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AJ-64 Series Installation/Operation & Service Manual Part

Contents

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5. nf x uar u I p EL Ik ux 14 gpa 24 NOTE All dimensions are in inches and are for reference only j A i CC H 11 hd f k ri D mor B A x 16 16 13 Y Y Y Y 26 SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS ILL BE OVIDED 27 T TEAM LINE DISHWASHER PRESSURE REGULATOR 10 20 PSI 4 Bl Hey IPT STEAM LINE T STEAM LINE TO STEAM BOOSTER HEATE oS u ELECTRICAL CONNECTION FOR BOOSTE IRE 208 rk a2 TEAM VOLUME REQUIREMENTS i FOR 140 INCUMIP DISHWASHER 1 LI BOOSTER 10 LI T 10 LBS 6 1 BHI ET F 110 INI ATE PI H LI l TER LI
6. pun 98 4 0 179 PAL Cou IE aml 19 ENS 6 98 usiq 9 ee sz 3 6 11e 2 991 59 JU I s 115 n roo_ 2 ET T utuz01 v uwogst foo 4 z kas g wwoest 29 06 zi 01 1 v wwges iz H 8 fuuzeoil e wwe 161 52 52 uwees tez vz misao 6621 81 ejeld Je 02 uj peddius pieius nono eur 2 807 90b 9 x PIM ZOL 92 o age ups OOF 10 AUIS 10014 eseg 9 9 9 021 8 jou lt 94H 29 c x 69 sz d Y 1 md y aes Fe I m Case e dee E EL 1 7 f Pg s Pd 24 9 T f y uugozl 8 9
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8. qni lq lusiq e oqy 4 uu ei we jo dr 1uBieH pue 1 u w g y Jejeeg BUODIIIS esr asl zee F Lv ior pele yey uuszy to1 1deooy qn L JON vo eejje nq eiqejsn pe o enp amp 1 suoisueuip 210 jeuondo LdN uono uuoo Buiquinid O 3 07 L 3 0LL LAN 191 YSeMeld N SUIYOELUYSIP 408 LAN uonoeuuoo 4 0 LAN 1 uonoeuuoo ejesuepuo uonoeuuoo 5 dN f uono uuoo unje1 jesu puoO LdN v 9 uogoeuuoo 5 IN 4 U9A 3 jeuondo 1ejoo uonoeuuoo O uonoeuuoo eou199 3 g 4 07 duiertH 1 08 LAN 1 eutuoey v 1uBrs 01391 21 SPECIFICATION INFORMATION SECTION 1 AJ 100 STEAM RIGHT TO LEFT epis 1619 z 8 25 1 j
9. 7 Aq sepoo p lle1su eq o 4 edid GO t M uonoeuuo SEO v Je1moejnueuJ Aq pepi oud gt euigoeulusip uo uonoeuuoo JORNO 4 081 LAN 1915004 526 210 j9 UI J9J M 4 071 LAN v Jeunjoejnueuu Aq asoy Bunoeuuooieju Jojeeu Jejsooq Buneeu yue 9 asun euy Ue 104 j9 U 4 081 LdN v d pJepuejs 3 jeuondo LAN 2 1 uonoeuuoo O uoieuuoo e24399 3 8 duu9 AO71 4 07 dwe iHq 3 081 19 ul Jeyem v 1uBrs 0 497 13 SPECIFICATION INFORMATION AJ 86 GAS RIGHT TO LEFT SECTION 1 epis 21 8 o 30024 921701 162 ues 01A 3H wg91 o epis 391 7T eal 9 i uuog ve 99 69 5 USIq uuuseo sz a EE H uuisge M jun Y 12 06 1 7 uuges yz
10. V tg 8 vc 9 dn Y 79 e wwigzy 91 1deooy qe 1 pepuewwosey 497 0 UBIY 16 SPECIFICATION INFORMATION SECTION 1 AJ 100 ELECTRIC LEFT TO RIGHT 10014 epis epis uuzgi 9 y 2 For PER 62 77 09029109 i n H i i i 5 EE J Ll K v 2 98 pe SAU 1 ur eA u R _ uuug9sg rL J E JO Jeay F ysejdsyoeg jqeL z 5 usiq OL 9 92 uutu06S 229 3 99 so 6 09 1 8 2 7 J gt EA 61 92 Ca 06 21 17 8
11. 6 9 0 y Y UMOPUIN 229 uutusg xe 2 eDue 4 9 uuzszg rL Beye 1 0 JO dr pue Jejees uoollis esp gel b e Y 8 7 vez dn oDue J ajqey e 1deoov loN Y uuussg p 9 6 p L lq lusiq 1uBIoH ey Wey Jayeay Jojsooq 526 4 0VL LAN v Aq p piAoid esou BunoeuuooJeju Jejeeu Jejsooq B5une u yug 9 esuu Iy UR YSEM JO j9 u 40081 LdN 4 moo 1u A 3 Jeuondo 3u9A 2 1 uonoeuuoo O uonoeuuoo g 4 07 307 3 0 LdN V Buiweiq pue6e1 juBr 01 427 SPECIFICATION INFORMATION AJ 64 GAS RIGHT TO LEFT SECTION 1
12. pue equ 988 4 07 duiej IH ee y sjees euooeesn 3 081 LAN 1 lu v NS 01 d 4 zi 2 X983 1 uuszr g unus Ly 79 IIM e3oN 11 13 SPECIFICATION INFORMATION AJ 86 GAS LEFT TO RIGHT SECTION 1 epis N IA 30014 apis 391 uugiz 6 2 9 4 0 ez 100291 9 rr x Ht ij 1 3 uwor fs j d EE i 1 14 b d 98 pe wun luueeeg fee AUC lysnosy Yun i 1 r 9 H deis
13. utug6z L L t7 wwzzz 8 uuuzsg rt uue9 0 sowy YM A Xen v ceBue 4 eBexyeo 1uo eld y 1 8 91 9 uuo Uuollo09S ww ees 12 o dq siqeyysiq e oqv CA 4 uw 6p e pue us weg N gt Jejeeg uool is esf U3 y 1 i 229 gt 91 8 2 YZ 0 dn e 9 1deooy IM 9oN uoneo2nqe J n ii pun M e Aud h Sulyoe jo z lt 4 l 1 luusz v 9 99 uedo 2 78 o enp 2 1 9 ON jeuondo LdN uono uuoo Buiquunid W d 0t L 4044 LAN t 1 43 PA 1 5 Aq sepoo eq o enj4 uonoeuuoo edid GO v M uogoeuuo SED IdN b e f Jeunjejnueu Aq pepi oJd esou uono uuoo
14. lq lusiq e oqy y 498 ajqe gt 919 ug uuu6g s uus 161 67 19400 peddius 5 Buoj 90v 9 X p m ZOL uedo uut Lc 99 enp 10044 WO Z suoisueulip E9n18A V 930N pJepuejs U9A 3 Ieuondo Jejoo LdN Z 4 uonoeuuoo 5 uonoeuuoo g 4 071 duu IH 408 LAN IU 1972M V 08 m wuugzg W ZL ubnoJ lqe1 des 9029 9 r uuoe 8 S 4 _ 9 sz g V dex LZ pp 7 22 UJnuututA wwgge p Buimesq 1 0 497 SPECIFICATION INFORMATION SECTION 1 AJ 64 ELECTRIC RIGHT TO LEFT
15. uwzoe dun 3 utuz0 L L uueesg iz 90219 T l uugss 2 3 uuuz69 99 863 ec L 9 sz l 609 u do 5 eur 97 6621202 wwggez 6 2 98 ww LoL eje d 1 AoO peddius 45 use dS IAOoO ul Buo wwyEeLz 8 pun eseg 10 AUIS 10014 mero 90 m 201 11 rh 3994 1ejnq qe sn pe enp JOO WOJ 2 1 SUOISUSLUIP EIA V 210 PT 9 92 O uwggs iz mi Jia Jeuondo t g uonoeuuoo Buiquunjd 9 7 3 0tL 3 0LL 2 Z 2 LAN Ysemald 4 pJepuejs U9A 3 7 uusse v jeuondo 1u A 8 9 6 9 t L Z uonoeuuoo 9 Y 2d E Y 6 e eec 12 XE oe 93004 o auryoew jo dri ant aY uogoeuuoo g je1souueu JOE M pIO2
16. V 6 1 Is zeg T i 8 vz o dn 1uBr4 01 1197 4 SSE e 79 d qn 9 ON 91 17 SPECIFICATION INFORMATION SECTION 1 AJ 100 ELECTRIC RIGHT TO LEFT epis 1uBiu 10019 opis 9 0 9 i 0 166 uui 1z 8 2 921 01 9 I h n n 1 1 h n Ti ct o ul Im F uwp9g 0 411 79 eAud P JO _ _ wwogst 09 999 9 5 usiq 9 9 4 Y wwz0 i wwggg iz uuusg9 se lt wwo6st 229 2 20 902 8 669 gz ww 19 vz unuzoi 8 260 16 29 uuL61 52 6
17. e 14 H 49 1d oov IIM 41129105 lqe1 SPECIFICATION INFORMATION SECTION 1 AJ 64 STEAM RIGHT TO LEFT 1u0J apis piS H IA 19014 PIS 997 mr luwug z rg 216 v Z m luwus OL L4 e uueeg pem wwgg1 a ez P i m i i Ti I mh 2 Yun Auq Es 98 pe 4 N AHGQ LM 3 e Jo uug6011 g b wig a Foo 99 269 L i s Y i al i f uuiz0 i g 1229 1 unugoz 8 91 99 T 9
18. 1deooy IIM GN JON Y lq lusiq e oqy 1uBi H oes Y duiej Mo7 J 0r L duiej 4H jeuondo LdN uonoeuuoo IN 3 0 1 5 01 LAN v 19 UI 7 Aq sepoo e20 eq enjj uornoeuuoo edid GO M uognoeuuo SEO v Jenjoejnueui Aq pepi oud uono uuoo euigoeulusip uo uogoeuuoo JejeM 4 081 LAN H 1ejsooq 526 10 49 M 4 0tL LAN v 9 Aq esou BunoeuuooiJeju 1ejsooq 526 Buneeu g asuu euy YU usen JO j9 U 93 M 408 LAN 4 pJepuejs 3 jeuondo 1u A 1 uonoeuuoo 5 uonoeuuoo g 40L L LAN v 1uBr4 0 497 l q 1 papuswwosey 19 SPECIFICATION INFORMATION SECTION 1 AJ 100 GAS RIGHT TO LEFT epis uuigiz tg9 ugs 34014 9 01 6 62 4 uus 0 o epis 7 wes 9 i
19. UO ul uonoeuuoo Jenno 408 LAN H 1ejsooq seb 10 U 98 M 4 0tL LAN v younjoejnuew Aq Jejeeu 19 S00q 526 yue asun jeu Iy Xue YSEM 10 j9 u 49J M 4081 LAN v 4 mo9 3 jeuondo uonoeuuoo O uonoeuuoo g 4 07 dOP 401 LAN 8U V Buiweiq ye o11u8n4 20 SPECIFICATION INFORMATION SECTION 1 AJ 100 STEAM LEFT TO RIGHT wu y o 1901 apis 1 rluuuoor fei IA Y 3 z p S 191 21 o 19 ez i 9 921 for 1 251 9 i l d n 7 Cquxtussz o 5 Ee BAL Yun N do 4
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22. i t Jejees SUODIIIS esf a E 8 vz o dn ma A N gt ES e 1deooy IIIAA JoN PE Eg uoneouqeJ uupeyz vg ejqeisn pe enp 10044 Woy aZ L suoisueuip JON jeuondo LdN uonoeuuoo Buiquunjd 1 O 3 07 173 01 LAN u P E 1 lu N 4 081 LAN w e N uonoeuuoo 4 0 LAN v 1 uonoeuuoo ejesuepuo 2 M uonoeuuoo LdN uonoeuuoo H ejesuepuo2 IdN v 9 uonoeuuoo 5 v 3 MO9 ju9A 3 Jeuondo 1ejoo 1u A ALAN uonoeuuoo uleq 9 uono uuoo g 4 2 08 LdN 1 lu V 14674 01 497 15 SPECIFICATION INFORMATION SECTION 1 AJ 86 STEAM RIGHT TO LEFT uui 29
23. 6L pue Side uornoeuuoo g Jejees uool is 955 Y 4 duu l IH 229 x 5 081 LAN ub 1 lu V 8 2 9 dn 4 e 1deooy IIIA JoN 4 497 o 14614 10 SPECIFICATION INFORMATION SECTION 1 AJ 86 ELECTRIC LEFT TO RIGHT epis U014 apis 4 8 9 01 17 6 uiuzsi 9 9 For 3 1 H 1 1 Th J yun 2 pe lunos A deos ud 1 250 vun uwose jp 77 L ysejdsyoeg eoueles D usiq u6tH OL 2 S 9991 G9 2 woes 09 L lt 2 2 9 x 2 7 m Lar fal ues 55 T 4 e 6 557
24. Water flow pressure is too high Follow the instructions provided in the maintenance section and adjust so that the flow pres sure is 20 5 PSI 10 Heat exchanger is clogged Replace the heat exchanger 11 Insufficient volume of steam to unit Check the line size and flow pressure PN 52
25. To connect the incoming power run the conduit for power wires through the open k hole in the back of the control box Connect the power wires to the terminal block as it is labeled 11 and L2 Run the ground wire to the grounding lug marked GND Tight connections and conduit nuts close the control box by putting the cover on and securing with the 10 32 screws T OPERATION gt WARNING heat exchanger used the D226 Booster system is pres g sure vessel with very precise operating parameters Safety equipment such as 5 r relief valves should never be tampered with or disabled These devices are meant to protect the equipment and the operator from harm damage and death D226 Conrtol Box 1 Ensure that water steam and any condensate drains are connected to the booster 2 Start the water flow first open the condensate drains and then begin steam flow 3 On the control box press the power switch and put it in the ON position The power light should illuminate The unit should run normally now A WARNING Do not shock the system by applying the steam before the water This can cause damage to the booster The following explanation describes the operation of the D226 Booster NOTE This explanation assumes that water and steam have been connected to the machine 1 When the power switch S1 is placed in the ON position power is provided to both the power light E1 and th
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31. 146 SECTION 1 SPECIFICATION INFORMATION SECTION 1 SPECIFICATION INFORMATION OPERATING CHARACTERISTICS RACKS PER HOUR AJ 64 86 100CE CS CGP DISHES OR GLASSES PER HOUR AJ 64 86 100CE CS CGP PREWASH TANK CAPACITY GALLONS AJ 86CE CS CGP AJ 100CE CS CGP WASH TANK CAPACITY GALLONS AJ 64 86 100CE CS CGP POWER RINSE TANK CAPACITY GALLONS AJ 86CE CS CGP AJ 100CE CS CGP PREWASH PUMP CAPACITY GPM AJ 86CE CS CGP AJ 100CE CS CGP WASH PUMP CAPACITY GALLONS PER MINUTE ALL MODELS POWER RINSE PUMP CAPACITY GALLONS PER MINUTE ALL MODELS VENTING REQUIREMENTS CFM 100 CAP INPUT END OUTPUT END TOTAL CONVEYOR SPEED FPM AJ 64 86 100CE CS CGP MACHINES GALLONS PER RACK AJ 64 86 100CE CS CGP MACHINES WATER TEMPERATURES AJ 64 86 100CE CS CGP MODELS WASH MINIMUM POWER RINSE MINIMUM FINAL RINSE MINIMUM FLOW PRESSURE PSI 287 7200 16 16 15 4 15 4 15 4 120 270 270 270 200 400 600 8 0 77 150 160 180 FLOWRATE GPM AJ 64 86 100CE CS CGP 3 7 STEAM COIL TANK HEAT CS MODELS ONLY STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG Ibs hr AJ 64 86 100CS CSL 100 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 WASH MOTOR HP 2 POWER RINSE MOTOR HP 2 PREWASH MOTOR HP AJ 86 MODELS 1 AJ 100 MODELS 2 NOTE Typical Electrical Circuit is based upon 1 125 of the full amperage l
