DP even when the control switch is in the "OFF"
position.
1) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet. WARNING! To reduce the risk of electric shock, do not touch the
control switch or plug with damp hands.
2) Remove all ice from the storage bin.
3) Plug the appliance back in.
4) Slowly pour 24 to 30 oz. (710 to 890 ml) of water over the storage bin drain hole in the
storage bin.
5) If water pumps out properly and DP then de-energizes, proceed to step 6. If water does
not pump out, confirm 115VAC to drain pump, replace as needed.
6) Move the control switch to the "ICE" position.
7) Pour another 24 to 30 oz. (710 to 890 ml) of water into the appliance's storage bin, then
completely restrict the discharge hose while DP is operating. See Fig. 3. Pour more
water into the appliance's storage bin until the appliance turns off. DP will continue to
operate. Check for leaks.
8) Remove the discharge hose restriction and
allow the water to be pumped out normally.
Power returns to the appliance when SFS
opens.
9) If the appliance fails to turn off with the
discharge hose restricted or the pump fails
to pump out the water, replace DP.
Legend: DP–drain pump; SFS–safety float switch
17
Upper Rear Panel
Vent Hose
Fig. 3
Discharge Hose
Lower Rear Panel
F. Diagnostic Tables
1. No Ice Production
No Ice Production - Possible Cause
Startup/Fill Cycle
1. Power Supply
a) Unplugged, off, blown fuse, or tripped breaker.
b) Not within specifications.
2. Optional Drain Pump HS-5061
a) Drain pump connection unplugged or loose.
b) Drain pump safety float switch open.
3. Control Switch
a) "OFF" position.
b) Bad contacts.
4. Bin Control Thermostat Assembly a) Open with bin filled with ice.
(with integrated heater)
b) Out of position.
c) Out of adjustment. See "II.C. Bin Control Check."
d) Bad contacts.
e) Bad thermostat heater.
5. Water Supply
a) Water supply off or improper water pressure.
6. Water Control Relay
a) Energized and not allowing water valve to energize.
See "II.D.1. Float Switch Check."
b) External water filters clogged.
b) Defective.
7. Inlet Water Valve
a) Screen or orifice clogged.
b) Defective.
8. Float Switch
See "II.D. Float Switch Check
and Cleaning."
a) Float does not move freely.
b) Defective.
Freeze Cycle
1. Water Control Relay
a) Defective.
2. Time Delay Relay
a) Defective.
3. Gear Motor
a) Gear motor external protector (2.4~3.0A) tripped.
b) Gear motor internal protector open or windings open.
c) Bad gear motor capacitor.
d) Locked bearings.
e) Spline coupling or gear broken and auger not turning.
4. Fan Motor
a) Fan blade does not move freely.
b) Defective.
5. Compressor Relay
a) Defective.
6. Compressor
a) PTC relay defective
b) Inefficient.
c) Defective.
7. Evaporator
a) Dirty.
b) Damaged or defective.
8. Condenser
a) Dirty.
9. Refrigerant
a) Low charge or overcharged.
b) Refrigerant lines or components restricted.
10. Water System
a) Water leaks.
18
Refill
1. Float Switch
See "II.D. Float Switch Check
and Cleaning."
a) Dirty/sticking.
2. Inlet Water Valve
a) Screen or orifice clogged.
3. Water Supply
a) Water supply off or improper water pressure (7 to 113 PSIG).
b) Defective.
b) Defective.
b) External water filters clogged.
4. Water Control Relay
a) Defective.
5. Time Delay Relay
a) Defective.
Shutdown
1. Bin Control Thermostat Assembly a) Open with bin filled with ice.
(with integrated heater)
b) Out of position.
c) Out of adjustment. See "II.C. Bin Control Check."
d) Bad contacts.
e) Bad thermostat heater.
19
III. Controls and Relays
The C-80BAJ(-C) utilizes a control switch, time delay relay, water control relay, and
compressor relay to control operation.
