Service Manual Commercial Series Refrigerated Kitchen Equipment Models Undercounter Worktop Prep Table hoshizakiamerica.
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.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this booklet carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 5 I.
VII. Technical Information...................................................................................................... 50 A. Electrical and Refrigerant Data.................................................................................... 50 B. Wiring Diagrams........................................................................................................... 51 1a. Undercounter and Worktop: Refrigerator; Cabinet Thermostat............................. 51 1b.
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, continued • The GREEN ground wire in the factory-installed power cord is connected to the appliance. If it becomes necessary to remove or replace the power cord, be sure to connect the power cord's ground wire. • Do not splash, pour, or spray water directly onto or into the appliance. This might cause short circuit, electric shock, corrosion, or failure. • Do not make any alterations to the appliance. Alterations could result in electric shock, injury, fire, or damage to the appliance.
WARNING, continued • All foods should be wrapped in plastic film or stored in sealed containers. Otherwise foods may dry up, pass their smells onto other foods, cause frost to develop, result in poor appliance performance, or increase the likelihood of cross‑contamination. Certain dressings and food ingredients, if not stored in sealed containers, may accelerate corrosion of the evaporator, resulting in failure. • Do not store items near air outlets.
I. Construction and Refrigeration Circuit Diagram A.
B. Refrigeration Circuit Diagram 1.
II. Sequence of Operation and Service Diagnosis The steps in the sequence are as outlined below. See the table for default cabinet temperature control settings. Model Default Cabinet Temperature Approximate Default Temperature Control Setting Undercounter Between 4 and 5 Refrigerator: 34°F (1°C) Worktop Freezer: -5°F (-21°C) Prep Table 6 34°F (1°C) A1. Thermostat Control Sequence of Operation Flow Chart 1.
2. Prep Table Prep Table/Mega Top Sequence Flow Chart 3. Cool Down Achieved CTh above setpoint CTh cools to setpoint CTh in control EvapFM energized (without DH) CTh closed Comp energized ConFM energized EvapFM energized (with DH) CTh open EvapFM energized Comp de-energized ConFM de-energized Legend: Comp-compressor ConFM-condenser fan motor CTh-cabinet thermostat DH-defrost heater DT-defrost timer EvapFM-evaporator fan motor MH-mullion heater PH-perimeter heater 4. Defrost 20 or 25 min.
A2. Thermistor/Control Module Sequence of Operation Flow Chart 1. Undercounter and Work Top: Refrigerator Refrigerator Sequence Flow Chart CTh cools to setpoint CTh above setpoint CTh in control 2-min. Comp Off cycle defrost off timer starts between run cycles Power on Red LED On (5 sec. Delay) * * 2-min.
EvapFM energized Legend: Comp-compressor ConFM-condenser fan motor CTh-cabinet thermistor DH-defrost heater DTh-defrost thermistor EvapFM-evaporator fan motor Power on Red LED On (5 sec. Delay) 3. Cool Down Achieved * Delays * DTh in control Defrost: time/temp. initiated temp. terminated Evap. Temp. reaches 44°F (6.7°C) DH de-energized 6-hr DT starts After DOT Delay: Comp energized ConFM energized After FDD EvapFM energized 44°F (6.7°C) achieved a) 2-min.
Comp energized ConFM energized EvapFM energized MH energized PH energized Comp de-energized ConFM de-energized EvapFM de-energized MH de-energized PH de-energized CTh warms above setpoint 6-hr. or 8-hr. DT terminates Evap. temp. below 41°F (5°C) 5-min. min. DT starts 60-min. max. DT starts DH energized Comp de-energized ConFM de-energized EvapFM de-energized MH de-energized PH de-energized DH de-energized 8-hr.
B1. Thermostat Control Service Diagnosis WARNING • The 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. • Make sure all food zones are clean after the appliance is serviced.
2. Prep Table 1) Unplug the appliance from the electrical outlet. 2) Remove the rear panel. 3) Plug the appliance back into the electrical outlet. 4) Startup/Cool Down–Temperature above setpoint. CTh closed. Comp, ConFM, and EvapFM energize. Diagnosis: Check that Comp, ConFM, and EvapFM energize. If not, confirm that the appliance is not in a defrost cycle. DT is operating properly, temperature is above setpoint, and CTh is closed. Check voltage on DT.
Diagnosis: Defrost Initiation: Manually advance DT cam to terminate DT. Confirm Comp and ConFM de‑energize or remain de-energized and on auxiliary code C-6 and later, confirm EvapFM de-energizes. For CRMR48-xx aux. code C-7 and later and all other aux. code D-8 and later, confirm DH energizes. If not, replace DT. Defrost Termination: Advance DT cam to terminate DT. If CTh closed, confirm Comp and ConFM energize and on auxiliary code C-5 and earlier, confirm EvapFM energizes. For CRMR48-xx aux.