32. D226 STEAM BOOSTER PARAMETERS AJ 100CE MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 148A 200 AMP 230 1 60 136A 175 AMP 208 3 60 88A 110 AMP 230 3 60 81A 110 460 3 60 41A 60AMP AJ 100CGP MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 28A 230 1 60 28 208 3 60 19A 25 230 3 60 19A 25 460 3 60 10A 15AMP AJ 100CS MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 28A 35 AMP 230 1 60 28A 35 AMP 208 3 60 18 25 230 3 60 18 25 460 3 60 9A 15 AMP NOTE Always refer to the machine data plate for specific electrical and water requirements The material provided on this page is for reference only and may be subject to change without notice D226 STEAM BOOSTER ELECTRICAL REQUIREMENTS VOLTAGE V 208 230 FREQUENCY HZ 60 PHASE SINGLE WATER REQUIREMENTS INCOMING WATER TEMPERATURE MINIMUM 110 F FLOW PRESSURE PSI 20 5 STEAM REQUIREMENTS INCOMING STEAM PRESSURE PSIG 15 25 HEAT EXCHANGER SPECIFICATIONS TUBESIDE WORKING PRESSURE PSI 125 SHELLSIDE WORKING PRESSURE PSI 125 TUBESIDE HYDROSTATIC TEST PRESSURE PSI 250 SHELLSIDE HYDROSTATIC TEST PRESSURE PSI 188 MAXIMUM OPERATING TEMPERATURE 295 F MAXIMUM SHELLSIDE STEAM PRESSURE PSI 125 ndicates typical design criteria but is subject to change without notice For more information contact you authorized Jackson service represe
33. LBS TOT LH LUMBER TH CONNECT ALL CONDENSATE RETURNS TO EITHER DRAI OR CONDENSATE RETURN LINE T INSE TANI T UNDENSATE ETI TEAM KET TRA l KSO Steam Booster Piping Double Tank Machine Water Water Gas Inlet PA Outlet Inlet J RIGHT SIDE VIEW Water Outlet Water Inlet Gas Inlet sit S SECTION 1 SPECIFICATION INFORMATION TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS Electric Booster Dimensions Typical lt 18 gt lt 30 1 2 gt B aat 24 gt e a OUTLET 34 NPT Coupling for 18 Temperature Pressure 2 7 78 21 4 mel ay 4 42 Relief Valve 57 mm 83 mm INLET 2 1 6 z Electical ti L U ectical connection 6 from side below SIDE VIEW REAR VIEW 36 gt 20 3 4 ____ A A Alternate TPRV Location Electrical Electrical 25 1 8 Water Outlet G Water Wat 31 1 4 Inlet Outlet Inlet Water Inlet x Gas Inlet ET LEFT SIDE VIEW FRONT VIEW Gas Booster Dimensions Typical Alt t as Flue o 4
34. amp Maintenance Factory filling WINSMITH speed reducers are oil filled at the factory to the proper level for the standard mounting position that you will find it in on the unit The oil level should be checked and adjusted if necessary prior to operation using the oil level plug provided and while the unit is oriented in its operating position Ambient temperature If the operating ambient temperature is other than 51 95 F then refer to the lubrication chart and refill the unit with the correct grade based on actual ambient temperature and operating speed See Oil changing below for additional information Oil changing When changing the oil for any reason it should be remembered that oils of various types may not be compatible Therefore when changing to a different oil it is recommended that the housing be completely drained and thoroughly flushed with a light flushing oil prior to refilling with the appropriate lubricant The oil level should be rechecked after a short period of operation and adjusted if necessary When changing double reduction models each housing should be drained and filled independently even though there may be a common level Initial oil change The new oil in a speed reducer should be changed at the end of 250 hours of operation This is equivalent to 30 days of peration for 8 hours per day 15 days of operation for 16 hours per day or 10 days of operation for 24 hours per day Subsequent oil changes U
35. e20 eq 9 sz 1 T enj4 uonoeuuoo edid GO M uuuses LZ i i uono uuoO 529 LAN v om MEN Jenjoejnueui elle um I Aq pepi oud esou ar i UO 7 7 JANOS 19EM 4208 LdN v H j 4 Jayeay 19 500 seb 19 715 al uugez L L 10 1 u J93eM 4 07 LdN v 9 wget EZ wwzzz 8 Jeu ejnueui Aq 7 kasi sou Buno uuoo1 lul 1 91e u 1915004 106 Buneeu yug 9 esuu jeuy YSEM lul J9 M 4081 v d T I Xe v c WEN 91 G 9 ua 3 12 lqe 1 1 jo ani aiqeys q e oqv jeuondo 1ejoo jueA q 61 pue lqe 1 u w g 1819H yoRY i 1 le S uoollIS esr LAN 2 11 uonoeuuoo 9 ME uonoeuuoo e2u199 3 g 229 y duu91 AO1 40 duey IH 48 4 ve dn L A071 4 0L LLAN 31 J9 eM BUIN V 4 qe 1 e 1deooy IIM 93oN uoneonqe J Buiweiq ye 0 14614 SPECIFICATION INFORMATION SECTION 1 AJ 64 STEAM LEFT TO RIGHT Le 9
36. you may put another rack in OPERATIONAL INSPECTION Based upon usage the pan strainer may become clogged with soil and debris as the workday progresses Operators should regularly inspect the pan strainer to ensure it has not become clogged If the strainer does become clogged it will reduce the washing capability of the machine Instruct operators to clean out the pan strainer at regu lar intervals or as required by work load SHUTDOWN AND CLEANING At the end of the workday remove the pan strainer and clean as required Wipe out the inside of the Side Loader and then reinsert the strainer 35 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION amp OPERATION INSTRUCTIONS CONCEALED DAMAGE OR MISSING PARTS A IMPORTANT FOR YOUR PROTECTION PLEASE READ AND OBSERVE THE FOLLOWING This steam booster has been thoroughly inspected and carefully packed before leaving our warehouse Concealed loss or damage means loss or damage which does not become apparent until the booster has been unpacked The contents may be damaged in transit due to rough handling even though the carton may not show external damage If it is found that the shipment has concealed damage PLEASE DO NOT RETURN IT TO JACKSON but notify the carrier within 48 hours asking them to send their agent to fill out an inspection report Save the cartons so he may inspect them and be sure to note in the report any black marks creases tears crush
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38. 15 20 25 30 40 50 60 80 100 920 0 347 0 263 0225 0 216 0202 0 191 0 215 0 200 0 188 0 182 0 164 0 161 Lubricant selections are provided by the lubricant manufacturer based on AGMA recommeded viscosity grades Viscosity grades are based on Lubrication Standard ANSI AGMA 9005 D94 48 SECTION 4 TROUBLESHOOTING SECTION SECTION 4 TROUBLESHOOTING COMMON PROBLEMS sonnel Certain procedures in this section require electrical tests or measurements while power is applied to the machine Exercise extreme caution at all times If test points are not easily accessible disconnect power attach test equipment and reapply power to test When replacing electrical parts disconnect power at source circuit breaker WARNING Inspection testing and repair of electrical equipment should be performed only by qualified service per Problem Nothing on dishmachine operates The power switch is ON and the power indicator light is OFF 1 Machine is not wired correctly to incoming power source Have an electrician verify wiring 2 Machine circuit breaker is tripped Reset the circuit breaker If it trips again contact an electrician to verify the machine amp draw 3 Service breaker is tripped Reset the service breaker If it trips again contact an electrician to verify the machine amp draw Problem Machine will not fill The power switch is ON and the power indicator light is ON 1 No water supply to machine Verify that water lines
39. DE OX or another similar anti oxidation agent be used on all power connections Terminal Block VOLTAGE CHECK Ensure that the power switch is in the OFF position and apply power to the dishmachine Check the incom ing power at the terminal block and ensure it corresponds to the voltage listed on the data plate If not contact a qualified service agency to examine the problem Do not run the dishmachine if the voltage is too high or too low Shut off the service breaker and mark it as being for the dishmachine Advise all proper per Incoming Power Connection sonnel of any problems and of the location of the service break er Replace the control box cover and tighten down the screws VENTILATION OF DISHMACHINE The dishmachine should be located with provisions for venting into an adequate exhaust hood or ventilation system This is essential to permit efficient removal of the condensation exhaust Ensure that the exhaust System is acceptable in accordance with all applicable codes and standards NOTE Any damage that is caused by steam or moisture due to improper ventilation is NOT covered under the war ranty This units covered in this manual have the following exhaust requirements Load End 200 CFM Unload End 400 CFM The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to 31 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED ELE
40. L unit with a side loader option Updated scrap basket drawings Vent cowl assembly for a hooded side loader Service instructions for replacing wash rinse motors Added prison pawl bar packages Thermostat replacement kits updated drain quench assembly replaced wash thermostat 05930 121 67 72 with 05930 003 13 65 Heater replacment instructions Updated steam booster schematic Rinse fill motor assembly Wash rinse amp PSI decals Update door assembly num bers Drain quench kit 7898 Added 09905 003 32 20 fan load decal Updated dimensions page Removed alternate table limit switch es 8044 Changed the part from a weldment 05700 021 67 50 to a casting 09515 003 58 12 QOF NDB 219 Updated Manufacturer information Updated Jackson Logo Updated temperatures on pg s 7 8 13 14 19 and 20 Updated drawing on pg 39 NON Updated rack rail assembly on pg 97 7572 7730 7634 7743 7428 7571 7554 7475 7463 7462 7367 7789 02 06 2014 10 06 2015 NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Jackson AJ 64CS AJ series of rack conveyors 64 64 wide machine 86 86 wide machine 100 100 wide machine CE Electrically heated hot water sanitizing machine CS Steam heated hot water sanitizing machine CGP Gas heated hot water sanitizing machine Model Jackson WWS INC provides technical support for all of the dishmachines detailed in this manual We Serial No strongly recomm