A. Control Switch
The control switch has 3 positions, "OFF," "ICE," and "DRAIN."
a) "OFF": All components except the optional drain pump are de-energized when the
control switch is in the "OFF" position. The optional drain pump circuit remains
energized when the control switch is in the "OFF" position.
b) "ICE": When placed in the "ICE" position, the inlet water valve energizes if upper
float switch (UFS) is open. If upper float switch (UFS) is closed, gear motor and
compressor energize.
c) "DRAIN": When placed in the "DRAIN" position, drain valve energizes, draining the
reservoir and evaporator.
B. Time Delay Relay
Time delay relay energizes once 115VAC is supplied to time delay relay #5 (P). Time
delay relay contacts close between time delay relay #8 (BR) and time delay relay
#9 (W/R), energizing the gear motor, fan motor, and compressor. When the lower float
switch opens, the water control relay de-energizes, de-energizing the time delay relay.
A 90 sec. low water safety timer starts. Once the upper float switch closes, the water
control relay energizes, energizing the time delay relay. The time delay relay 90 sec.
timer resets at this time. Once the 90 sec. low water safety timer is exceeded, gear
motor, fan motor, and compressor de-energize.
C. Water Control Relay
The water control relay is controlled by the float switch. The water control relay energizes
when the reservoir is full and the upper float switch closes. The water control relay
de‑energizes when the water in the reservoir lowers and the lower float switch opens.
When energized, the time delay relay energizes and the inlet water valve de-energizes.
When de-energized, the time delay relay de-energizes and the inlet water valve
energizes.
20
IV. Refrigeration Circuit and Component Service Information
WARNING
• This appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet before servicing.
• 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 icemaker and storage bin are clean after service.
A. Refrigeration Circuit Service Information
WARNING
• Repairs requiring the refrigeration circuit to be opened must be performed by
properly trained and EPA-certified service personnel.
• Use an electronic leak detector or soap bubbles to check for leaks. Add a trace
of refrigerant to the system (if using an electronic leak detector), and then raise
the pressure using nitrogen gas (140 PSIG). Do not use R‑134a as a mixture with
pressurized air for leak testing.
NOTICE
• Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
• Do not leave the system open for longer than 15 min. when replacing or servicing
parts. The Polyol Ester (POE) oils used in R-134a applications can absorb
moisture quickly. Therefore it is important to prevent moisture from entering the
system when replacing or servicing parts.
• Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1. Refrigerant Recovery
No refrigerant access valves are provided on this appliance. Using proper refrigerant
practices, utilize a temporary tap-line valve on the high side to recover the refrigerant.
Store the refrigerant in an approved container. Do not discharge the refrigerant into
the atmosphere. After recovery is complete, replace the tap-line valve with a proper,
permanent access valve.
21
2. Brazing
WARNING
• R-134a itself is not flammable at atmospheric pressure and temperatures up to
212°F (100°C).
• R-134a itself is not explosive or poisonous. However, when exposed to high
temperatures (open flames), R-134a can be decomposed to form hydrofluoric
acid and carbonyl fluoride both of which are hazardous.
• Do not use silver alloy or copper alloy containing arsenic.
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
NOTICE
• Always install a new drier every time the sealed refrigeration system is opened
Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace
of refrigerant to the system (if using an electronic leak detector), and then raise
the pressure using nitrogen gas (140 PSIG). Do not use R-134a as a mixture with
pressurized air for leak testing.
3. Evacuation and Recharge (R-134a)
1) Attach a vacuum pump to the system. Be sure the high-side charging hose is connected
to the field-installed high-side access valve.
IMPORTANT
The vacuum level and vacuum pump may be the same as those for current
refrigerants. However, the rubber hose and gauge manifold to be used for
evacuation and refrigerant charge should be exclusively for POE oils.
2) Turn on the vacuum pump, then open the high-side valve on the gauge manifold. Never
allow the oil in the vacuum pump to flow backwards.
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends
on pump capacity.
4) Close the high-side valve on the gauge manifold.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a
refrigerant service cylinder. Remember to loosen the connection and purge the air
from the hose. For the required refrigerant charge, see the nameplate. Hoshizaki
recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard
700 (latest edition) be used.
