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Jackson AJ-44 User's Manual

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3. puoBe 01 119 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 09 29 2007 14 SPECIFICATION INFORMATION SECTION 1 AJ 66 STEAM LEFT TO RIGHT uwz Lv 891 H 1 W 996 9 2 559 Ue d uSeMeJd 4 N Te 91 591 2 A XEN p e 96 9 uMopuun 9182 2 0 dq pue usemjog 61 Jejeeg euoolllS esf gt 229 48 1 ve o1 dn qn 910M P v 91 6 V L eigeiusiq e oqv qn Wey xeu 9142 epis wwoor tsi 14044 apis 871 piss gt 221 01 1 62 1 9 9 9 01 IIII29L19 i i id i i j in 3 m I 2 5 yun ve 9 i D 19192 heno wun
4. uonoeuuoo 9 uonoeuuoo o OF 3081 V 6 01 1 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 09 29 2007 20 SPECIFICATION INFORMATION SECTION 1 AJ 80 STEAM LEFT TO RIGHT 8 epis 1614 Lv 89 10014 epis wwoor E 8 162 121 uusgz 8LL 11 P pun Ht 014 PNEU 9 89 T 5119 70 1 1 1 i 1 1 f D L 7 7 aki ge ds an un 996 8 W Dreh 9 3 uwepo Lp Suq Y 9 6 4 9LIV95 VV 601 _ py 194988 usejdsxyoeg aiqe Pisos LI usi OL 41689 se 3 wwoest 09 4789 799 SN 5 N wwe 161 99 2i 3 4 ww L91 fe o L 06 9 V M uuo v 902 8 Diosa ez N 1 gt wwees 12 g 12 v 9 LI 299 Lp 114009 fez uuse9 2 uedo 5 00
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6. uedo Le 8 99 ejqeisn pe 6 1 suoisueuiip eonJeA 910 pJepuejs 3 reuogdo 1909 uonoeuuoo 9 e2U199 3 duiej M07 40r L duiei IH 081 7 5 194 V 01 1964 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION AJ 44 GAS LEFT TO RIGHT SECTION 1 epis 14614 10014 971 uu 6 96 01 22 119 uwos H j IVIII59L1 29 i 6 ez 7 F 5 2 i i I 711 wun 141 6 td pie 1 I 19 uwose rim 4 n jo usejdsyoeg 6 98 ees sue Md 91292 3 OL 9 L z wwoes 709 V uupgo 799 uugz Z 7 5 069 11 229 wuz wwzoe 8 a v b
7. RIGHT SIDE VIEW REAR VIEW AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 28 SECTION 2 INSTALLATION amp 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
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12. A m C C a 5 5 Tl ox I ON zx ais CC B Qo O amp a a a a __ 9 5 C 25 5 5 I I 2 2 gt ER Dr M wem CC ee I aa 8 al _ z 5 8 __ oO 8 m tc 5 ON uj ZU NE J AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 40 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 mechanism 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 he
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23. The chart above lists the conveyor switches and their func tions depending on the direction of travel for the machine As you can see when you change the direction of the conveyor you must also alter the way the conveyor switches operate There is no need to remove the switches only to change the wiring inside the heater box Terminal board inside the heater box 34 Note Before beginning any part of this maintenance evo lution that deals with the wiring of the machine ensure that it is performed by qualified technicians only Always refer to the machine schematic located inside the control box for any questions Wash Switch 1 and the Rinse Switch need to have their wire positions changed on the terminal board pictured above Locate the gray yellow wire for Wash Switch 1 do not con fuse it with the gray yellow wire for Wash Switch 2 and the orange yellow wire for the Rinse Switch Exchange their posi tions on the terminal board 35 Verify that the plumbing has been reassembled correctly and that the hole cover weldment has been replaced and none of the gaskets are torn or pinched as this could lead to leaking when the machine operates 35 Re install the heater box cover SPECIAL PARTS Gasket Rinse Injector Mfg No 05330 111 42 81 Incoming plumbing assembly for a Left to Right machine note hole cover weldment in lower right corner Incoming plumbing assembly for a Right to Left machine note h
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33. 66 80CEL CSL MACHINES 6 5 GALLONS PER RACK AJ 44 66 80CE CS CGP MACHINES 94 AJ 44 66 80CEL CSL MACHINES 1 00 WATER TEMPERATURES AJ 44 66 80CE CS CGP MODELS PREWASH RECOMMENDED 110 140 F WASH MINIMUM 160 F RINSE MINIMUM 180 F AJ 44 66 80CEL CSL MODELS PREWASH RECOMMENDED 110 140 F WASH MINIMUM 140 F RINSE MINIMUM 140 F FLOW PRESSURE PSI 20 5 FLOWRATE AJ 44 66 80CE CS CGP 3 9 AJ 44 66 80CEL CSL 3 9 MINIMUM CHLORINE PPM AJ 44 66 80CEL CSL MODELS ONLY 50 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 2 SECTION 1 SPECIFICATION INFORMATION ELECTRICAL REQUIREMENTS AJ 44CE CEL MODELS AJ 66CE CEL MODELS TYPICAL TYPICAL TOTAL ELECTRICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT VOLTS PH HZ AMPS CIRCUIT 208 50 55 70AMP 208 3 50 58A 220 3 50 49A 70 220 3 50 53A 70 AMP 20 3 50 51A 70AMP 230 3 50 54A 70AMP 30 3 50 29A 40 30 3 50 81A 40AMP 445 3 50 28A 415 3 50 34A 45 AMP 440 3 50 28A 440 8 50 45AMP 208 1 60 83A 110AMP 28 1 60 89A 125 AMP 20 1 60 76A 100 AMP 20 1 60 82A 110AMP 20 3 60 60AMP 200 3 60 51A 70AMP 208 60 49A 70AMP 208 3 60 52A 70AMP 20 3 60 45A _ 60 20 3 60 _ 48 60 3 60 29 40AMP 30 3 60 81A 40AMP 460 60 23A 40 60 24 600 3 60 19A 25 60 3 60 22A
34. MAW 7913 Added instructions and all necessary information for change of sanitization mode 5 thru 22 111 08 29 2007 7 dimension pages Removed alternate table limit switch NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Jackson AJ 44CSL AJ AJ series of rack conveyors 44 44 wide machine 66 66 wide machine 80 80 wide machine CE Electrically heated hot water sanitizing machine CEL Electrically heated chemical sanitizing machine CS Steam heated hot water sanitizing machine CSL Steam heated chemical sanitzing machine CGP Gas heated hot water sanitizing machine Model Jackson MSC LLC provides technical support for all of the dishmachines detailed in this manual We strongly recommend that you refer to this manual before making a call to our technical support staff Please have this manual with you when you call so that our staff can refer you if necessary to the prop er page Technical support is available from 8 00 a m to 5 00 p m EST Monday through Friday 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 Serial No Installation Date Service Rep Name Phone No SECTION TABLE OF CONTENTS DESCRIPTION SPECIFICATION INFORMATION Operating Characteristics Electrical Requirements D226 Steam Booster Parameters AJ 44 El