41. Models AJ 64 Series Drain Plumbing Assemblies AJ 86 amp AJ 100 Drain Plumbing Assemblies Left to Right AJ 86 amp AJ 100 Drain Plumbing Assemblies Right to Left Drain Quench Assembly Prewash amp Wash Motor Assemblies Prewash amp Wash Pump Weldments Prewash amp Upper Wash Arm Assemblies Lower Wash Arm Assembly Upper amp Lower Power Rinse Arm Assemblies Final Rinse Assembly Drive Assembly Door Assemblies Pawl Bar Roller Bracket AJ 64 amp AJ 86 Pawl Bar Assemblies AJ 64 Rack Rail Assembly Miscellaneous Parts amp Weldments Manifolds Strainer Support Weldments Strainers Float Switch Components Scrap Basket Assembly Curtains Tub Magnets Vent Cowl Assembly Vent Scoop Option Exhaust Fan Control Option Table Limit Switch Options SIDE LOADER SECTION Side Loader Track Assembly Leg Replacements Side LoaderPawl Bar Assemblies Side Loader Vent Cowl Option D226 STEAM BOOSTER SECTION Control Box Assembly Plumbing Assembly Go Box Components Rinse Fill Motor Option vi 54 56 58 59 60 62 63 64 66 67 68 69 70 71 72 74 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 111 112 Vil VIII TABLE OF CONTENTS ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS AJ 64CE 208 230 Volt 60 Hz 1 Phase Primary Side 208 230 Volt 60 Hz 1 Phase Secondary Side 208 230 Volt 60 Hz 3 Phase Primary Side 208 230 Volt 60 Hz 3 Ph
42. amp OPERATION INSTRUCTIONS Installation Instructions Deliming Operations Curtain Installation Diagram Side Loader Installation amp Operation Instructions D226 Steam Booster Installation amp Operation Instructions Gas Conveyor Hose Installation Dishmachine Operating Instructions Detergent Control Striker Plate Limit Switch Installation Instructions PREVENTATIVE MAINTENANCE General Maintenance D226 Maintenance Lubrication Chart for Drive Gear Drive Motor Gear Reducer Preventative Maintenance TROUBLESHOOTING SECTION Common Problems D226 Common Problems 30 33 34 35 36 38 40 42 43 45 46 47 48 50 52 TABLE OF CONTENTS VI PARTS PARTS SECTION AJ 64 Control Box Assembly AJ 86 AJ 100 Control Box Assembly Motor Overload Chart Heater Box Assembly Heater Assembly Frame Weldments Front Dress Panels Prewash Plumbing Assembly Incoming Plumbing Assembly Rinse Header Plumbing Assembly CGP Models External Electric Booster Option Incoming Plumbing External Electric Booster Option Outlet Plumbing WPRK Plumbing Option 3 4 Solenoid Valve amp 3 4 NPT Vacuum Breaker Repair Parts Kits Steam Unit Wash Tank Coil Assembly Steam Inlet Plumbing Left to Right Steam Inlet Plumbing Right to Left Steam Outlet Plumbing Left to Right Steam Outlet Plumbing Right to Left Gas Coil Assembly CGP Models Rinse Booster Tank Assembly CGP Models Recirculating Pump Assembly CGP Models Hose Connections CGP
43. end of every workday as per the instructions in the manual 10 Always contact Jackson whenever a serious problem arises 11 Follow all safety procedures whether listed in this manual or put forth by local state or national codes regulations O 45 SECTION 3 PREVENTATIVE MAINTENANCE Y D226 MAINTENANCE WARNING Maintenance should only be performed by authorized service personnel in order to ensure safe and effective workmanship while minimizing danger to operating personnel The D226 Steam Booster is designed to operate at temperatures capable of causing burns to personnel Always allow the unit to cool down to an accept able temperature prior to performing any maintenance Very little maintenance is required to be performed on the D226 Booster So long as the steam and water used with the unit have the proper filtration and are operated at the correct temperature and pressures then you should expect many years of reliable service out of your system MAINTENANCE OF THE WATER PRESSURE REGULATOR Incoming water pressure can be regulated by adjusting the water pressure regulator on the system In order to adjust pressure loosen the top nut on the regulator This will allow you to turn the adjusting screw Turn the adjusting screw clockwise to increase pressure and counter clockwise to decrease Pressure can be read on the pressure gauge located on the water out let side of the heat exchanger Once th
44. fees such as those for air or boat travel without prior authorization WARRANTY REGISTRATION CARD The warranty registration card supplied with the machine must be returned to Jackson WWS within 30 days to validate the warranty REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the factory which ever occurs first PRODUCT CHANGES AND UPDATES Jackson WWS reserves the right to make changes in design and specification of any equipment as engineering or necessity requires THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON WWS JACKSON S LIABILITY ON ANY CLAIM OF ANY KIND INCLUDING NEGLIGENCE WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER SHALL IN NO CASE EXCEED THE PRICE OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING FOR FITNESS OR MERCHANTABILITY THAT ARE NOT SET FORTH HEREIN OR THAT EXTEND BEYOND THE DURATION HEREOF UNDER NO CIRCUMSTANCES WILL JACKSON WWS BE LIABLE FOR ANY LOSS OR DAMAGE DIRECT OR CONSEQUENTIAL OR FOR THE DAMAGES IN THE NATURE OF PENALTIES ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS ITEMS NOT COVERED This warranty does not cover cleaning or deliming of the unit or any component such as but not limited to wash arms rinse arms or strain ers at anytime Nor does it cover adjustments such as but not l
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46. low of pressure results in too little water To adust the regulator loosen the nut at the top this will allow you to screw or unscrew the adjustment With a screwdriver turn the adjuster clockwise to increase pressure or counter clock wise to decrease it Do not confuse static pressure with flow pressure Static pressure is the line pressure in a no flow condition all valves and services are closed Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle It is also recommended that a shock absorber not supplied be installed in the incoming water line This prevents line hammer hydraulic shock induced by the solenoid valve as it operates from causing damage to the equipment 30 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED STEAM LINE CONNECTIONS Some machines covered in this manual are designed to use low pressure steam as a source of heat for wash tank water The machines come with lines by which outside source steam needs to be connected Connect all incoming steam lines in accordance with the steam booster manufacturer s instructions Ensure that all applicable codes and regulations are adhered to See machine data plate for information concerning steam flow pressure GAS CONNECTIONS Some machines covered in this manual are designed to use gas as an outside source of heat for wash tank water The machines come with connections by which an out
47. period of time either prior to installation or during use it is recommended that the unit be filled completely with oil to protect interior parts from rust and corrosion due to internal condensation Be sure to drain the oil to the proper level before placing the speed reducer in service Grease fittings Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash These fittings must be lubricated every 3 6 months depending on operating conditions bearing greases must be compatible with the type of gear lubricant being used i e mineral synthetic food grade etc For mineral oils use a high quality lithium base NLGOI 2 bearing grease For synthetic oils use a synthetic bearing grease such as Mobil Synthetic Universal gease Mobilith SHC 100 or a sutable equivalent For food grade lubricants use Chevron FM grease NGLI 2 or equivalent Low input speeds under 1600 RPM When input speeds are less than 1600 RPM grease fittings will be required to lubri cate any bearings not partially covered by the normal oil level Oil temperature Speed reducers in normal operation can generate temperatures up to 200 F depending on the type of reduc er and the severity of the application 9loading duration of service ambient temperatures Excessive oil temperatures may be the result of several factors including overloading overfilling underfilling or inadequate cooling Nominal Ratio Size 5 7 5 10
48. the dishmachine under a variety of conditions along with good training in the operation of the machine can go a long way in ensuring your dishmachine operates as effi ciently as possible Certain dishmachine models require that chemicals be provided for proper operation and sanitization Some models even require the installation of third party chemical feeders to introduce those chemicals to the machine Jackson does not recom mend or endorse any brand name of chemicals or chemical dispensing equipment Contact your local chemical distributor for questions concerning these subjects Some dishmachines come equipped with integral solid detergent dispensers These dispensers are designed to accommodate detergents in a certain sized container If you have such a unit remember to explain this to your chemical distributor upon first contacting them As explained before water temperature is an important factor in ensuring that your dishmachine functions properly The data plate located on each unit details what the minimum temperatures must be for either the incoming water supply the wash tank and the rinse tank depending on what model of dishmachine you have installed These temperatures may also be followed by temperatures that Jackson recommends to ensure the highest performance from you dishmachine However if the minimum requirements are not met the chances are your dishes will not be clean or sanitized Remember a dish can look clean but it ma
49. 1 LdN v d piepuejs MO9 1U9A 3 jeuondo 1u A uonoeuuoo ueq O uonoeuuoo g dui8j MO7 4 duu l IH A OVL 3 011 IPU OUYN V Bulmeig 437 o1 10614 14 SPECIFICATION INFORMATION SECTION 1 AJ 86 STEAM LEFT TO RIGHT uwz o epis 110443 epis 437 2 uuug z tg9 wwg6z LL __ 2 21 2 i 50 6 9 lt uwzs1 2 for 2549 i i i 1 5 i 1 i iii 1 L L uuussz 01 uun 98 ve n I luueegl ze 2 SAU yenos un M 4 2 21 deis enu Jo 1693 uiui use v i _ 1 wwz60oL ev yse dsyoeg i n z 99UEJE9 2 USIq 3 OL wwg 9 sz 229 e 99 1 9 tc d 2 4 H I l
50. 102 mm TPRV Location Vent Adapter y REAR VIEW 28 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS NOTE THE INSTRUCTIONS PROVIDED HEREIN UNLESS OTHERWISE SPECIFIED ARE FOR THE DISHMA CHINES ONLY THERE ARE SEPARATE DIRECTIONS FOR THE GAS BOOSTER VISUAL INSPECTION Before installing the unit check the container and machine for damage A damaged container is an indi cator that there may be some damage to the machine If there is damage to both the container and machine do not throw away the container The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new undam aged condition However rough handling by carriers or others may result in damage to the unit while in transit If such a situ ation occurs do not return the unit to Jackson instead contact the carrier and ask them to send a representative to the site to inspect the damage to the unit and to complete an inspection report You must contact the carrier within 48 hours of receiving the machine Also contact the dealer through which you purchased the unit UNPACKING THE DISHMACHINE The machine should be unboxed and removed from shipping pallet prior to being installed Open the front door and remove all of the packing materials Once unpacked ensure that there are no missing parts from the machine This may n