22
6) A liquid charge is required when charging an R-134a system. Place the service cylinder
on the scales; if the service cylinder is not equipped with a dip tube, invert the service
cylinder, then place it on the scales. Open the high-side valve on the gauge manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) Close the high-side valve on the gauge manifold, then close the refrigerant access valve
(if applicable). Disconnect the gauge manifold hose.
9) Cap the refrigerant access valve to prevent a possible leak.
23
B. Component Service Information
NOTICE
• When replacing a component listed below, see the notes to help ensure proper
operation.
• When replacing evaporator assembly and water circuit components, make sure
there are no water leaks after the repair is complete.
Component
Notes
Extruding Head • Seal bolts must be replaced once removed because seal material is one-time use only.
• If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent
threadlocker to seal bolt threads.
• Tighten down the new seal bolts to a torque of 11.1 ft-lb/15 N·m.
Compressor
• Install a new drier and PTC relay.
Upper and
• Inspect the upper bearing for wear. See "IV.B.1. Upper Bearing Wear Check." Replace if
Lower Bearings
necessary.
• When replacing the upper bearing it is advised to also change the lower bearing at the
same time.
Evaporator
• Install a new drier.
• Inspect the mechanical seal and O-ring prior to installing the new evaporator. If worn,
cracked, or scratched, the mechanical seal should also be replaced.
Gear Motor
• Install a new gear motor capacitor.
Top Panel
Top Panel Bracket
Evaporator Assembly
Upper Rear Panel
Fig. 4
C-80BAJ-AD Shown
24
Evaporator Assembly
Thumbscrew
Seal Bolts
Inspect for leakage around seal bolts.
Tighten (11.1 ft-lb/15 N·m) or replace as
necessary.
Seal bolts must be replaced once removed
because seal material is one-time use only.
If new seal bolts do not have preapplied
threadlocker, apply Loctite 243 or
equivalent threadlocker to seal bolt threads.
Spout
Cutter
(motionless)
Packing
Evaporator
Flange
Extruding Head and
Upper Bearing
Evaporator
Condensate
Drain Pan
Evaporator
Reservoir Outlet
Hose Connection
Auger
Vinyl Cap
Spring Retainer
Mechanical Seal
Socket Head
Cap Screw
with Washer
O-Ring
Hex Head Bolt with
Washer
Housing and
Lower Bearing
Spline Coupling
Gear Motor
Socket Head
Cap Screw
with Washer
Fig. 5
25
1. Upper Bearing Wear Check
To ensure that the bearing inside the extruding head does not exceed the wear tolerance
of .02", follow the instructions below.
1) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
2) Remove all ice from the storage bin.
3)Remove the top panel. See Fig. 4.
4) Remove the spout and packing.
5) Remove the cutter.
6) Grasp the top of the auger and move the auger towards you and then try to insert a .02"
round stock or pin gauge in between the back side of the auger shaft and the bearing
surface. See Fig. 6. Check several locations around the auger shaft. If the gauge goes
between the shaft and the bearing at any point or if the bearing is scratched or cracked,
both the top bearing in the extruding head and the lower bearing in the housing should
be replaced. Instructions for removing the extruding head and housing are located later
in this procedure.
Note: Replacing the bearing requires a bearing press adaptor. If one is not available,
replace the entire extruding head and housing.
7) Replace the removed parts and panel in the reverse order of which they were removed.
8) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
.02" Round Stock or Pin Gauge
Auger
Extruding Head
Fig. 6
26
2. Removal and Replacement of Extruding Head
1) Close the water supply line shut-off valve.
2) Move the control switch to the "DRAIN" position.
3) Allow the water system to drain for 1 minute.
4) Remove all ice from the storage bin.
5) After all of the water has drained, move the control switch to the "OFF" position.
Unplug the appliance from the electrical outlet.
6) Remove the top panel. See Fig. 4.
7) Remove the spout and packing.
8) Loosen the cutter (do not remove).
9) Remove the seal bolts securing the extruding head and evaporator flange, then grasp
the cutter and lift off. NOTICE! Discard existing seal bolts after removal. Seal bolts
must be replaced once removed because seal material is one-time use only.