35. Support Weldments Strainers Float Switch Components Scrap Baskets Vent Cowl Assembly Vent Scoop Option Exhaust Fan Control Table Limit Switch SIDE LOADER SECTION Side Loader Track Assembly Leg Replacements Strainer Side LoaderPawl Bar Assemblies Pawl Bar Bracket Magnet Side Loader Vent Cowl Option D226 STEAM BOOSTER SECTION Control Box Assembly Plumbing Assembly Go Box Components BC Ferries Options vi 115 119 VI VIII TABLE OF CONTENTS ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS AJ 44CE CEL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 460 600 Volt 60 Hz 3 Phase Primary Side 380 460 600 Volt 60 Hz 3 Phase Secondary Side 380 415 Volt 50 Hz 3 Phase Primary Side 380 415 Volt 50 Hz 3 Phase Secondary Side 440 Volt 50 Hz 3 Phase Primary Side 440 Volt 50 Hz 3 Phase Secondary Side 440 Volt 50 Hz 3 Phase 5 Wire Primary Side 440 Volt 50 Hz 3 Phase 5 Wire Secondary Side AJ 44CS CSL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Primary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Secondary Side AJ 66CE CEL amp AJ 80CE CEL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 V
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37. cause staining A filter designed to remove iron from the supply water is highly recommended for sup plies in excess of 0 1 ppm parts per million Adjusting screw CONNECTING THE DRAIN LINE The drain for the models covered in this Locking nut 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 be 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 gt WATER SUPPLY CONNECTION Ensure that you have read the section enti tled PLUMBING THE DISHMACHINE above before proceeding 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 dishma chine line strainer It is recommended that a water shut off valve be installed in the water line between the main supply and the machine to allow access for ser vice The water supply line is to be capable of 25 PSI flow pressure at the rec ommended temperature indicated on the data plate Incoming Plumbing Connection 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 low of pressure results in too little water To adust the regulator loosen the nut at the top th
38. jodq X pue 1 19 95 5 esf 91 9 9 1 eigeiusiq e oqv 1 Y ERE uoneouqe 1 eur deog m uuges t 09 97 6 JO 20014 e8 gt eiqe oi ege 8 LL 8LL LI vv _ iz 1 EN 9 sz v 1 pm xo E 2 L IIVII E 441668 vL ejqeisn pe enp 1001 C L eorueA e1oN 5 IM0 3 Jeuondo 2 L L uonoeuuoo uonoeuuoo duie1 MO7 0r 408 LAN V 6 01391 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION SECTION 1 AJ 44 ELECTRIC RIGHT TO LEFT epis 1614 11014 5 uwos 4
39. the bolts that secure the tub weldment to the frame Install the brackets one at a time and ensure that they are firmly tightened down once installed 21 Remove the hole cover weldment from the top of the hood The cover is located on the end of the hood opposite of the rinse injector weldment Once removed set to the side along with its gasket AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 37 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED Removing the hole cover weldment 22 Separate the rinse plumbing from the rest of the incoming plumbing by loosening the union Ensure that the gasket on the bottom of the rinse injector stays with the assembly as you remove it Loosening the union on the incoming plumbing 23 Remove the remaining half of the union from the incoming plumbing 24 Remove the incoming water pressure regulator from the incoming plumbing and replace with the union half that was removed in step 23 Place the water pressure regulator on the end that the union half was removed from 25 Place the removed rinse plumbing assembly with the gas ket in the hole left open from when you removed the hole cover weldment in step 21 Tighten the two halves of the union together 26 Place the hole cover weldment with its gasket over the hole from where the rinse plumbing assembly was originally installed Tighte
40. 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 66 and AJ 80 operators should also take the time to inspect the prewash 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 46 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE
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42. 0 51 53 54 55 56 58 60 SS TABLE OF CONTENTS PARTS PARTS SECTION AJ 44 Control Box Assembly AJ 66 AJ 80 Control Box Assembly Motor Overload Chart Heater Assembly Thermostats Dress Panels Prewash Plumbing Assembly Wash Section Plumbing External Electric Booster Option Incoming Plumbing External Electric Booster Option Outlet Plumbing Water Hammer Arrestor OptionWPRK Plumbing Option 3 4 Solenoid Valve amp 3 4 NPT Vacuum Breaker Repair Parts Kits Steam Unit Wash Tank Coil Assembly Steam Plumbing Left to Right Steam Plumbing Right to Left Gas Coil Assembly CGP Models Rinse Booster Tank Assembly CGP Models Recirculating Pump Assembly CGP Models Hose Connections CGP Models Wash Fill Plumbing Assembly CGP Models Rinse Header Plumbing Assembly CGP Models AJ 44 Series Drain Plumbing Assemblies AJ 66 Drain Plumbing Assemblies AJ 80 Drain Plumbing Assemblies AJ 66 Drain Plumbing Assembly Left to Right CGP Models AJ 66 Drain Plumbing Assembly Right to Left CGP Models Drain Quench Assembly Motor Assemblies Prewash amp Wash Pump Weldments Lower Wash Arm Assembly Prewash Arm Upper Wash Arm Assembly Curtains Tub Magnets Final Rinse Assembly Drive Assembly Door Assemblies Pawl Bar Miscellaneous Components AJ 44 amp AJ 66 Pawl Bar Assemblies AJ 80 Pawl Bar Assemblies AJ 44 Rack Rail Assembly AJ 66 Rack Rail Assemblies AJ 80 Rack Rail Assemblies Miscellaneous Parts amp Weldments Manifolds Strainer