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52. 4 5 u A 3 jeuondo 2 uonoeuuoo ure4q O uornoeuuoo e2ujoe a g 4 071 3 081 LAN v 1 lu eutuoelw v ye 0 1uBr 18 SPECIFICATION INFORMATION SECTION 1 LEFT TO RIGHT AJ 100 GAS 39014 PIS 3401H epis ye1 uugizifg 09 Bass 9 AD uY 19 II A 1 TT l d 111 69 T pun 98 wweeg vee 9 SAU Hun 9 H deis e uq rL t JO y ues 9 6195 A IL useidepeg 12 91 292 ME is 5 OL wwg6 Fre N usiq 991 9 sz 29 too ya nj 7 1 12 r wwogst 29 lt v 5 a duuzoi y unug 61 fz uusz 0 zi 0218 1 999 159 uueeg iz Zee unug6s fez uuze91 99 uuseo se 609 7
53. 621 SLL eur unululw 2 80 92 n eiae 001L JO AUIS JOO 4 6106 5 un eseg 9 0 021 94 i eas IZ Sar H 8 B 2 A n 7 f Z jejsouueu UNA Xe t g 4 eBeyeeqjuanald y 91 9 9 ees 12 dq qnL lq usiq e oqv ue d useweJgd uwopuun L 61 pue lqe1 u w g 1uBieH oes Y j uus 79 uuszr lg 1 e s esf Meo zeg 4 C 1 8 2 vc o1 oDue J 10 00 qn L JON lqe 1 2 7 3 L 69 99 uedo siooq ue 21 v9 ejqeisnfpe o 1004 Z JEA Iv 210 jeuondo LdN uonoeuuoo Buiquunid 9 01 1 LAN v 1 lu
54. AJ 64 SERIES RACK CONVEYOR DISHMACHINE INSTALLATION OPERATION amp TECHNICAL MANUAL FOR JACKSON MODELS AJ 64CE AJ 86CE AJ 100CE AJ 64CS AJ 86CGP AJ 100 CGP AJ 64CGP AJ 86CS AND ASSOCIATED OPTION PACKAGES INCLUDING SIDE LOADER D226 EXTERNAL STEAM BOOSTER Jackson Warewashing Systems Jackson WWS INC P O Box 1060 Barbourville KY 40906 606 523 9795 October 06 2015 Fax 606 523 9196 P N 7610 002 30 93 Revision K www jacksonwws com MANUFACTURERS WARRANTY ONE YEAR LIMITED PARTS amp LABOR WARRANTY ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP UNDER NORMAL USE AND OPERATION FOR A PERIOD OF 1 ONE YEAR FROM THE DATE OF PURCHASE BUT IN NO EVENT TO EXCEED 18 EIGHTEEN MONTHS FROM THE DATE OF SHIPMENT FROM THE FACTORY Jackson WWS agrees under this warranty to repair or replace at its discretion any original part which fails under normal use due to faulty material or workmanship during the warranty period providing the equipment has been unaltered and has been properly installed main tained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to the authorized service agency within the warranty period This includes the use of factory specified genuine replacement parts purchased directly from a Jackson authorized parts distributor or servi
55. CTRIC HEAT The thermostats for the machines covered in this manual are factory set They should not be adjusted except by an authorized service agent CHEMICAL FEEDER EQUIPMENT Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting Remove the bulkhead plug in the side of the tub to install the deter gent concentration probe For more information concerning detergent concerns please refer to the page entitled Detergent Control Detergent Connection Point Machine rear view Brass Plug 1 8 brass plugs on the incoming plumbing rinse injector may be removed to install rinse aid injection fittings Brass Plugs All wires for the chemical injectors should be routed through one of the extra openings in the back of the control box Terminals in the control box marked CVS provide a constant voltage signal whenever the 4 drive motor is operating Dot B Terminals the control box marked DET provide a voltage signal whenever the wash motor 3 lis operating Connection Points 32 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DELIMING OPERATIONS DELIMING OPERATIONS In order to maintain the dishmachine at its optimum performance level it will be required to remove lime and corrosion deposits on a frequent basis A deliming solution shoul
56. ION Based upon usage the pan strainers may become clogged with soil and debris as the work day progresses Operators should regularly inspect the pan strainers to ensure they have not become clogged If the strainers do they will reduce the washing capability of the machine Instruct operators to clean out the pan strainers at regular intervals or as required by work load NOTE On units equipped with prewash sections AJ 86 and AJ 100 operators should also take the time to inspect the pre wash section strainers and clean them as required by workload SHUTDOWN AND CLEANING ELECTRICALLY HEATED MODELS At the end of the workday place the power switch in the OFF position and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap bas ket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstruc tions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rinse tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the inside of the unit and then reassemble with the components previously removed 40 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATION INSTRUCTIONS CONTINUED SHUTDOWN AND CLEANING
57. N 4 TROUBLESHOOTING D226 TROUBLESHOOTING SECTION sonnel Certain procedures in this section require electrical tests or measurements while power is applied to the machine Exercise extreme caution at all times If test points are not easily accessible disconnect power attach test equipment and reapply power to test When replacing electrical parts disconnect power at source circuit breaker WARNING Inspection testing and repair of electrical equipment should be performed only by qualified service per Problem Power light does not illuminate 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light 2 Service breaker tripped or open Verify that the breaker is closed 3 Power switch connections could be loose Ensure that the connections are of sound quality 4 Power switch is faulty Replace the power switch 5 Power light is faulty Replace the light Problem Water pressure is too low 1 Water pressure regulator is out of adjustment Follow the instructions provided in the maintenance section and adjust so that the flow pressure is 20 5 PSI 2 Water pressure regulator internal strainer is clogged Clean in accordance with the instructions provided in the maintenance section 3 Water pressure regulator is faulty Replace the regulator 4 Water pressure gauge is faulty or the cut off from the system Verify that the test cock v
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59. STEAM HEATED MODELS At the end of the workday place the power switch in the OFF position secure the flow of steam to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strain ers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rinse tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the inside of the unit and then reassemble with the components previously removed SHUTDOWN AND CLEANING GAS HEATED MODELS At the end of the work day shut down the gas booster in accor dance with manufacturer s instructions Place the power switch in the OFF position secure the flow to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rins
60. TED TO THE LEFT OF THE DISHMACHINE HOOKUP WHEN GAS BOOSTER HEATER IS LOCATED TO THE RIGHT OF THE DISHMACHINE P d THE RINSE TANK INLET PIPE IS ROTATED 180 TO ACCOMMODATE THE HOSE COMING FROM THE OPPOSITE DIRECTION n NOTE HOW THE 90 ELBOW SWITCHES TO THE OPPOSITE SIDE OF THE PIPING TEE TO ACCOMMODATE THE HOSE COMING FROM THE OPPOSITE DIRECTIONS CONNECTION HOSES ARE CUT TO LENGTH DURING INSTALLATION ENOUGH HOSE IS PROVIDED TO LOCATE THE GAS BOOTER HEATER APPROXIMATELY 9 FEET AWAY FROM THE DISHMACHINE ADDITIONAL HOSE MUST BE ORDERED IF A GREATER DISTANCE IS REQUIRED DISTANCES GREATER THAN 20 FEET AWAY CAN AFFECT THE HEATING PERFORMANCE OF THE UNIT B HOSES MARKED A IN THE ABOVE ILLUSTRATIONS CONNECT TO THE INLET WATER CONNECTION OF THE GAS BOOSTER HEATER HOSES MARKED B IN THE ABOVE ILLUSTRATIONS CONNECT TO THE OUTLET WATER CONNECTION OF THE GAS BOOSTER HEATER ITEMS MARKED ARE THE INCOMING PLUMBING CONNECTIONS TO MACHINE THAT SHOULD BE 110 140 DEGREES 39 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATING INSTRUCTIONS PREPARATION Before proceeding with the start up of the unit verify the following 1 Close door s on dishmachine 2 Close the drain valve s POWER UP ELECTRICALLY HEATED MODELS To energize the unit turn on the po
61. TION INSTRUCTIONS CURTAIN INSTALLATION DIAGRAMS Please refer to the chart for placement of the curtains ead R XL 5 24 5 12 XL 5 245 12 86 100 s 2 42 B ip GAS MACHINES 64 24 5 42 XL S 245 12 w az E HOODED SIDE LOADER HOODED SIDE LOADER L L o na 0 4 74 74 Wy 9 ox u c a 2 5 p W Q Q 9 8 os 2 2 5 5 s 4 Vilis os LL 14 86 100 5 12 12 ELECTRIC amp STEAM MACHINES 64 L Ls L 34 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS SIDE LOADER INSTALLATION amp OPERATION INSTRUCTIONS This accessory assists in the delivery of a full dish rack from the break down scrapping table to the dishmachine It will con vert the direction of travel 90 Since the Side Loader is shipped mounted on the conveyor dishwasher there is no additional installation required for this option As it is operated mechanically by the dishwasher it does not require any plumbing or elec trical connections This Side Loader does not require or add any additional electrical or mechanical devices to the unit which could create opera tional or maintenance problems As designed the drive mechan
62. UOHOSUUOD SEO v i Eg n ____ q asoy SY I j euigoeulusip UO Sul oj uopeuuoo uus Fy Jenno 4 081 LAN t H 862 L L by uus 9 seb lUu 4 071 LAN v 6 9 gg uu 94 9 uwg aeunmpeinuel Aq 92 0 gt XEN an Y oiqeyusiq e oqv esou BunoeuuooiJeju 297694 1916006 1972M YM uu egg uMopuin jo yue 9 euy jr uono8S ue d 4 PUP 91481 usemeg ue YSEM 10 j9 U J9J M 4 08 LAN 3 l Jejees BUODIIIS esf 5 3 N i zeg y Y ejoo jueA L tz o1dn 2 1 uono uuoo 9 SS lqe e Joey gomos g L d o5V IIM qn loN unu duu Ao1 40 uuszy 9 lqe s 3 0t1 3 01 LAN P E 1 lu 187eM UYN V 1uBrs 01 497 SPECIFICATION INF