6a) Defrost Early DT's were designed with 8-hr. interval and 20-min. defrost cycle. Later DT's were designed with 6-hr. interval and 25-min. defrost cycle. Manual advance in and out of defrost by turning the defrost dial is quickest way to troubleshoot components. Defrost Initiation: DT terminates. DH energizes. If CTh closed, Comp, ConFM, EvapFM, PH, and MH de-energize. Defrost Termination: DT terminates. DH de-energizes. If CTh closed, Comp, ConFM, EvapFM, PH, and MH energize.
B2. Thermistor/Control Module Service Diagnosis WARNING • The 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. • Appliance is heavy. Use care when lifting or positioning. Work in pairs when needed to prevent injury or damage.
3) Plug the appliance back into the electrical outlet. If appliance was in defrost when power supply was disconnected, defrost is terminated and normal cooling cycle begins when power supply is reconnected. 4) Startup/Cool Down–There is a slight delay (solid red LED for 5 sec., then flashing green LED). Temperature above setpoint at CTh and if applicable, confirm appliance is not in a defrost cycle (PT and Freezers). Comp, CondFM, and EvapFM energize. 2-min. Comp on timer starts.
5) Cool Down Achieved–Temperature cools to setpoint. Comp and ConFM de‑energize. UC/WT Refrigerators and Freezers: EvapFM de-energizes. Prep Table: EvapFM continues. Diagnosis: If temperature setpoint achieved and Comp, ConFM, and EvapFM (except PT models) does not de-energize, check CTh and TD continuity. If CTh or TD is defective, replace. If CTh and TD are good and either the Comp, ConFM, and/or EvapFM (except PT models) continue, or if EvapFM on PT models de‑energizes, replace CM.
Defrost Diagnosis: 1) Manual-Initiation or Time-Initiation: TD rotated to max. position and back or 6-hr. or 8-hr. DT terminates. After rotating TD several times and defrost still not activated, wait 1 to 2 min. and repeat process. Replace TD as needed. (2) CM Diagnosis: Confirm DH energizes (if applicable) and Comp, ConFM, and EvapFM (if applicable) de‑energize. If not, replace CM. (3) Comp and ConFM Diagnosis: Confirm Comp and ConFM de-energize. If not, check for 115VAC at CM 1 (C) (BR) to neutral (W).
C. Defrost Timer Check The defrost timer (DT) starts once the appliance in plugged into the electrical outlet. There are 2 possible interval and defrost cycle times: 8-hr./20min. and 6-hr./25min. 1. Defrost Timer Before replacing a DT that does not show a visible defect and that you suspect is bad, conduct the folowing check procedure. This procedure will help you verify your diagnosis.
D. Control Module Check 1. Control Module Before replacing a CM that does not show a visible defect and that you suspect is bad, conduct the following check procedure. This procedure will help you verify your diagnosis. Always choose a neutral (W) to establish a good power supply and neutral connection to CM: 115VAC at CM 2 (L) (BR) 2. Startup/Cool Down At startup, CM displays a solid red LED for 5 sed. After 5 sec. CM turns red LED off and begins flashing a green LED. This is normal operation.
b) Prep Table: DTh warms to 44°F (6.6°C). DH de-energizes. Confirm continuity of DTh. Replace as needed. If DTh is good and DH continues after DTh achieves 44°F (6.6°C), replace CM. c) Freezer: DTh warms to 45°F (7°C) or 50°F (10°C). DH de-energizes. Confirm continuity of DTh. Replace as needed. If DTh is good and DH continues after DTh achieves 45°F (7°C) or 50°F (10°C), replace CM.
E. Diagnostic Table Before consulting the diagnostic tables, check the following: • Check the cabinet temperature control setting. See the table for default cabinet temperature control settings. Model Default Cabinet Temperature Approximate Default Temperature Control Setting Undercounter Between 4 and 5 Refrigerator: 34°F (1°C) Worktop Freezer: -5°F (-21°C) Prep Table 6 34°F (1°C) • Make sure the doors are not left open or opened too often and that they are sealing properly.
Appliance Not Cooling - Possible Cause 9. Compressor External Protector a) Dirty condenser. b) Condenser fan motor not operating. c) Defective. d) Start relay defective. e) Low charge. f) Start capacitor (if applicable) defective. 10. Compressor a) Defective. 11. Condenser a) Dirty. Evaporator 12. a) Dirty or frozen up. a) Gas leak. 13. Refrigerant/Refrigerant Lines b) Refrigerant lines or components restricted. a) Dirty condenser. 10. High-Pressure Switch (if applicable) b) Ambient temperature too warm.