43. 0 230 27 50 SIAME FREQUENCY HZ 50 60 0 3 50 62A 80 AMP 20 3 50 63A 80AMP PHASE SINGLE 380 3 50 34A 45AMP 415 3 50 25A 35 AMP WATER REQUIREMENTS 440 3 50 22A 30 AMP INCOMING WATER TEMPERATURE MINIMUM 110 F FLOW PRESSURE PSI 20 5 208 1 60 91 125 230 1 60 84A 110 STEAM REQUIREMENTS 200 3 60 53A 70 AMP INCOMING STEAM PRESSURE PSIG 15 25 208 3 60 54A 70 AMP 230 3 60 70 HEAT EXCHANGER SPECIFICATIONS 380 3 60 34A 45 AMP TUBESIDE WORKING PRESSURE PSI 125 460 3 60 25A 35 AMP SHELLSIDE WORKING PRESSURE PSI 125 600 3 60 22A 30 AMP TUBESIDE HYDROSTATIC TEST PRESSURE PSI 250 SHELLSIDE HYDROSTATIC TEST PRESSURE PSI 188 AJ 80CS CSL MODELS MAXIMUM OPERATING TEMPERATURE 295 TYPICAL MAXIMUM SHELLSIDE STEAM PRESSURE PSI 125 TOTAL ELECTRICAL VOLTS HZ AMPS CIRCUIT Indicates typical design criteria but is subject to change 2 5 P 152 z ae without notice For more information contact you authorized 230 3 50 19A 25 AMP Jackson service representative 380 3 50 7A 15 AMP 415 3 50 8A 15 AMP STEAM RELIEF VALVE SET PRESSURE PSI 50 440 3 50 8A 15 AMP WATER OUTLET SAFETY VALVE SET PRESSURE PSI 125 208 1 60 19A 25 AMP 230 1 60 19A 25 AMP 200 3 60 13A 20 AMP 208 3 60 13A 20 AMP 230 3 60 13A 20 AMP 380 3 60 13A 20 AMP 460 3 60 7A 15 AMP 600 3 60 8A 15 AMP NOTE Always refer to the machine data plate for specific electrical and water requirements The material provided on this page is fo
44. 3 PREVENTATIVE MAINTENANCE gt _ gt SECTION 3 PREVENTATIVE MAINTENANCE 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 to 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 if they are clogged Have operators reg ularly 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 Wi
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47. 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 amp 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 55 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 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 amb
48. AJ 44CGP MODELS AJ 66CGP MODELS TYPICAL TYPICAL TOTAL ELECTRICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT VOLTS PH 2 AMPS CIRCUIT 208 1 60 12 15AMP 208 1 60 17 15 230 1 60 11 15AMP 280 1 60 17A 15 208 3 60 15AMP 208 3 60 15AMP 20 3 60 7 15AMP 280 3 60 15AMP 460 60 5 15AMP 460 60 6A 15AMP AJ 44CS CSL MODELS AJ 66CS CSL MODELS TYPICAL TYPICAL TOTAL ELECTRICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT VOLTS PH HZ AMPS CIRCUIT 208 50 18A 20 28 3 50 17A 25AMP 220 50 13A 20AMP 220 50 17A 25AMP 20 3 50 13A 20 20 3 50 17A 25AMP 30 3 50 1 30 3 50 6A 15 AMP 455 50 15AMP 415 3 50 15AMP 440 3 50 15AMP 440 8 50 6A 1 208 1 60 1 28 1 60 18A 2 280 1 60 15 20 1 60 25 20 3 60 1 200 60 12A 15AMP 208 3 60 1 208 3 60 12A _ 15AMP 20 3 60 1 20 3 60 12A 15 380 3 60 6A 15AMP 3800 3 60 12A 15 460 3 60 4 15AMP 40 60 1 60 3 60 4A 60 3 60 15AMP AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 3 SECTION 1 SPECIFICATION INFORMATION n ELECTRICAL REQUIREMENTS CONTINUED D226 STEAM BOOSTER PARAMETERS AJ 80CE CEL MODELS D226 STEAM BOOSTER TYPICAL TOTAL ELECTRICAL ELECTRICAL REQUIREMENTS VOLTS PH HZ AMPS CIRCUIT VOLTAGE V 20
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50. E no d IS AJ 44 RACK CONVEYOR DISHMACHINE SERIES INSTALLATION OPERATION amp TECHNICAL MANUAL FOR JACKSON MODELS AJ 44CE AJ 66CE AJ 80CE AJ 44CEL AJ 66CEL AJ 80CEL AJ 44CGP AJ 66CGP AJ 80CS AJ 44CS AJ 66CS AJ 80CSL AJ 44CSL AJ 66CSL Jackson MSC LLC P O Box 1060 Barbourville KY 40906 606 523 9795 September 29 2007 Fax 606 523 9196 P N 07610 001 76 22 Revision H www jacksonmsc com MANUFACTURERS WARRANTY N 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 MSC 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 service agency Use of generic replacement parts may create a hazard
51. ICATION INFORMATION SIDE LOADER INSTALLED DIMENSIONS 23 SIDE LOADER DIMENSIONS MODEL AJ 44 AJ 66 AJ 80 Left to Right installation shown for reference 30 SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ 44 82 AJ 66 104 AJ 80 118 NOTE ALL DIMENSIONS ARE TYPICAL lt x 23 30 gt Refer to chart above AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 25 D226 STEAM BOOSTER DIMENSIONS SECTION 1 SPECIFICATION INFORMATION 43 11 MI ES n ug 7 24 NOTE All dimensions are in inches and are for reference only c 16 13 Y I Y II mmo 7 S C I AE I AJ 44C Series Technical Manual 7610 001 76 22 26 Issued 03 21 2006 Revised N A MY SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS 4 ANK
52. OPERATION INSTRUCTIONS CONTINUED SHUTDOWN AND CLEANING 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 pum
53. R PREVENT LEAK AGE 4 1 2 2 25 _ MINIMUM DISHWASHER g SECTION p lt 12 1 2 DISHMACHINE VENT CONNECTION OPENING _ lt lt 25 gt 5 DISHMACHINE SPLASH SHIELD FG 662 amp Y Y f 0 E 2 gt N f Y 15 on 30 model 30 on 30 model ia A ES AE US 1 2 14 1 2 gt 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN 29 ea LINE AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 23 TS SECTION 1 SPECIFICATION INFORMATION SIDE LOADER RIGHT TO LEFT DIMENSIONS DISHTABLE 1 2 MINIMUM USE SILICONE WALL OF SIDE NOTE ALL DIMENSIONS ARE TYPICAL BETWEEN TABLE LOADER AND LIP OF SIDE LOADER TO PRE VENT LEAKAGE 1 2 25 4 1 2 5 7 DISHWASHER MINIMUM SECTION A A 1 2 CENTER ENT ud DISHMACHINE VENT CONNECTION OPENING CONVEYOR EP DISHMACHINE 2 SPLASH z SHIELD gt m E gt Q i 14 12 15 on 30 model lt 29 gt 30 on 30 model 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 24 __ SECTION 1 SPECIF
54. Steam Booster Piping Single Tank Machine Steam Booster Piping Double Tank Machine AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 27 MY SECTION 1 SPECIFICATION INFORMATION n TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS Electric Booster Dimensions Typical 18 ra 30 1 2 gt 24 OUTLET S 34 NPT Coupling for ie Temperature Pressure 7 7 8 i Relief Valve 57 mm 83 INLET EN 24 Electical ti U L U ectical connection 3j 6 from side or below H SIDE VIEW REAR VIEW gt 36 e 2034 Alternate TPRV Location Electrical Electrical 898 Water 31 1 4 Inlet Outlet Inlet Water Inlet 4 Gas Inlet 7 ns Y LEFT SIDE VIEW FRONT VIEW Gas Booster Dimensions Typical Alt t qu Eli 4 102 mm TPRV Location Vent Adapter y Water Water Gas Well Sule Inlet Outlet Inlet Water Inlet Gas Inlet NC d S