10) Remove the cutter from the old extruding head and place it on the new extruding head.
11) Place and align the new extruding head and evaporator flange. See Fig. 7.
Spout
Packing
Flat section towards storage bin
(front of machine)
Flange
Fig. 7
12) If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent
threadlocker to seal bolts. Tighten new seal bolts to a torque of 11.1 ft-lb/15 N·m.
13) Tighten down the cutter.
14) Secure the packing and spout in their correct positions.
15) Open the water supply line shut-off valve.
16) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
17) Once the appliance starts to produce ice, allow it to run for another 30 minutes. Check
for water leaks.
18) After 30 minutes, move the control switch to the "OFF" position. Unplug the appliance
from the electrical outlet.
19) Pour warm water into the storage bin and melt the ice. Clean the storage bin liner using
a neutral cleaner. Rinse thoroughly after cleaning.
20) Replace the top panel in its correct position.
21) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
27
3. Removal and Replacement of Auger
1) Close the water supply line shut-off valve.
2) Move the control switch to the "DRAIN" position.
3) Allow the water system to drain for 1 minute.
4) After all of the water has drained, move the control switch to the "OFF" position.
Unplug the appliance from the electrical outlet.
5) Remove all ice from the storage bin.
6) Remove the top panel. See Fig. 4.
7) Remove the spout and packing.
8) Remove the seal bolts securing the extruding head and evaporator flange, then grasp
the cutter and lift off. NOTICE! Discard existing seal bolts after removal. Seal bolts
must be replaced once removed because seal material is one-time use only.
9) Grasp the auger and carefully lift out.
10) When pulling out the auger, the upper part of the mechanical seal should come out with
it. The mechanical seal consists of two parts. One moves along with the auger, and the
other is fixed on the lower housing. Inspect the part of the mechanical seal that came
out with the auger. If the contact surface on the bottom of the seal is worn, cracked
or scratched, the mechanical seal may cause water leaks and both the upper and
lower parts of the mechanical seal should be replaced. Instructions for removing the
mechanical seal are located later in this procedure.
11) Remove the mechanical seal from the old auger and place it on the new auger.
12) Install the new auger.
13) Replace the extruding head (with cutter), and evaporator flange in their correct positions.
Confirm the cutter is tight. See Fig. 7.
14) If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent
threadlocker to seal bolts. Tighten to a torque of 11.1 ft-lb/15 N·m.
15) Replace the packing and spout in their correct positions.
16) Open the water supply line shut-off valve.
17) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
18) Once the appliance starts to produce ice, allow it to run for another 30 minutes. Check
for water leaks.
19) After 30 minutes, move the control switch to the "OFF" position. Unplug the appliance
from the electrical outlet.
20) Pour warm water into the storage bin and melt the ice. Clean the storage bin liner using
a neutral cleaner. Rinse thoroughly after cleaning.
21) Replace the top panel in its correct position.
22) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
28
4. Removal and Replacement of Evaporator
NOTICE
• Always install a new drier every time the sealed refrigeration system is opened. Do
not replace the drier until after all other repair or replacement has been made.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1) Close the water supply line shut-off valve.
2) Move the control switch to the "DRAIN" position.
3) Allow the water system to drain for 1 minute.
4) After all of the water has drained, move the control switch to the "OFF" position.
Unplug the appliance from the electrical outlet.
5) Remove all ice from the storage bin.
6) Remove the top panel and rear panels. See Fig. 4.
7) Remove the spout and packing.
8) Remove the seal bolts securing the extruding head and evaporator flange.
NOTICE! Discard existing seal bolts after removal. Seal bolts must be replaced
once removed because seal material is one-time use only.
9) Grasp the cutter and carefully lift out the extruding head and auger. When pulling out the
auger, the upper part of the mechanical seal should come out with it.
10) Disconnect the reservoir outlet hose from the evaporator.
11) Remove the evaporator condensate drain pan.
12) Install a temporary tap-line valve on the high side, then recover the refrigerant and store
it in an approved container.