63. alve under the gauge is open to allow for the sensing of line pressure Replace gauge if necessary 5 Heat exchanger is clogged Replace the heat exchanger Problem Solenoid valve is not opening shutting 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light 2 Service breaker tripped or open Verify that the breaker is closed 3 Power switch connections could be loose Ensure that the connections are of sound quality 4 Power switch is faulty Replace the power switch 5 Thermostat is faulty Replace the thermostat 6 Solenoid wires are loose or broken Verify that the electrical connections are of sound quality 7 Faulty solenoid coil Replace the solenoid Problem Outlet water temperature too low 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light Service breaker tripped or open Verify that the breaker is closed Power switch connections could be loose Ensure that the connections are of sound quality Power switch is faulty Replace the power switch Thermostat is faulty Replace the thermostat Solenoid wires are loose or broken Verify that the electrical connections are of sound quality Faulty solenoid coil Replace the solenoid Steam flow pressure is too low for the unit Verify that the steam flow is 15 25 PSIG
64. ase Secondary Side 460 575 600 Volt 60 Hz 3 Phase Primary Side 460 575 600 Volt 60 Hz 3 Phase Secondary Side AJ 64CS 208 230 Volt 60 Hz 1 Phase Primary Side 208 230 Volt 60 Hz 1 Phase Secondary Side 208 230 Volt 60 Hz 3 Phase Primary Side 208 230 Volt 60 Hz 3 Phase Secondary Side 460 575 600 Volt 60 Hz 3 Phase Primary Side 460 575 600 Volt 60 Hz 3 Phase Secondary Side AJ 86CE amp AJ 100CE 208 230 Volt 60 Hz 1 Phase Primary Side 208 230 Volt 60 Hz 1 Phase Secondary Side 208 230 Volt 60 Hz 3 Phase Primary Side 208 230 Volt 60 Hz 3 Phase Secondary Side 460 575 600 Volt 60 Hz 3 Phase Primary Side 460 575 600 Volt 60 Hz 3 Phase Secondary Side AJ 86CS amp AJ 100CS 208 230 Volt 60 Hz 1 Phase Primary Side 208 230 Volt 60 Hz 1 Phase Secondary Side 208 230 Volt 60 Hz 3 Phase Primary Side 208 230 Volt 60 Hz 3 Phase Secondary Side 460 575 600 Volt 60 Hz 3 Phase Primary Side 460 575 600 Volt 60 Hz 3 Phase Secondary Side AJ 86CGP amp AJ100CGP 208 230 Volt 60 Hz 1 Phase Primary Side 208 230 Volt 60 Hz 1 Phase Secondary Side 208 230 Volt 60 Hz 3 Phase Primary Side 208 230 Volt 60 Hz 3 Phase Secondary Side 460 575 600 Volt 60 Hz 3 Phase Primary Side 460 575 600 Volt 60 Hz 3 Phase Secondary Side Exhaust Fan Hook Up Schematic D226 Steam Booster Drain Quench Conveyor Side Loader Schematics MAINTENANCE amp REPAIR CENTERS vii 114 115 116 117 119 120 122 123 124 125 126 138 145
65. ause damage to components WARE PREPARATION Proper preparation of ware will help ensure good results and less re washes If not done properly ware may not come out clean and the efficiency of the dishmachine will be reduced It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are good ideas especially for silverware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to sanitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine DAILY MACHINE PREPARATION Refer to the section entitled PREPARATION at the top of this page and follow the instruc tions there Afterwards check that all of the chemical levels are correct and or that there is plenty of detergent available for the expected workload WASHING A RACK OF WARE To wash a rack simply slide a rack of soiled ware into the load end of the machine Once the the machine is started it should pull the rack through the machine and push it out the unload end Once a rack has started through you may put another rack in OPERATIONAL INSPECT
66. ce agency Use of generic replacement parts may create a hazard and void war ranty certification The labor to repair or replace such failed part will be paid by Jackson WWS within the continental United States Hawaii and Canada dur ing the warranty period provided a Jackson WWS authorized service agency or those having prior authorization from the factory performs the service Any repair work by persons other than a Jackson WWS authorized service agency is the sole responsibility of the customer Labor coverage is limited to regular hourly rates overtime premiums and emergency service charges will not be paid by Jackson WWS Accessory components not installed by the factory carry a 1 one year parts warranty only Accessory components such as table limit switch es pressure regulators pre rinse units etc that are shipped with the unit and installed at the site are included Labor to repair or replace these components is not covered by Jackson WWS This warranty is void if failure is a direct result from shipping handling fire water accident misuse acts of god attempted repair by unau thorized persons improper installation if serial number has been removed or altered or if unit is used for purpose other than it was origi nally intended TRAVEL LIMITATIONS Jackson WWS limits warranty travel time to 2 two hours and mileage to 100 one hundred miles Jackson WWS will not pay for travel time and mileage that exceeds this or any
67. ct voltage coming to the machine Verify that the voltage matches that on the machine data plate Wash pump cavitation due to low water level Verify that the drains are shut and that the water level is correct O Problem Spotting of silverware glasses and dishes 1 Incorrect final rinse temperature Verify that the rinse water temperature matches that which is listed on the machine data plate 2 Clogged wash and or rinse nozzles and arms Remove the arms and verify that they and their nozzles are from debris 3 Excessively hard water Install a water softener to reduce hardness 4 Loss of water pressure due to clogged obstructed wash pump Turn the power off to the machine at the source Drain the wash tank of water and verify that the pump intake is free from debris 5 Improper scrapping procedures Review the paragraph entitled Ware Preparation in Operating Instructions 6 incorrect detergent chemcial concentrations Verify that the detergent chemical concentrations are correct for the associat ed water volume TORQUE SETTINGS When replacing components either in the control box or the heater box area the manufacturer has suggestions on how much to torque the screws and nuts used in securing items to the machine Refer to the table below for the torque specific tions ITEMS TORQUE SPEC Relays 16 In Ibs Heater Contactor 35 In Ibs Heater Nuts 16 In Ibs Terminal Block 50 In Ibs 51 SECTIO
68. d be available from your detergent supplier Read and follow all instructions on the label of the deliming solution To proceed with the deliming operation fill the dishmachine and add the correct amount of deliming solution as recommended by the deliming solution manufacturer The water capacity of the various tanks of the dishmachine can be verified on the spec ification sheet s of this manual Perform the following operations to delime the dishmachine AUTQMATIC 1 Turn the AUTOMATIC DELIME switch on the back of the control box to the DELIME position 2 Disconnect or turn off all chemical feeder pumps MANUAL DELIME 3 Close all doors after adding the deliming solution 4 Run the machine for the recommended period of time 5 Turn the unit off and open the doors Delime Switch 6 Wait five minutes then inspect the inside of the machine If the machine is not delimed run another time cycle as per the deliming solution s instructions 7 When clean drain and re fill the machine 8 Run in MANUAL for 10 minutes to remove residual deliming solution 9 Drain and re fill the machine This equipment is not recommend for use with deionized water or other aggressive fluids Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components Use of deionized water or other aggressive fluids will void the manufacturer s warranty 33 SECTION 2 INSTALLATION OPERA
69. e desired pressure is achieved tighten the top nut to ensure that the adjustment can not be accidently changed The water pressure regulator has an internal strainer that can be removed through the bottom hexagonal plug This may need to be periodically checked depending on the water quality It is important that the water supply to the water pressure regulator be secured prior to trying to clean the strainer MAINTENANCE OF THE RELIEF VALVES SAFETY VALVES AND THERMOSTAT These components are shipped from the factory preset and should not be tampered with None of these components are con sidered adjustable and no attempt should be made to do so If a component does not appear to be working properly then it should be replaced immediately by an authorized service representative 46 SECTION 3 PREVENTATIVE MAINTENANCE LUBRICATION CHART FOR DRIVE GEAR Note The maintenance procedures detailed here are manufacturer s instructions for the WINSMITH brand of gear reducer that is installed on the rack conveyors covered in this manual Ambient Temperature Final Stage Worm Speed ISO Viscosity Grade AGMA Lubricant No Mobil American Lubricants Castrol Chevron Conoco Exxon Esso Fiske Brothers Shell Texaco 30 15 F up to 2000 FPM 220 5S SHC 630 SHC 90W Tribol 800 220 Tegra 220 SynconR amp O 220 Teresstic SHP220 SPO MG Omala RL 220 Pinnacle 220 16 50 F up to 2000 FPM 460 7 Co
70. e thermostat TS1 2 The thermostat TS1 will close when the water falls below the minimum setpoint energizing the steam solenoid light E2 and the steam solenoid FS1 3 The steam solenoid FS1 will remain open allowing steam into the booster until the water temperature reaches the desired temperature At that point the thermostat TS1 will open de energizing the steam solenoid FS1 and the steam solenoid light E2 IMPORTANT Please remember that all of the components in the control box are under line voltage 208 240 volts Under no circumstance is the control box cover to be removed or opened during normal operations SHUTDOWN FOR SERVICE ONLY WARNING The D226 Booster is designed to heat water to a minimum of 180 F and is extremely hot during operations Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur 1 Turn the power switch to the OFF position The power light should extinguish 2 Secure steam flow to the unit 3 Secure water flow 4 Close the condensate drains as required by procedure and or code 5 Do not attempt to clean wipe down or perform any maintenance on the booster until it has been given a generous amount of time to cool down 37 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS GAS CONVEYOR HOSE INSTALLATION Barbed Hose Fitting Attach the hose fitting to this Cut the hose at the location connection before makin