55. TION gt _ gt SECTION 1 SPECIFICATION INFORMATION RR OPERATING CHARACTERISTICS RACKS PER HOUR STEAM COIL TANK HEAT CS CSL MODELS ONLY AJ 44 66 80CE CS CGP 248 STEAM INLET PRESSURE PSIG 10 20 AJ 44 66 80CEL CSL 234 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG Ibs hr DISHES OR GLASSES PER HOUR AJ 44 66 80CS CSL 60 AJ 44 66 80CE CS CGP 6200 AJ 44 66 80CEL CSL 5850 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 PREWASH TANK CAPACITY GALLONS WASH MOTOR HP 2 AJ 66CE CEL CS CSL CGP 16 POWER RINSE MOTOR HP 2 AJ 80CE CEL CS CSL CGP 16 PREWASH MOTOR HP AJ 66 MODELS 1 WASH TANK CAPACITY GALLONS AJ 80 MODELS 2 AJ 44 66 80CE CS CGP 15 4 NOTE Typical Electrical Circuit is based upon 1 125 of PREWASH PUMP CAPACITY GPM the full amperage load of the machine and 2 typical AJ 66CE CEL CS CSL CGP 120 fixed trip circuit breaker sizes as listed in the NEC 2002 AJ 80CE CEL CS CSL CGP 270 Edition Local codes may require more stringent protec tion than what is displayed here Always verify with your WASH PUMP CAPACITY electrical service contractor that your circuit protection is GALLONS PER MINUTE ALL MODELS 270 adequate and meets all applicable national and local codes These numbers are provided in this manual sim VENTING REQUIREMENTS 100 CAP ply for reference and may change without notice at any INPUT END 200 given time OUTPUT END 400 TOTAL 600 CONVEYOR SPEED FPM AJ 44 66 80CE CS CGP MACHINES 6 9 AJ 44
56. al block as it is labeled L1 and L2 Run the ground wire to the grounding lug marked GND Tight connections and conduit nuts and close the control box by putting the cover on and securing with the 10 32 screws 52 OPERATION WARNING The heat exchanger used in the D226 Booster system is a pres sure vessel with very precise operating parameters Safety equipment such as 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 the 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 w
57. al equipment should be performed only by qualified service per 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 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 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 i
58. and void war ranty certification The labor to repair or replace such failed part will be paid by Jackson MSC within the continental United States Hawaii and Canada during the warranty period provided a Jackson MSC authorized service agency or those having prior authorization from the factory performs the service Any repair work by persons other than a Jackson MSC 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 MSC 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 MSC 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 MSC limits warranty travel time to 2 two hours and mileage to 100 one hundred miles Jackson MSC will not pay for travel time and mileage that exceeds this or any fees such as those for air or boat travel without prior authoriza
59. ater 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 installed 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 Ev
60. ave 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 dam age 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 lubri cant remains free of contamination over this period See comments under Subsequent oil changes for discussion of severe ambient con ditions Long term storage or infrequent operation If a speed reducer is to stand idle for an extended 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 com
61. 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 and serial number Decal showing L1 L2 amp 13 8 phase models only To install the incoming power lines open the control box Install 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 DE OX or another simila
62. ck of the control box Terminals in the control box marked CVS provide a constant voltage signal whenever the drive motor is operating Terminals in the control box marked DET provide a voltage signal whenever the wash motor 115 operating Aid Connection Points AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 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 should 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 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 Delim Switch 6 Wait five
63. combination wrench or 7 16 nutdriver will be required in order to hold the bolt head inside the control box Removing bracket bottom view Removing bracket control box view Remove the locknuts from the opposite bolts used to hold down the control box do not remove the bolts and secure the bracket to underside of the hood The folded part of the brack et should be facing the rear of the machine Immediately tight en down the locknuts 5 Remove the splash shield which is bolted to the underside of the hood next to the wash manifold and turn it 180 Removing and turning splash shield 6 Remove the pawl bar and set to the side Remove the pawl bar by grasping firmly and lifting up 7 Remove the lower wash arm assembly by turning the lock ing screw to unlatch it The entire assembly should then lift out Locking screw 8 Remove the lower wash arm support bracket Place it to the side with its locknuts AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED Removing the locknuts for the lower wash arm support bracket 9 Remove the lower rinse arm support bracket which is mounted directly opposite of the lower wash arm support bracket Removing the lower rinse arm support bracket 10 Remove the lower and upper rinse arms by unscrewing them and then ge
64. e 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 CALL 1 888 800 5672 TO REGISTER THIS PRODUCT FAILURE TO DO SO WILL VOID THE WARRANTY LLAME AL 1 888 800 5672 PARA REGISTRAR ESTE PRODUCTO AL NO HACERLO LA GARANTIA SERA ANULADA S V P APPELER 1 888 800 5672 POUR ENREGISTRER CE PRODUIT LA GARANTIE SERA ANNULEE POUR TOUT PRODUIT NON ENREGISTREE REVISION REVISION MADE APPLICABLE DETAILS PAGE DATE BY ECN 05 14 2004 Added exhaust fan hook up schematic Updated installation instructions Added 3 instruction sheets for E 03 08 2005 MAW 7096 limit switches Added instruction sheet for curtain installation Changed layout 01 13 2006 7470 Added service kits and maintenance instructions 01 26 2006 7600 Added Gas Exhaust Fan Schematic amp component kits 7571 7558 Added themostat replacement kits Added vent cowl assembly for H 03 21 2006 MAW 4 hooded side loader Replaced rinse drain weldment Added scrap 7634 basket strainer kit 04 19 2007 MAW 7898 Added 09905 003 32 20 fan load decal to the exhaust fan control kit Added warranty pages and service centers listings 35 amp 36 05 03 2007
65. e 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 INSPECTION Based upon