13) Disconnect the inlet and outlet tubing.
14) Remove the socket head cap screws securing the evaporator to the lower housing.
15) Lift off the evaporator.
16) Inspect the mechanical seal and O-ring prior to installing the new evaporator. The
mechanical seal consists of two parts. One moves along with the auger, and the other
is fixed on the lower housing. If the contact surfaces of these two parts are worn,
cracked or scratched, the mechanical seal may cause water leaks and should be
replaced. Instructions for removing the mechanical seal and lower housing are located
later in this procedure.
17) Make sure the lower mechanical seal and the O-ring are in place, then place the
evaporator assembly in position. Secure the evaporator to the lower housing using the
socket head cap screws.
18) Replace the tap-line valve with a proper, permanent access valve.
19) Remove the drier, then place the new drier in position.
20) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
29
21) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace
of refrigerant to the system (if using an electronic leak detector), and then raise
the pressure using nitrogen gas (140 PSIG). Do not use R-134a as a mixture with
pressurized air for leak testing.
22) Evacuate the system, then charge it with refrigerant. See the nameplate for the required
refrigerant charge.
23) Reattach and secure the reservoir outlet hose. Replace the evaporator condensate
drain pan and all hoses in their correct positions.
24) Install the auger assembly with the upper part of the mechanical seal attached. Replace
the cutter, extruding head, and evaporator flange in their correct positions and align the
extruding head and evaporator flange holes. See Fig. 7.
25) If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent
threadlocker to seal bolts. Tighten seal bolts to a torque of 11.1 ft-lb/15 N·m.
26) Replace the packing and spout in their correct positions.
27) Open the water supply line shut-off valve.
28) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
29) Once the appliance starts to produce ice, allow it to run for another 30 minutes. Check
for water leaks.
30) After 30 minutes, move the control switch to the "OFF" position. Unplug the appliance
from the electrical outlet.
31) Pour warm water into the storage bin and melt the ice. Clean the storage bin liner using
a neutral cleaner. Rinse thoroughly after cleaning.
32) Replace the rear panels and top panel in their correct positions.
33) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
5. Removal and Replacement of Mechanical Seal and Lower Housing
5a. Mechanical Seal
1) Close the water supply line shut-off valve.
2) Move the control switch to the "DRAIN" position.
3) Allow the water system to drain for 1 minute.
4) After all of the water has drained, move the control switch to the "OFF" position.
Unplug the appliance from the electrical outlet.
5) Remove all ice from the storage bin.
6) Remove the top panel and upper rear panel. See Fig. 4.
7) Remove the spout and packing.
8) Remove the seal bolts securing the extruding head and evaporator flange.
NOTICE! Discard existing seal bolts after removal. Seal bolts must be replaced
once removed because seal material is one-time use only.
30
9) Grasp the cutter and carefully lift out the extruding head.
10) Grasp the auger and carefully lift it out. When pulling out the auger, the upper part of the
mechanical seal should come out with it.
11) Remove the socket head cap screws securing the evaporator to the lower housing.
12) Raise the evaporator up to access the lower housing.
13) The mechanical seal consists of two parts. One moves along with the auger, and the
other is fixed on the lower housing. If the contact surfaces of these two parts are worn,
cracked or scratched, the mechanical seal may cause water leaks and should be
replaced.
14) Remove the mechanical seal from the housing. If only replacing the mechanical seal,
proceed to step 17. NOTICE! To help prevent water leaks, be careful not to damage
the surfaces of the O‑ring or mechanical seal.
5b. Lower Housing
15) Remove the O-ring and the bolts securing the lower housing to the gear motor and
remove the housing from the gear motor. If inspection of the upper bearing inside the
extruding head (see "IV.B.1. Upper Bearing Wear Check") indicates that it is out of
tolerance, replace both it and the bearing inside the lower housing.
Note: Replacing the bearing requires a bearing press adaptor. If one is not available,
replace the entire extruding head and housing.
16) Mount the lower housing onto the gear motor, then install the O-ring onto the lower
housing.
17) Install the lower part of the mechanical seal onto the lower housing.