III. Controls and Adjustments A. Temperature Settings 1. Temperature Reading A thermometer with both °F and °C scales is mounted in the cabinet. See Fig. 1. 2. Cabinet Temperature The appliance features a cabinet temperature control dial (TD). The warmest setting is 1 and the coldest setting is 7. See the table for default cabinet temperature control settings.
2. Prep Table and Freezer Time-Initiated Defrost Cycle: 20-min. or 25-min. defrost cycle once every 8 or 6 hrs. (25/8 or 20/6). Defrost cycle initiation and termination are controlled by the defrost timer or control module and defrost thermistor. Prep Table Refrigerators: The evaporator fan motor remains energized and all other components de-energize during the defrost cycle. Freezers: The defrost heater energizes and all other components de-energize during the defrost cycle.
C. Safety Devices 1. Compressor External or Internal Protector (All Models) If combined temperature/amperage value is above the limit specified by the compressor manufacturer, the compressor protector operates independently to turn off the compressor. The compressor protector de-energizes the compressor until the temperature/amperage value returns to an acceptable level. 2.
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. • To reduce the risk of electric shock, do not touch the plug with damp hands. • Unplug the appliance from the electrical outlet before servicing. • Make sure all food zones in the appliance are clean after the appliance is serviced. A.
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. • Use an electronic leak detector or soap bubbles to check for leaks.
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. See the nameplate for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets the requirements of ARI Standard 700 (latest edition) be used. 6) A liquid charge is recommended when charging an R-134a system.
C. Door Reversal This appliance is provided with a cabinet design which, after being delivered to the installation location, permits changing of the door swing from left to right or right to left. To change the door swing, follow the steps below. Example shows change from right hinged to left hinged. WARNING • Wear eye protection when reversing the doors. • Keep fingers away from edge of upper hinge bracket. Spring cartridge can cause the upper hinge bracket to move suddenly with extreme force.
Upper Hinge Bracket Removal and Spring Cartridge Relocation 7) While preventing the upper hinge bracket from rotating, remove the upper hinge bracket from the spring cartridge. See Fig. 7. Note which side of the upper hinge bracket is facing up. 8) Remove the filler cap, filler screws, and spring cartridge. See Fig. 16. Leave the thrust washers in place on the spring cartridge. NOTICE! Spring cartridge may be difficult to remove. Be careful not to damage the finish. See Fig. 8.
Door Installation 12) Remove the black plastic filler cap located from the hole above where the spring cartridge screw will line up. Note: The black plastic filler cap is not reusable. 13) Remove the upper hinge bracket screws from the new location and apply Loctite Threadlocker Blue 242 or 243 to the threads. Next, start the upper hinge bracket outer screw into the appliance. Rotate a few threads into the appliance; do not tighten the screw. See Fig. 12.
16) Close the door and tighten the upper hinge bracket outer screw. See Fig. 14. Door Fully Closed Upper Hinge Bracket Outer Screw Upper Hinge Bracket Fig. 14 17) Check the door operation to assure it opens and closes properly. Note: Hold door at 45° angle from closed position and release. Door should close on its own. If not, adjust hinge bracket. 18) Unlock the casters and move the appliance back into its original position.
2) Remove the drawers. Pull the drawer out to its fully extended position. Open the safety clips (one on each side) by sliding them forward, then rotating them up. See Fig. 16. Lift up on the handle slightly, then pull to disengage the drawer. Be sure to support the rear and front of the drawer while removing it. WARNING! Be sure to close the safety clips when reinstalling the drawer. Safety Clip Closed Safety Clip Open Safety Clips Drawer Slides Upper Drawer Lower Drawer Fig.
4) Remove the hex-bolts from the 2 right (front and rear) and 2 left (front and rear) brackets (2 hex-bolts per bracket), then remove the right and left drawer frames. See Fig. 18.
Pilaster and Inner Brackets Relocation 5) Remove the shelf from the door section, then remove the pilasters. See Fig. 19. Right Side Pilasters Vertical Mullion Shelf Center Rear Drawer Frame Bracket Vertical Mullion Pilaster Center Rear Pilaster Fig. 19 6) Remove the center rear drawer frame bracket and the filler screw. See Fig. 20. Slide the center rear drawer frame bracket over to the new location and secure it. Place the filler screw in the former center rear drawer frame bracket hole.