66. ectric Left to Right AJ 44 Electric Right to Left AJ 44 Gas Left to Right AJ 44 Gas Right to Left AJ 44 Steam Left to Right AJ 44 Steam Right to Left AJ 66 Electric Left to Right AJ 66 Electric Right to Left AJ 66 Gas Left to Right AJ 66 Gas Right to Left AJ 66 Steam Left to Right AJ 66 Steam Right to Left AJ 80 Electric Left to Right AJ 80 Electric Right to Left AJ 80 Gas Left to Right AJ 80 Gas Right to Left AJ 80 Steam Left to Right AJ 80 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 amp OPERATION INSTRUCTIONS Installation Instructions Deliming Operations Changing the AJ 44CE CS Direction of Travel Curtain Installation Diagrams Side Loader Installation amp Operation Instructions D226 Steam Booster Installation amp Operation Instructions Gas Conveyor Hose Installation Dishmachine Operating Instructions Changing Dual Sanitizatio Mode 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 40 41 42 44 46 48 5
67. en 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 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 i
68. ersonnel should ever perform any maintenance evolution on the dishmachine PREPARATION 1 Power must be secured to the unit at the service breaker Tag or lock out the service breaker to prevent acci dental or unauthorized energizing of the machine 2 Disconnect incoming water at the water pressure regulator or Y strainer 3 Disconnect the service drain line from the drain plumbing of the dishmachine itself Ensure that the unit is completely drained before doing this 4 Remove the locking screw from the control box 5 Remove the front dress panel TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 5 16 nutdriver 7 16 nutdriver 7 16 combination wrench 7 16 socket with drive ratchet and 4 extension 12 pipe wrench 10 adjustable wrench Wire cutters Phillipshead screwdriver TIME REQUIRED It is estimated that it will take 1 person three hours to perform this task not including all of the items indicated in the section entitled PREPARATION IMPORTANT NOTES 1 Do not lose hardware Place hardware in a safe spot away from the machine ensuring that it does not fall loose into the machine tub Hardware that is drawing into the suction of the wash pump will damage the equipment If you do need more hardware contact your JACKSON representa tive to purchase new items 2 Read these instructions thoroughly before attempt ing
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70. flow pressure AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 60
71. he 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 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
72. ied 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 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 valve 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 t
73. ient 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 Under 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 corrosive envi ronment 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 h
74. ill 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 43 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 making the where the hose is even cut at the other end of the with the yellow plastic stop hose Hose Connection Due to the fact
75. is 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 30 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED 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 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 outside source needs to
76. 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 1 3 RACK WIDTH how to wire the switch INSTALL AT FAR END OF TABLE 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 inside 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 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 TABLE LIMIT SWITCH THROUGH ROD HOLES TABLE SWITCH RODS STRIKE PLATE STRIKE PLATE BOLTS 3 00 MOUNTING BOLTS TABLE BOTTOM 2 00 sp gt 00 75 1 875 00 25 1 50 Unless noted all dimensions are in inches TABLE BOTTOM AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 51 SECTION
77. ity 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 41 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION amp OPERATION INSTRUCTIONS CONCEALED DAMAGE OR MISSING PARTS 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 crushed 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 booste
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79. lp 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 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 capabil
80. 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 33 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL The AJ 44 dishmachine has the ability to have its direction of travel changed from left to right or from right to left Direction of travel is determined by which end the rack of ware is put into the machine and which end the rack comes Out There may come times when it is necessary to change the direction of travel after the unit is installed The instructions provided here are for maintenance personnel only Unauthorized persons should not attempt any of the steps contained in these instructions Warning many of the instructions and steps within this document require the use of tools and may also require that personnel change the wiring of the machine Only authorized p
81. mportant 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 may 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 50 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions 1 Wiring The switch
82. n down with the locknuts 27 Re install the rinse manifold with its gasket by connect ing it to the rinse injector weldment at its new location Remove the locknut from the stud for the bracket down near the rack rails and then secure the bracket to the machine using the same lock nut 28 Re install the lower wash arm support bracket to the pawl bar support on the end of the tub opposite from where it was removed 29 Re install the upper and lower rinse arms Reinstall the lower rinse arm support bracket 30 Re install the lower wash arm assembly turning it 180 and locking it in place with the locking screw 31 Re install the pawl bar Ensure that the pawl bar is placed so that when racks are placed in the unit the pawl bar dogs fold down 32 Re install the upper wash arm assembly If you performed all of the actions outlined in step 2 when you install it it will be directly over the lower wash arm assembly 33 Remove the heater box cover by unscrewing the four screws holding it on Removing the heater box cover Front of rack conveyor showing the conveyor switches AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 38 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED Conveyor Switch Chart Unit Direction Left to Right Rinse Switch Right to Left Rinse Switch e