71. e tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the inside of the unit and then reassemble with the components previously removed 41 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DETERGENT CONTROL Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate Using detergent in the proper amount can become in time a source of substantial savings A qualified water treatment spe cialist can tell you what is needed for maximum efficiency from your detergent but you should still know some basics so you ll understand what they are talking about First you must understand that hard water greatly effects the performance of the dishmachine Water hardness is the amount of dissolved calcium and magnesium in the water supply The more dissolved solids in the water the greater the water hard ness Hard water works against detergent thereby causing the amount of detergent required for washing to increase As you use more detergent your costs for operating the dishmachine will increase and the results will decrease The solids in hard water also may build up as a scale on wash and rinse heaters decreasing their ability to heat water Water temperature is important in removing soil and sanitizing dishes If the water cannot get hot enough your results may not be satisfactory This is why Jackson recommends that if you have install
72. ed corners or any other marks indicating rough handling Also notify your JACKSON dealer immediately If it is discovered that there are missing parts please notify your JACKSON dealer immediately EQUIPMENT MOUNTING Your booster should come pre assembled and will require that it be permanently mounted in place The platform has pre punched holes to allow for mounting to the installation floor NOTE The D226 Booster must be properly mounted and level before being used Once the platform is secure to the floor attach the water and steam lines in accordance with local and national codes PLUMBING NOTE ALL CONNECTIONS MUST COMPLY WITH ALL APPLICABLE LOCAL STATE AND NATIONAL PLUMBING CODES The plumber is responsible for ensuring that the water line is THOROUGHLY FLUSHED BEFORE connecting it to any manu al or solenoid valve It is necessary to remove all foreign matter such as chips resulting from cutting or threading pipes pipe joint compound or if soldered fittings are used bits of solder or cuttings from the lines This debris if not removed may lodge in the valves and render them inoperative The D226 Booster is designed to take incoming water from a minimum temperature of 110 F to approximately 180 F for use in the final rinse of your Jackson dishmachine In order to do this water is supplied to the booster and is heated by tubes carry ing 15 25 PSIG flow steam Heat is transferred from the steam into the water raising the t
73. ed the machine in an area with hard water that you also install some type of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine Second hard water may have you adding drying agents to your operating cycle to prevent spotting when the real problem is deposited solids on your ware As the water evaporates off of the ware the solids will be left behind to form the spotting and no amount of drying agent will prevent this Again using treated water will undoubtedly reduce the occurrences of this prob lem Third treated water may not be suitable for use in other areas of your operation For instance coffee made with soft water may have an acid or bitter flavor It may only be feasible to install a small treatment unit for the water going into the dishmachine itself Discuss this option with your qualified water treatment specialist Even after the water hardness problems have been solved there still must be proper training of dishmachine operators in how much detergent is to be used per cycle Talk with your water treatment specialist and detergent vendor and come up with a complete training program for operators Using too much detergent has as detrimental effects as using too little The proper amount of detergent must be used for job It is important to remember that certain menu items may require extra detergent by their nature and personnel need to be made aware of this Experience in using
74. emperature Install condensate drains in accordance with applicable codes The D226 Booster is designed to operate at a water flow rate of 20 5 PSI The assembly comes with a water pressure reg ulator which is preset at the factory However adjustment may be required so ensure that you verify the the flow pressure before beginning operations See the instructions regarding adjustment and maintenance of the water pressure regulator for more information WARNING The D226 Booster is designed to heat water to a minimum of 180 F and is extremely hot during operations Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur This equipment is not recommend for use with deionized water or other aggressive fluids Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components Use of deion ized water or other aggressive fluids will void the manufacturer s warranty 36 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION amp OPERATION INSTRUCTIONS CONTINUED ELECTRICAL WARNING Electrical and grounding connections must comply with applicable portions of the National Electrical Code ANSI NFPA 70 latest edition and or other electrical codes Disconnect electrical power supply and place a tag or lock at the disconnect switch to indicate that you are working on the circuit Block
75. end that you refer to this manual before making a call to our technical support staff Installation Date Please have this manual with you when you call so that our staff can refer you if necessary to the prop Service Rep Name er page Technical support is available from 8 00 a m to 5 00 p m EST Monday through Friday Phone No Technical support is not available on holidays Contact technical support toll free at 1 888 800 5672 Please remember that technical support is available for service personnel only SECTION TABLE OF CONTENTS DESCRIPTION SPECIFICATION INFORMATION Operating Characteristics Electrical Requirements D226 Steam Booster Parameters AJ 64 Electric Left to Right AJ 64 Electric Right to Left AJ 64 Gas Left to Right AJ 64 Gas Right to Left AJ 64 Steam Left to Right AJ 64 Steam Right to Left AJ 86 Electric Left to Right AJ 86 Electric Right to Left AJ 86 Gas Left to Right AJ 86 Gas Right to Left AJ 86 Steam Left to Right AJ 86 Steam Right to Left AJ 100 Electric Left to Right AJ 100 Electric Right to Left AJ 100 Gas Left to Right AJ 100 Gas Right to Left AJ 100 Steam Left to Right AJ 100 Steam Right to Left Side Loader Left to Right Dimensions Side Loader Right to Left Dimensions Side Loader Installed Dimensions D226 Steam Booster Dimensions D226 Steam Booster Plumbing Line Drawings Typical Electric and Gas Booster Dimensions INSTALLATION
76. er 4 fe 3i 1 1 4 uc g 1 twuzoul 1 69 12 H 2 N Zoo 98 gg wwges fez 9 1 99 uusgg gz 1 609 2 4 9 1 Ea unullulN ww esz zor mm 97 p 6 eje d 19409 peddius pjeius ules JO AUIS 1004 aqe Z 98 use dS IMoO jue ui yp wurosl ez yun eseg ee 90p 9 X PIA 201 1 5 9 v9 699 ZZ T Zo 12097 ye d r 1 eog eo oe M g 3 L H FS E uuueoz uuseg sz 5 zl 7 ex 3 7 v as utuu6S Yo i ox NA N uu996 8 gt yyy wwssel y 7 Xe Buelq z PIOO uu ees 12 1 wo os USEA 1d uw 61 aulyoe JO 4 T 1uBi H pey pue
77. g the where the hose is even cut at the other end of the with the yellow plastic stop hose Connection Due to the fact that each customer may have different requirements for the orientation of the gas booster heater relative to the main dishmachine the hose lengths that connect the two units must be customized during each installation The appropriate 3 4 hosing fittings and gaskets have been provided To prevent incorrect measurements of the hose it is recommended to place one barbed hose fitting into the end of the uncut length of hose coil and attach that fitting to an appropriate connection Run the hose to the corresponding connection on the other unit before cutting the hose Use a barbed hose fitting that is screwed into the second connection on the other unit before cutting the hose Use a barbed hose fitting that is screwed onto the second connection to gauge the correct distance Ensure a smooth flow of hose without any sharp turns or kinks To aid in pushing the barbed hose fitting into the hose place the fitting on a hard surface i e the floor with the barbed end of the fitting pointing upward and push the hose down onto the fitting A small amount of lubricant i e petroleum jelly may aid in this process 38 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS GAS CONVEYOR HOSE INSTALLATION CONTINUED TYPICAL RECIRCULATING WATER HOOK UP FOR ALL GAS HEATED CONVEYORS HOOKUP WHEN GAS BOOSTER HEATER IS LOCA
78. have been connected to the machine 2 Dishmachine doors are not closed Close doors completely 3 Incoming water solenoid valve damaged faulty Verify that the valve is operating If not replace 4 Tank floats faulty Verify the wiring of the floats Verify that no debris is jamming the floats Replace if necessary Problem Machine fills but fill is weak 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Low wash tank temperature 1 Low incoming water temperature Verify that the incoming water temperature matches what is indicated on the machine data plate 2 Heater not energizing Verify that the wash tank heater is operating If not replace 3 Low incoming voltage Have an electrician verify that the power coming to the machine is the same as indicated on the data plate Problem Low wash arm pressure poor spray pattern 1 Clogged wash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged wash tank or wash pump strainers Clean out strainers if necessary 3 Worn wash pump impeller Verify status of impeller replace if necessary Problem Low prewash arm pressure poor spray pattern 1 Clogged prewash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged prewash tank or prewash pump st
79. ide and the outside con nector nuts for the connector box so that it lines up even with the limit switch and the base plate 5 Tighten down the nuts for the seal so that they are tight TABLE LIMIT SWITCH THROUGH ROD HOLES TABLE SWITCH RODS STRIKE PLATE ah MOUNTING BOLTS TABLE BOTTOM STRIKE PLATE BOLTS 1 3 RACK WIDTH INSTALL AT FAR END OF TABLE 6 If you have any difficulty you might have to adjust the connectors to the seal screwing in or screwing out until the installation is straight on the table and the limit switch is actuated correctly by the rack E 00 75 Unless noted all dimensions inches 3 00 2 00 d 1 875 1 50 TABLE BOTTOM Y SECTION 3 PREVENTATIVE MAINTENANCE SECTION 3 PREVENTATIVE MAINTENANCE Y PREVENTATIVE MAINTENANCE The dishmachines covered in this manual are designed to operate with a minimum of interaction with the operator However this does not mean that some items will not wear out in time Jackson highly recommends that any maintenance and repairs not specifically discussed in this manual should be performed by QUALIFIED SERVICE PERSONNEL ONLY Performing main tenance on your dishmachine may void your warranty if it is still in effect so if you have a question or concern do not hesitate to contact Jackson There are many things that operators can do t