18) Lower the evaporator down and secure it to the lower housing.
19) Install the auger assembly with the upper part of the mechanical seal attached. Replace
the cutter, extruding head, and evaporator flange in their correct positions. Align the
evaporator flange holes with the extruding head holes. See Fig. 7.
20) If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent
threadlocker to seal bolts. Tighten new seal bolts to a torque of 11.1 ft-lb/15 N·m.
21) Tighten the cutter on the auger.
22) Replace the packing and spout in their correct positions.
23) Open the water supply line shut-off valve.
24) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
25) Once the appliance starts to produce ice, allow it to run for another 30 minutes. Check
for water leaks.
26) After 30 minutes, move the control switch to the "OFF" position. Unplug the appliance
from the electrical outlet.
27) Pour warm water into the storage bin and melt the ice. Clean the storage bin liner using
a neutral cleaner. Rinse thoroughly after cleaning.
31
28) Replace the upper rear panel and top panel in their correct positions.
29) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
6. Removal and Replacement of Gear Motor
NOTICE! Hoshizaki recommends that the gear motor capacitor be replaced at the
same time as the gear motor.
1) Close the water supply line shut-off valve.
2) Move the control switch to the "DRAIN" position.
3) Allow the water system to drain for 1 minute.
4) After all of the water has drained, move the control switch to the "OFF" position, then
unplug the appliance from the electrical outlet.
5) Remove all ice from the storage bin.
6) Remove the top panel and upper rear panel. See Fig. 4.
7) Remove the bolts securing the lower housing to the gear motor. Lift the evaporator up
slightly.
8) Remove the bolts securing the gear motor.
9) Disconnect the gear motor wires, then remove the gear motor.
10) Attach the spline coupling from the old gear motor to the new gear motor.
11) Install the new gear motor.
12) Lower the evaporator onto the gear motor. Secure the lower housing to the gear motor.
13) Reconnect the electrical wires.
14) Open the water supply line shut-off valve.
15) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
16) Once the appliance starts to produce ice, check for water leaks.
17) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
18) Pour warm water into the storage bin and melt the ice. Clean the storage bin liner using
a neutral cleaner. Rinse thoroughly after cleaning.
19) Replace the upper rear panel and top panel in their correct positions.
20) Plug the appliance into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
32
V. Maintenance
The appliance must be maintained in accordance with the instruction manual and labels
provided. Consult with your local Hoshizaki Certified Service Representative about
maintenance service.
WARNING
• Only qualified service technicians should service the appliance.
• To reduce the risk of electric shock, do not touch the control switch with damp
hands.
• Before Servicing: Move the control switch to the "OFF" position. Unplug the
appliance from the electrical outlet to prevent the power supply from being turned
back on inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after any maintenance is done to the appliance. Make sure that
none have fallen into the storage bin.
• Do not place fingers or any other objects into the ice discharge opening.
• After service, make sure that there are no wires pinched between the panels and
appliance. Make sure you do not damage or pinch the water supply line, drain
line, or power cord.
33
A. Maintenance Schedule
The maintenance schedule below is a guideline. More frequent maintenance may be
required depending on water quality, the appliance's environment, and local sanitation
regulations.
Maintenance Schedule
Frequency Area
Weekly
Monthly
Every 3
Months
Every 6
Months
Yearly
Task
Scoop
Clean the scoop using a neutral cleaner. Rinse thoroughly after cleaning.
Drain the Appliance Move the control switch to the "DRAIN" position. Allow the water system
to drain for 1 minute. Clear ice away from the bin control bulb. Move the
control switch to the "ICE" position. After the gear motor starts, move the
control switch to the "DRAIN" position. Allow the water system to drain for
1 minute. Move the control switch to the "ICE" position to start the automatic
icemaking process.
Appliance Exterior Wipe down with a clean, soft cloth. Use a damp cloth containing a neutral
cleaner to wipe off oil or dirt build up. Clean any chlorine staining (rust
colored spots) using a non-abrasive cleanser.
Storage Bin Drain Maintain as outlined in the instruction manual.