83. ntenance 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 the 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 i
84. ntly pulling them out Unscrewing and removing the lower rinse arm 11 Behind the rinse manifold remove the nut on the bracket Removing the bracket nut 12 Remove the nuts from the rinse manifold mounting brack et located on the underside of the hood These nuts are mounted directly to the rinse injector weldment on the hood top Removing the locknuts from the rinse mani fold mounting bracket 13 The rinse manifold must be removed This may prove dif ficult while the rinse injector is still mounted With great care it is possible to gently lift the rinse injector off of the hood to allow the rinse manifold to be removed from the unit Ensure that the gasket in the underside of the hood stays with the rinse manifold as it must be replaced when re installing the manifold If the gasket becomes lost or torn order a new one immediately Lifting the rinse injector to make room 14 Remove the entire rinse tray assembly including the pan AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 36 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED and the strainer within in The assembly should lift right out See next page for photograph detailing this step 15 Remove the front and rear rinse pan locator brackets Note the brackets are mounted to the bolts that secure the tub weldment to the frame Once the locknuts are rem
85. ole cover weldment in upper left corner AETER MAINTENANCE ACTIONS 1 Reconnect the incoming water and drain lines and then restore power to the unit Run the unit for at least 1 2 hour to ensure there are no leaks Test the unit with an empty rack to ensure that it pulls the rack all of the way through the unit If any problems arise you can contact your Jackson rep resentative 2 Replace the front dress panel once the unit is ready for service again SPECIAL NOTES 1 There is a possibility that you may be required to shorten or lengthen the conduit and wire lengths for the inlet solenoid on the rinse plumbing once it is moved This work should be performed by qualified technicians who will do the work according to applicable local state and national codes Questions concerning this should be directed to your Jackson representative AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A Please refer to the chart for placement of the curtains SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CURTAIN INSTALLATION DIAGRAMS EE to IC 2 a ul z z 5 i 5 55 lt a lt y N m 8 5 p x xi tc jam MI os 8 5
86. olt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 460 600 Volt 60 Hz 3 Phase Primary Side 380 460 600 Volt 60 Hz 3 Phase Secondary Side 380 415 440 Volt 50 Hz 3 Phase Primary Side 380 415 440 Volt 50 Hz 3 Phase Secondary Side AJ 66CS CSL amp AJ 80CS CSL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Primary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Secondary Side AJ 44CGP 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 Hz 3 Phase Primary Side 200 230 Volt 50 Hz 3 Phase Secondary Side 460 Volt 60 Hz 3 Phase Primary Side 460 Volt 60 Hz 3 Phase Primary Side AJ 66CGP AJ 80CGP 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 460 Volt 50 60 Hz 3 Phase Primary Side 460 Volt 50 60 Hz 3 Phase Secondary Side Conveyor Side Loader D226 Steam Booster Exhaust Fan Hook Up Schematics MAINTENANCE amp REPAIR CENTERS vii 121 122 123 124 126 127 128 130 131 132 133 134 135 137 138 139 140 141 142 144 145 146 147 SECTION 1 SPECIFICATION INFORMA
87. onoeuuo Seo Jeunjoejnueui Aq pepi oJd esou euigoeulusip uo uonoeuuoo Jenno 4081 LAN v Jejeeu 1e1sooq 526 19 U L LdN v Jeunjoejnueui Aq pepi oud esou DunoeuuooJelu Jejeeu 1919000 ui0J4 yug asun eui YUL YSEM 10 19 u 40081 LdN V 6 4 3 2 1 uonoeuuoo uonoeuuoo 6 II129 3 4 Op L duer IH 3081 LAN V Buiweiq pue6e1 01 191 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION AJ 44 GAS RIGHT TO LEFT SECTION 1 epis 1V I 14043 uus e 1 12 5 i Z Da d Y 61 37 114 9 E PM i 1 ve SAU iN Y T 0 19 2
88. ose the heater thermostat box Remove the cover from the heater thermostat box Locate the wash tank regulating thermostat see diagram Wash Thermostat The wash tank regulating thermostat will maintain the correct wash water temperature NSF requirements specify that the wash water during operation be 140 F minimum in the chem ical sanitizing mode and 160 F minimum in the hot water san itizing mode Adjust the thermostat to achieve the required minimum temperatures during operation Turn the adjustment screw clockwise to increase the temperature set point coun terclockwise to decrease the temperature set point Replace heater thermostat box cover and front dress panel Control Box Gauge Location IDENTIFICATION OF SANITIZING MODE Apply the correct temperature gauge label to the face of the temperature gauges In the chemical sanitizing mode the temperature gauge labels must specify 140 F minimum wash temperature and 140 F minimum rinse temperature In the hot water san itizing mode the temperature gauge labels must specify 160 F minimum wash temperature and 180 F minimum rinse temperature Apply the correct sanitizing mode label in a visible location on the side of the control box NOTICE THIS MACHINE IS CURRENTLY IN CHEMICAL SANITIZING MODE Yellow background Orange background INSTALL SANITIZER DISPENSER For machines in the chemical sanitizing mode a NSF Standard 29 approved chemical dispenser mu