80. imited to timer cams thermostats or doors beyond 30 days from the date of installation In addition the warranty will only cover the replacement of wear items such as curtains drain balls door guides or gaskets during the first 30 days after installation Also not covered are conditions caused by the use of incorrect non Commercial grade detergents incorrect water temperature or pressure or hard water conditions STOP PARE ARRET CALL1 888 800 5672 TO REG BIER THB PRO DUC T DO SO W IL VO D THE WARRANTY LLAM EAL1 888 800 5672 PARA REG BIRAR ESTE PRO DUC ALNO HACERIO LA GARANTA SERA ANULADA S APPELER 1 888 800 5672 PO UR ENREG DIRER C E PRODUI LA GARANTE SERA ANNULEE PO UR TO UT PRO DUINO N EN REG SIREE REVISION MADE APPLICABLE 6999 7193 Updated drawings for limit switch actuators Changed AJ 86 drain 7217 7064 plumbing copper lengths Added rack rail stabilizer kit Replaced 04 06 05 un 7212 7259 heater 04540 121 76 93 with 04540 002 29 82 Updated installa 05 02 06 6685 7096 tion instructions Added 3 instruction sheets for limit switches 6964 7006 Added instruction sheet for curtains Added AJ 86CGP amp AJ 100CGP models PG 116 04 19 07 5 thru 22 104 09 29 2007 Added gas exhaust fan schematic updated electric exhaust fan 7600 7558 schematic updated dimensions pages Replace Drain Weldment 05700 021 68 28 with 05700 002 51 12 Pawl bar for AJ 86 R
81. ism is powered by the conveyor drive motor on the dishma chine An extension on the pawl bar provides the drive to push the racks into the unit PREPARATION Before proceeding with the start up of the unit verify that the Side Loader pan strainer is installed WARE PREPARATION Proper preparation of ware will help ensure good results and less re washes If not done properly ware may not come out clean and the efficiency of the dishmachine will be reduced It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are good ideas especially for silverware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to sanitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine WASHING A RACK OF WARE Once a rack is fully loaded it should be positioned against the front of the dish table The rack should then be moved into the Side Loader until it activates the actuator switch Once the the machine is started it should pull the rack through the machine and push it out the unload end Once a rack has started through
82. m wp 16 g9 ege 9 91921 00 221 801 ejqejsn pe enp 2 1 SUOISUBLUIP JELIMA 93oN wwo l tr g eseg ww r nun 929 vo Jeuondo LdN uonoeuuoo Buiquunid O 9 sz LZ 2 g 209 400 LAN 1910 N O 4 081 LAN uonoeuuoo 4 0 LAN 1 uonoeuuoo p H 1 6 fo n Sape 3 9 wusgz uogoeuuoo WEIS LAN uono uuoo H 996 N Z Z ejesuepuo LdN uv E 9 jeisouueu 19 eA uonoes ue d EE N uus ip Zor uuszy 91 ees 12 A uono uuoo LdN v d MOO 1U9A 3 jeuondo 4ejoo ju9A C L uonoeuuoo 9 uonoeuuoo 8 y uug uuo v t aigelysiq e oqy 1UBI9H T X xen eB
83. mpounded 600W Super Cylinder AGMA 7 Gear Oil Tribol 1105 7C Cylinder Oil W460 Inca Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 51 95 F up to 450 FPM 680 8 Compounded Extra Hecla Super AGMA 8 Gear Oil Tribol 1105 8C Cylinder Oil W680 Inca Oil 680 Spartan EP 680 SPO 288 Valvata J 680 Vanguard 680 51 95 F above 450 FPM 460 7 Compounded 600W Super Cylinder AGMA 7 Gear Oil Tribol 1105 7 Cylinder Oil W460 Inca Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 96 131 F up to 450 FPM 680 85 5 636 N A Tribol 800 680 Tegra 680 N A Teresstic SHP 680 N A Omala RL 680 Pinnacle 680 96 131 F above 450 FPM 460 7S SHC 634 N A Tribol 800 460 Tegra 460 Syncon R amp O 460 Teresstic SHP 460 N A Omala RL 460 Pinnacle 460 1 The sliding velocity in feet per minute FPM for standard ratios is determined by multiplying the speed of the worm in RPM by the factor from the table below For selecting proper lubricant use the speed of the worm in the final stage input RPM divided by the first stage ratio 47 SECTION 3 PREVENTATIVE MAINTENANCE DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE Note The maintenance procedures detailed here are manufacturer s instructions for the WINSMITH brand of gear reducer that is installed on the rack conveyors covered in this manual Lubrication
84. nder normal conditions after the initial oil change the oil should be changed after every 2500 hours of operation or every 6 months whichever occurs first Under severe conditions rapid temperature changes moist dirty or cor rosive environment it may be necessary to mchange oil at intervals of one to three months Periodic examination of oil samples taken from the unit will help establish the appropriate interval Synthetic oils Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable have a much longer life and operate over a wider temperature range These oils are appropriate for any application but are especially useful when units are subjected to low start up temperatures or high operating temperatures However continuous operation above 225 F may cause damage to seals or other components It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation to remove metal particles that accumulate during break in Subsequent oil changes should be made after 5000 hours operation if units are operating in a clean environment This can be extended to 10 000 hours if using new reformulated Mobil SHC lubricants orange in color and the lubricant remains free of contamination over this period See comments under Subsequent oil changes for discussion of severe ambient conditions Long term storage or infrequent operation If a speed reducer is to stand idle for an extended
85. ned to remove iron from the supply water is highly recommended for sup plies in excess of 0 1 ppm parts per million CONNECTING THE DRAIN LINE The drain for the models covered in this manual are gravity discharge drains All piping from the machine to the drain must be a minimum 1 1 2 NPT and should not be reduced There must also Locking nut x an air gap between the machine drain line and the floor sink or drain If a grease trap is required by code it should have a flow capacity of 30 gallons per minute Adjusting screw gt WATER SUPPLY CONNECTION Ensure that you have read the section enti PLUMBING THE DISHMACHINE above before proceeding It is also oa recommended that a pressure regulator not supplied be installed in the in hi coming water line The supply water temperature must meet the minimum requirements listed on the machine data plate Install the water supply line 3 4 pipe size minimum to the dishmachine line strainer It is recommended that water shut off valve be installed in the water line between the main supply and Incoming Plumbing Assembly the machine to allow access for service The water supply line is to be capable of 25 PSI flow pressure at the recommended temperature indicated on the data plate Optional If the water level is too low or too high check the incoming water pressure It should be 20 5 PSI Too high of pressure results in too much water too
86. ntative WATER OUTLET SAFETY VALVE SET PRESSURE PSI 125 STEAM RELIEF VALVE SET PRESSURE PSI 50 SPECIFICATION INFORMATION SECTION 1 AJ 64 ELECTRIC LEFT TO RIGHT epis 1uBiu 10019 apis 8 2 S 5 OL 9 1 1 H a eng uum 98 pe pones MIS unu m use Jo Jeoy 7 Ws eoueJeo usiq UBIH 0 z w 709 99 99 v Z N meme utuggs i zo uuuz0g zim 1 uwgoz luucol 269 1299 xen b e lwwees iz 64 v e Y uuu ees 12 929 GZ eur 97 JO AUIS 10014 zeg 8 vc 9 dn Bue j e 1deooy IIM qn JoN jue eld 0 JO dr pue ueewjeg Jejeeg uoollis esf r lqeL
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88. o prevent catastrophic damage to the dishmachine One of the major causes of component failure has to do with prescrapping procedures A dishmachine is not a garbage disposal any large pieces of mate rial that are put into the machine shall remain in the machine until they are either broken up after spreading out on your ware or physically removed Strainers are installed to help catch debris but they do no good of they are clogged Have operators regularly inspect the pan strainers to ensure 1 that they are free of soil and debris and 2 they are laying flat in the tub When cleaning out strainers do NOT beat them on waste cans The strainers are made of metal and can be forgiving but once severe damage is done it is next to impossible for the strainer to work in the way it was designed to Wipe out strainers with a rag and rinse under a faucet if necessary For stubborn debris a toothpick should be able to dislodge any obstructions from the perforations Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub You may wish to also refer to the page entitled Detergent Control in order to learn more about how your water hardness will effect the performance of your machine Hard water makes dishmachines work harder and decreases efficiency Again it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larg er problems or even ca
89. oad of the machine and 2 typical fixed trip circuit breaker sizes as listed in the NEC 2002 Edition Local codes may require more stringent protec tion than what is displayed here Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes These numbers are provided in this manual sim ply for reference and may change without notice at any given time ELECTRICAL REQUIREMENTS AJ 64CE MODELS AJ 86CE MODELS TYPICAL TYPICAL TOTAL ELECTRICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT VOLTS PH HZ AMPS CIRCUIT 208 1 60 139A 175 AMP 208 1 60 145A 200 230 1 60 128A 175 AMP 230 1 60 134A 175 AMP 208 3 60 82A 110 AMP 208 3 60 86A 110 AMP 230 3 60 100 230 3 60 79A 100 AMP 460 3 60 38 A 50 AMP 460 3 60 39A 50 AMP AJ 64CS MODELS AJ 86CGP MODELS TYPICAL TYPICAL TOTAL ELECTRICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT VOLTS PH HZ AMPS CIRCUIT 208 1 60 19A 25 AMP 208 1 60 26A 35 AMP 230 1 60 19A 25 AMP 230 1 60 26A 35 AMP 208 3 60 13A 20 AMP 208 3 60 17A 25 AMP 230 3 60 13A 20 AMP 230 3 60 17A 25 AMP 460 3 60 15 460 3 60 9 15 AMP AJ 86CS MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 25A 35 AMP 230 1 60 25A 35 AMP 208 3 60 16A 20 AMP 230 3 60 16A 20 AMP 460 3 60 8A 15 AMP SECTION 1 SPECIFICATION INFORMATION SECTION 1 SPECIFICATION INFORMATION ELECTRICAL REQUIREMENTS CONTINUED