Icemaker and
Storage Bin
Evaporator
Condensate Drain
Pan and Gear
Motor Drain Pan
Extruding Head
Seal Bolts
Optional Drain
Pump (HS-5061)
External Water
Filters
Water Supply Inlet
Condenser
Water Hoses
Upper Bearing
(extruding head)
After
Upper Bearing
3 Years,
(extruding head);
then Yearly Lower Bearing
and O-Ring
(lower housing);
Mechanical
Seal; Evaporator
Cylinder; Auger
Clean and sanitize per the cleaning and sanitizing instructions provided in
the instruction manual.
Wipe down with clean cloth and warm water.
Inspect for leakage around seal bolts. Tighten (see torque value below) or
replace as necessary. Seal bolts must be replaced once removed because
seal material is one-time use only. If new seal bolts do not have preapplied
threadlocker, apply Loctite 243 or equivalent threadlocker to seal bolt
threads.
Torque: 11.1 ft-lb/15 N·m
Test as outlined in "II.E. Optional Drain Pump HS-5061."
Check for proper pressure and change if necessary.
Close the water supply line shut‑off valve and drain the water system. Clean
the water supply inlet screen.
Inspect. Clean if necessary.
Inspect the water hoses and clean/replace if necessary.
Check for wear using .02" round stock or pin gauge. Replace both upper
bearing and lower bearing if wear exceeds factory recommendations. See
"IV.B.1. Upper Bearing Wear Check."
Inspect. Replace both upper bearing and lower bearing if wear exceeds
factory recommendations. Replace the mechanical seal if the seal's contact
surfaces are worn, cracked, or scratched.
34
VI. Preparing the Appliance for Periods of Non-Use
During extended periods of non-use, extended absences, or in sub-freezing
temperatures, follow the instructions below. When the appliance is not used for two or
three days under normal conditions, it is sufficient to move the control switch to the "OFF"
position.
WARNING
Only qualified service technicians should service the appliance.
NOTICE
During extended periods of non-use, extended absences, or in sub-freezing
temperatures, follow the instructions below to reduce the risk of costly water
damage.
1) Move the control switch to the "OFF" position. WARNING! To reduce the risk of
electric shock, do not touch the control switch or plug with damp hands.
2) Close the water supply line shut-off valve, then open the water supply line drain valve.
3)Allow the line to drain by gravity.
4) Move the control switch to the "DRAIN" position.
5) Allow the water system to drain for 1 min.
6) Attach a compressed air or carbon dioxide supply to the water supply line drain valve.
7) Move the control switch to the "ICE" position.
8) Blow the water supply line out using the compressed air or carbon dioxide supply.
9) Close the water supply line drain valve.
10) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
11) Remove the screws securing the upper rear panel, then remove it. See Fig. 8.
12) Remove the clamp securing the reservoir outlet hose to the reservoir. Disconnect the
reservoir outlet hose from the reservoir.
13) Attach a compressed air or carbon dioxide supply to the reservoir outlet hose.
Upper Rear Panel
Fig. 8
Reservoir
Clamp
Reservoir
Outlet
Hose
Overflow Hose
35
14) Plug the appliance back in, then move the control switch to the "DRAIN" position.
15) Blow out the reservoir outlet hose using the compressed air or carbon dioxide supply.
16) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
17) Reconnect the reservoir outlet hose to the reservoir, then secure with the clamp. Make
sure all hoses are connected and secure.
18) Replace the rear panel in its correct position.
19) Clean the storage bin by using a neutral cleaner. Rinse thoroughly after cleaning.
36
VII. Disposal
The appliance contains refrigerant and must be disposed of in accordance with
applicable national, state, and local codes and regulations. Refrigerant must be
recovered by properly certified service personnel.
37
VIII. Technical Information
A. Specification and Performance Data
1. C-80BAJ(-DS)(-AD)(-ADDS)
DATA PENDING
38
B. Wiring Diagrams
1. C-80BAJ(-DS)(-AD)(-ADDS)
39
2. Optional Drain Pump HS-5061
To Icemaker
40
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