89. oved pull the locator brackets off and immediately replace the locknuts back onto the bolts Failure to do so at a minimum may cause excessive leaking of the tub once the unit is placed back in operation Removing a rinse tray guide bracket 16 On the drain plumbing the rinse drain tube needs to be removed from the plumbing as well as the wash drain tube Both of these tubes are secured with hose clamps Loosen the hose clamps and pull the tubes off Loosening the rinse drain hose from the rinse drain nipple 17 The tee that the rinse drain nipple is in must be turned 180 so that it is facing the opposite direction This may require dis mantling the plumbing by removing the tee with the wash drain barb in it Put the plumbing back together after ensuring that the rinse drain tee has been rotated Use thread tape to pro tect the threads while putting the plumbing back together Ensure that the wash drain barb is in the exact same position it was prior to this step 18 On the underside of the tub remove the rinse drain weld ment and the rinse drain plug Switch their locations so that the rinse drain weldment is in the spot that the rinse drain plug was in Removing the rinse drain plug 19 Reconnect the rinse drain hose and the wash drain hose to the drain plumbing 20 On the opposite end from where they were removed install the front and rear rinse pan assembly locating brackets Note the brackets are mounted to
90. own on the threaded shaft by turning it approximately 1 2 turn counter clockwise Tighten the Adjustment Nut by turning it clockwise Retighten the Bottom Jam Nut against the Top Jam Nut MODEL XXXXXXXXX WASH MOTOR 2 0 HP DRIVE MOTOR 1 4 WASHHEATERLOAD 15KW TOTAL AMP LOAD HOT WATER SANITIZING 6 9 FPM 1607 F MIN 1807 F MIN 20 5 PSI CONVEYOR SPEED WASH TANK TEMPERATURE FINAL RINSE TEMPERATURE FLOW PRESSURE SERIAL XXX XXXX X 60 HZ 3 PHASE 3 WIRE 208V 230V 460V 56A 56A 28 11A 0 6 41 7 37 7A 18 8 CHEMICAL SANITIZING 6 5 FPM 1407 F MIN 1407 F MIN 20 5 PSI NOTE SEE INSTRUCTION IN MANUAL FOR MODIFYING MODE OF SANITIZATION Commercial Dishwasher 597G US Patent Number s 6 012 567 Canadian Patent Number s 2 205 331 Made in the USA Jackson MSC Inc P O Box 1060 Barbourville KY 40906 606 523 9795 09905 021 70 81 E Please note the parameters for both modes of sanitization If your data plate has this information it is convertible from one mode to another _ Adjustment Nut Top Jam Nut Bottom Jam Nut Figure 2 Figure 1 Drive Mechanism AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 05 03 2007 48 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING DUAL SANITIZATION MODE CONTINUED THERMOSTAT ADJUSTMENT Remove the front dress panel from the machine to exp
91. p 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 47 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING DUAL SANITIZATION MODE If the machine has a dataplate like the one shown which indi cates both Hot Water Sanitizing and Chemical Sanitizing operation parameters the area within dashed box it is pos sible to change the sanitizing mode after the machine has left the original manufacturer s facility This change can only be performed by an authorized Jackson service technician If the machine does not have a dataplate like the one shown the sanitization mode CAN NOT be changed Follow the instructions below to change the mode of sanitiza tion Failure to follow these instructions can result in a viola tion of applicable regulatory codes DRIVE MECHANISM MAXIMUM SPEED ADJUSTMENT Note This adjustment is only required when changing from hot water sanitizing to chemical sanitizing mode Locate the maximum speed adjustment mechanism at the top of the conveyor drive mechanism Figure 1 Figure 2 shows an enlarged view of the maximum speed adjustment mecha nism Loosen the Bottom Jam Nut approximately one turn counterclockwise Move the Top Jam Nut d
92. parts from the machine This may not 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 No to side and from front to back before making any connections You will be able to adjust the over Frame with Adjustable Foot all height of the unit by turning the bullet feet from between 75 1 2 to 76 1 2 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
93. patible 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 equiva lent 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 lubricate 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 reducer and the severity of the application 9loading duration of service ambient temperatures Excessive oil temperatures may be the result of sev eral factors including overloading overfilling underfilling or inadequate cooling Nominal Ratio Size 5 7 5 10 15 20 25 30 40 50 60 80 100 920 0 347 0 263 0 225 0 216 0 202 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 56 SECTION 4 TROUBLESHOOTING SECTION SECTION 4 TROUBLESHOOTING T COMMON PROBLEMS WARNING Inspection testing and repair of electric
94. pe 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 cause 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 a
95. perature 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 lbs Heater Nuts 16 In Ibs Terminal Block 50 In Ibs AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 59 SECTION 4 TROUBLESHOOTING D226 COMMON PROBLEMS WARNING Inspection testing and repair of electrical equipment should be performed only by qualified service per sonnel Certain procedures in this section require electrical tests or measurements while power is appl
96. r 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 sonnel of any problems and of the location of the service break er Replace the control box cover and tighten down the screws Incoming Power Connection 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 31 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED The exhaust system must be sized to handle this volume fo
97. r reference only and may be subject to change without notice AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 4 SPECIFICATION INFORMATION SECTION 1 AJ 44 ELECTRIC LEFT TO RIGHT epis 10014 9015 39 2 1 22 9 g 62 L J 1 1 9 1 1 4061 4 c wun 2 4798 pe i 99 uus 1 109 I Jo 168 1 E ENS 2 69 V5I0 3 441065 229 52 X ysejdsyoeg uw161 52 V wwz991 269 1 EN 6911 99 Xe b g auel E H wwzo p B e 61 V C gt wwgoz g _ EES LC uedo 51000 zea paddiys peius YS E V56I05 IM0 1nojno E19 90 91 201 1deooy qn 910M 0