8) Place and secure the pilasters and shelf support clips in their new location. See Fig. 22. Replace the shelf. Center Rear Pilaster Left Side Pilasters Center Rear Drawer Frame Bracket Vertical Mullion Bracket Vertical Mullion Pilaster Vertical Mullion Fig. 22 Door Relocation 9) With the door closed, loosen, but do not remove, the upper hinge bracket outer screw. See Fig. 23. Next, open the door to the fully open position and remove the upper hinge bracket inner screw. See Fig. 24.
12) Remove the lower hinge bracket. See Fig. 25. Be sure to leave the thrust washer in place. 13) Install the lower hinge bracket in its new location. Be sure the lower hinge bracket is pushed all the way in and the thrust washer is in its original position. Lower Hinge Bracket Mounting Holes Thrust Washer Thrust Washer Lower Hinge Bracket Lower Hinge Bracket Bolts Fig. 25 Bolts 14) Remove the black plastic filler cap located from the hole above where the spring cartridge screw will line up.
18) Close the door and tighten the upper hinge bracket outer screw. See Fig. 28. Upper Hinge Bracket Door Fully Closed Upper Hinge Bracket Outer Screw Fig. 28 19) Check the door operation to assure it opens and closes properly. Note: Hold door at 45° angle from closed position and release. Door should close on its own. If not, adjust hinge bracket.
22) Place the left drawer frame in the appliance and align under the left rear bracket and tighten, then align under the left front bracket and tighten. See Fig. 30. Note: Be sure the left drawer frame is under both the left rear bracket lip and left front bracket lip. Left Rear Bracket Lip Left Drawer Frame Left Front Bracket Lip Fig. 30 Right Drawer Frame Relocation 23) Place the right rear bracket in place on the right side panel with the hex-bolts removed in step 4.
25) Place the right drawer frame in the appliance and align under the right rear bracket and tighten, then align under the right front bracket and tighten. See Fig. 32. Note: Be sure the right drawer frame is under both the right rear bracket lip and right front bracket lip. Right Rear Bracket Lip Right Drawer Frame Right Front Bracket Lip Fig.
Horizontal Mullion Replacement 26) Place the horizontal mullion in its correct position and secure with screws removed in step 3. 27) Place a bead of food grade silicone down the 2 outside vertical gaps between the mullion and appliance. See Fig. 33. Horizontal Mullion Model Shown: CRMR48-D2 Silicone Location for Horizontal Mullion Silicone Location for Horizontal Mullion Fig.
28) Place the lower drawer in the lower drawer slides and the upper drawer in the upper drawer slides. See Fig. 34. WARNING! Be sure to close the safety clips when reinstalling the drawer. 29) Make sure all gaskets are making good contact. Using a flashlight, check that there are no openings around all gaskets. 30) Unlock the casters and move the appliance back into its original position. Lock the casters once in position, then plug the appliance back into the electrical outlet.
V. Preparing the Appliance for Periods of Non-Use When shutting down the appliance for periods of non-use, follow the instructions below. WARNING Prevent the doors from closing to reduce the risk of children getting trapped. NOTICE Clean the cabinet interior, door gaskets, and shelves. 1) Before shutting down the appliance, move the stored food into another refrigerator or freezer. 2) Unplug the appliance. WARNING! To reduce the risk of electric shock, do not touch the plug with damp hands.
VI. Disposal When disposing of the appliance, follow the instructions below. WARNING Remove the door to reduce the risk of children getting trapped. Leave the shelves in place so that children may not easily climb inside. This 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.
VII. Technical Information A.
CRMR27: DBU for auxiliary code A-5(K) and earlier CRMR27 and CRMR48: Auxiliary Code C-6 and Later B. Wiring Diagrams 1a.
1b.
* 53 300±10 PSIG 190±20 PSIG Cut-Out Cut-In * High-Pressure Switch 2a.
300±10 PSIG 190±20 PSIG Cut-Out Cut-In * High-Pressure Switch 120°F±5°F (49°C±3°C) 70°F±5°F (21°C±3°C) Cut-Out Cut-In * Defrost Thermostat ** * 2b.
Cut-Out Cut-In 120°F±5°F (49°C±3°C) 70°F±5°F (21°C±3°C) Cut-In 190±20 PSIG 300±10 PSIG ** High-Pressure Switch Cut-Out * Defrost Thermostat ** * 2c.
190±20 PSIG Cut-In 120°F±5°F (49°C±3°C) 70°F±5°F (21°C±3°C) Cut-Out Cut-In * Defrost Thermostat 300±10 PSIG Cut-Out ** High-Pressure Switch ** * DBU for auxiliary code A-5(K) and earlier 3a.
70°F±5°F (21°C±3°C) Cut-In 300±10 PSIG 190±20 PSIG Cut-Out Cut-In ** High-Pressure Switch 120°F±5°F (49°C±3°C) Cut-Out * Defrost Thermostat ** * 3b.