90. ot be obvious at first If it is discovered that an item is missing contact Jackson immediately LEVEL THE DISHMACHINE The dishmachine is designed to operate while being level This is important to prevent any damage to the machine during operation and to ensure the best results when washing ware The unit comes with adjustable bullet feet which can be turned using a pair of channel locks or by hand if the unit can be raised safely Ensure that the unit is level from side to side and from front to back before making any connections You will be able to adjust the over all height of the unit by turning the bullet feet from between 75 1 2 to 76 1 2 Frame with Adjustable Foot PLUMBING THE DISHMACHINE All plumbing connections must comply with all applicable local state and national plumb ing codes The plumber is responsible for ensuring that the incoming water line is thoroughly flushed prior to connecting it to any component of the dishmachine It is necessary to remove all foreign debris from the water line that may potentially get trapped in the valves or cause an obstruction Any valves that are fouled as a result of foreign matter left in the water line and any expenses resulting from this fouling are not the responsibility of the manufacturer Water hardness should be a maximum of 6 grains per gallon Harder water should be treated prior to using the machine Iron in the water supply can cause staining A filter desig
91. rainers Clean out strainers if necessary 3 Worn prewash pump impeller Verify status of impeller replace if necessary Problem Inadequate rinse 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Pawl bar moves with no load but does not move when loaded 1 Clutch on drive assembly is out of adjustment Adjust as required 50 SECTION 4 TROUBLESHOOTING COMMON PROBLEMS Problem Pawl bar does not move 1 Failed or broken overload spring Replace spring if necessary 2 No power to the drive motor failed drive motor Verify power and wiring connections to the motor If necessary replace the motor 3 Pawl bar not properly installed Verify that the pawl bar is installed correctly Problem Racks go through the machine but results are poor 1 Verify that detergent is being dispensed into the machine at the appropriate quantities for the water volume If not get deter gent to appropriate level and review results of washing ware Clogged strainers scrap basket Clean out strainers and scrap basket and replace Ware not being properly prescrapped Review paragraph entitled Ware Preparation in Operating Instructions Wash or rinse arms missing end plugs or caps Verify and replace as required Low tank heat Inadequate rinse Incorre
92. side source needs to be connected Connect all incoming gas lines in accordance with the gas booster manufacturer s instructions Ensure that all applicable codes and regulations are adhered to PLUMBING CHECK Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been installed Check for any leaks and repair as required All leaks must be repaired prior to placing the machine in operation ELECTRICAL POWER CONNECTION Electrical and grounding connections must comply with the applicable portions of the National Electrical Code ANSI NFPA 70 latest edition and or other electrical codes Disconnect electrical power supply and place a tag at the disconnect switch to indicate that you are working on the circuit The dishmachine data plate is located on the right side and to the front of the machine Refer to the data plate for machine operating requirements machine voltage total amperage load Decal showing and serial number L1 L2 amp L3 8 phase models To install the incoming power lines open the control box Install only conduit into the pre punched holes in the back of the control box Route power wires and connect to power block and grounding lug Install the service wires L1 L2 and L3 3 phase only to the appropriate terminals as they are marked on the terminal block Install the grounding wire into the lug provided Tighten the connections It is recommended that
93. t SNIN3dO vIE 0 1 2 MINIMUM WALL OF SIDE LOADER 25 DISHWASHER lt 12 1 2 CONVEYOR DISHMACHINE 4 1 2 MINIMUM HI9N31I ANIHOVWHSIG gt lt 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE deux lt 9 lt 14 127 gt 24 29 gt 15 for 30 Model V gc wt obo 30 for 30 Model waww SECTION 1 SPECIFICATION INFORMATION SIDE LOADER INSTALLATION DIMENSIONS 23 SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ 64 95 AJ 86 117 AJ 100 131 Left to Right installation shown for reference 30 SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ 64 102 AJ 86 124 AJ 100 138 H 1 NOTE ALL DIMENSIONS ARE TYPICAL TH 10 Y B z lt amp 23 or 30 Depending on the width of the sideoloader lt Refer to chart above gt 25 o SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER DIMENSIONS 4r 17 t3 l UT
94. t g 1 eulyoey jodi 9 6 s 1 n ura es 3 pue u w g 9lqe1usiq m sc Jeuondo 3u8A euooiS esf 1 oes V I Z L uonoeuuoo 9 ud uc uonoeuuoo E21129 3 XA 4 071 eil 7 7 x 7 7777 gt duiei IH 4 081 res uoneouqe J pepuswwosey LAN 1 lu V 437 o11u6r4 SPECIFICATION INFORMATION AJ 64 GAS LEFT TO RIGHT SECTION 1 apis 1614 11024 p S 97 r uuursz OF wwe Ze s uisgi f9 too uusgilfo A wwees 226 1 ez i JAM i i 1 d P 11 f i vw 4 l 1 9 yun AUC 1 1 1 uus g k Jo seay 6 9 yseidsyoeg Igor eger L ooUeJe9 2
95. uejy eBeye jlu A ld age dq qnl ww 61 y e pue u w g Jejees euooiis OS 4 07 dui l IH zeg 3 081 LAN v 1 UYN v 48 4 vc 01 dn eiqer ebue 4 e ley yoey 4 lqe1 011U Bry 22 n SECTION 1 SPECIFICATION INFORMATION SIDE LOADER LEFT TO RIGHT DIMENSIONS 1 2 DISHTABLE MINIMUM USE SILICONE BETWEEN TABLE AND LIP OF SIDE LOADER TO 25 SIDE PREVENT LEAK AGE 4 1 2 25 MINIMUM DISHWASHER 5 4 2 y lt 1212 gt SECTION f DISHMACHINE VENT CONNECTION OPENING T CONVEYOR uj gt lt E 2 o 220 j DISHMACHINE SPLASH SHIELD zis N oo LLI Z f O eo Z q S o A x LZ 2 012222214 1 1 2 DRAIN CONNECTED TODISHMACHINE DRAIN LINE 14 1 2 29 gt 15 for 30 Model 30 for 30 Model 23 SECTION 1 SPECIFICATION INFORMATION SIDE LOADER RIGHT TO LEFT DIMENSIONS DISHTABLE USE SILICONE BETWEEN TABLE AND LIP OF SIDE LOADER TO PRE VENT LEAKAGE 1 2 SECTION DISHMACHINE VENT CONNECTION OPENING SPLASH SHIELD 21 l
96. use harm to the operator If a problem is discovered secure the dishmachine using proper shut down procedures as listed in this manual and contact Jackson Some problems however may having nothing to do with the machine itself and no amount of preventative maintanence is going to help A common problem has to do with temperatures being too low Verify that the water temperatures coming to your dishmachine match the requirements listed on the machine data plate There can be a variety of reasons why your water tem perature could be too low and you should discuss it with Jackson to determine what can be done By following the operating and cleaning instructions in this manual you should get the most efficient results from your machine As a reminder here are some steps to take to ensure that you are using the dishmachine the way it was designed to work Ensure that the water temperatures match those listed on the machine data plate Ensure that all strainers are in place before operating the machine Ensure that all wash and or rinse arms are secure in the machine before operating Ensure that drains are closed sealed before operating Remove as much soil from dishes by hand as possible before loading into racks Do not overfill racks Ensure that glasses are placed upside down in the rack Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations Clean out the machine at the
97. wer at the service breaker The volt age should have been previously verified as being correct If not the voltage will have to be verified POWER UP STEAM HEATED MODELS To energize the unit turn on the power at the service breaker The voltage should have been previously verified as being correct If not the voltage will have to be verified Ensure that the steam service is con nected and that steam is flowing to the machine Without steam the water will not reach the required minimum temperatures that the machine is designed to operate at POWER UP GAS HEATED MODELS To energize the unit turn on the power at the service breaker The voltage should have been previously verified as being correct If not the voltage will have to be verified Ensure that the gas service is connected and that gas is flowing to the machine Without gas the water will not reach the required minimum temperatures that the machine is designed to operate at FILLING THE WASH TUB Ensure that the delime switch is in the NORMAL position and place the power switch into the ON position The machine should fill automatically and shut off when the appropriate level is reached just below the pan strainer The wash tub must be completely filled before operating the wash pump to prevent damage to the component Once the wash tub is filled the unit is ready for operation Machines equipped with prewash sections should not be run without water in those sections This can c
98. y not be sanitized Instruct your dishmachine operators to observe the required temperatures and to report when they fall below the minimum allowed A loss of temperature can indicate a much larger problem such as a failed heater or it could also indicate that the hot water heater for your operation is not up to capacity and a larger one may need to be installed There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it and that it operates at peak efficiency for many years Discuss your concerns with your local chemical distributor and water treatment specialist before there is a problem 42 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions 1 Wiring The switch is wired common and nor mally open because of the hinge design By interrupting the line in series with the door switches the dishmachine ceases to operate Refer to the machine schematic for details on how to wire the switch 2 Parts of the table switch are mounted in the dishtable at the end of the table and under the table See the drawing s for the relationship of the switch to the table 3 Move the limit switch as far down on the two slots as possible and see that the limit switch is straight on the base plate This might require adjustment of the nut on the connector for the limit switch 4 Then adjust the ins

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