98. r 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 temperature Install condensate drains in accordance with applicable codes The 0226 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 facto
99. r the dishmachine to operate as it was designed to ELECTRIC 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 The AJ 44CEL CSL AJ 66CEL CSL and AJ 80CEL CSL are designed to operate with a third party chemical injection system Jackson does not endorse any particular chemical injection system The system select ed must be able to provide detergent and sanitizer in the required concentrations The minimum chlorine concentration for prop er sanitization is 50 PPM Furthermore the selected feeder needs to be able to operate against a head of 25 PSI and deliver 7 38 ml of a 10 chlorine sanitizer per minute 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 detergent concentration probe For more information concerning detergent concerns please refer to Brass Plug the page entitled Detergent Control Detergent Connection Point Machine rear view The 1 8 brass plugs on the incoming plumbing rinse injector may be removed to install sanitizer and rinse aid injection fittings Brass Plugs Back of Control Box All wires for the chemical injectors should be routed through one of the extra openings in the ba
100. re 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 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 gt AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 53 SECTION 3 PREVENTATIVE MAINTENANCE ERR 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 acceptable temperature prior to performing any mai
101. ry 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 42 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 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 Terminal Block To connect the incoming power run the conduit for power wires through the open hole in the back of the control box Connect the power wires to the termin
102. s 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 strainers 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 as
103. sembly is out of adjustment Adjust as required AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 58 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 Incorrect 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 Problem Spotting of silverware glasses and dishes 1 Incorrect final rinse temperature Verify that the rinse water tem
104. 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 cause damag
105. st be installed to dispense sanitizer into the final rinse line Follow instructions included with the chemical dispenser The system selected must be able to pro vide detergent and sanitizer in the required concentrations The minimum chlorine concentration for proper sanitization is 50 PPM Furthermore the selected feeder needs to be able to operate against a head of 25 PSI and deliver 7 38 ml of a 1096 chlorine sanitizer per minute FINAL CHECK Verify that the incoming water matches the flow pressure and temperature requirements listed on the machine data plate Verify that minimum wash and rinse tem peratures are maintained during operation AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised 04 30 2007 49 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 gre
106. t should be replaced immediately by an authorized service representative AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 54 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 Syncon amp 220 Teresstic SHP220 SPO MG Omala RL 220 Pinnacle 220 16 50 F up to 2000 FPM 460 7 Compounded 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 450 680 8 Compounded Extra 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 450 460 7 Compounded 600W Super Oylinder AGMA 7 Gear Oil Tribol 1105 7C Cylinder Oil W460 Inca Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 96 131 F up to 450 FPM 680 8S SHC 636 N A Tribol 800
107. 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 AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A 44 INSTALLATION OPERATION INSTRUCTIONS SECTION 2 GAS CONVEYOR HOSE INSTALLATION CONTINUED YALVSH 8 15008 SVD JHL 40 NOLLO3NNOO H31VM 99100 AHL OL LOANNOO SNOILVELSNTH 3AO8V JHL S3SOH kx Y3LY3H H31S008 SVO JHL HO NOILOANNOO H31VM
108. this maintenance evolution Become familiar with the parts and what actions need to be taken This will save time in the long run STEPS 1 Remove the upper wash arm assembly by loosening the spin nut The spin nut has a stop so it will not come off Once it is loosened the wash arm assembly should slide off Spin nut 2 Remove the end cap from the wash arm assembly and place in the opposite end securing it snugly End cap 3 With the end cap securely in the opposite end of the wash arm assembly set the assembly gently to the side Go back inside the unit to where the upper wash arm assembly secured in the unit and turn the spin nut so that it is all the way down This needs to be done because in a further step if the spin nut is out it will get in the way Do not over tighten the spin nut as it only needs to be out of the way not secured AJ 44C Series Technical Manual 7610 001 76 22 Issued 03 21 2006 Revised N A SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED 4 Remove the upper wash arm assembly bracket This step may require that you have help as the bolts for securing the bracket to the top of the inner hood are the same bolts that hold the control box to the hood top Do not remove the bolts once the nuts are taken off Once the bracket is removed place the nuts immediately back on the bolts To hold the bolts to keep them from spinning a 7 16
109. tion WARRANTY REGISTRATION CARD The warranty registration card supplied with the machine must be returned to Jackson MSC 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 MSC 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 MSC 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 MSC 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 limited to timer cams thermostats or doors beyond 30 days from th

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