Jackson AJ-44TE User's Manual
Contents
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5. V 1 01 497 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 12 SPECIFICATION INFORMATION SECTION 1 AJ 66T GAS RIGHT TO LEFT epis 14614 10014 epis gt es oi 1 ez uwz 12 er e uwos for 3 west 9 1 luueoi E ii Fd CF is wun 9 yu 19 rz 4d E lt 0 91 i UTOR 9 292 Ev d eoueJee ysiad 18 441959 sz wwr 16 9 3 d wwoes 09 799 9 s B Wd 0691 Zeg 4 1 nl Muumglerte 8 018 3 EE wwees iz H 4466 tee 1 fut por Lg 6161 9 V Soe uuise9 sz 019 pz wwzs01 27 E d uedo 100 WIM eau 28 ui paddiys Doug wwe iz rg eur 92 1u9A 1nojno Duo 8 p4 90p 91 x 201 0 91 og e ueq 10
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11. TABLE OF CONTENTS SECTION DESCRIPTION PAGE VII ELECTRICAL SCHEMATICS AJ 66TG amp AJ 80TG 208 230 Volt 60 Hz 1 Phase 110 208 230 Volt 60 Hz 3 Phase 111 460 Volt 60 Hz 3 Phase 112 AJ 66TS amp AJ 80TS 208 230 Volt 60 Hz 1 Phase 113 208 230 Volt 60 Hz 3 Phase 114 460 Volt 60 Hz 3 Phase 115 Conveyor Side Loader Drain Quench Schematics 116 Exhaust Fan Hook Up Schematics 117 VIII JACKSON MAINTENANCE amp REPAIR CENTERS 118 SECTION 1 SPECIFICATION INFORMATION SECTION 1 SPECIFICATION INFORMATION OPERATING CHARACTERISTICS RACKS PER HOUR STEAM COIL TANK HEAT TS MODELS ONLY AJ 44 66 80TE TG TS 204 STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 DISHES OR GLASSES PER HOUR CONSUMPTION 15 PSIG Ibs hr 60 AJ 44 66 80TE TG TS 5100 MOTOR ELECTRICAL CHARACTERISTICS PREWASH TANK CAPACITY GALLONS DRIVE MOTOR HP 1 4 AJ 66TE TG TS 17 25 WASH MOTOR HP 2 1725 POWER RINSE MOTOR 2 S PREWASH MOTOR HP AJ 66TE TG TS MODELS 1 WASH TANK CAPACITY GALLONS AJSOTE TG TS MODELS E ree pole SES NOTE Always refer to the machine data plate for specific PREWASH PUMP CAPACITY GPM electrical and water requirements The material provided on this is reference only and may be subject to AJ 66TE TG TS 120 change without notice AJ 80TE TG TS 270 WASH PUMP CAPACITY GALLONS PER MINUTE ALL MODELS 270 VENTING REQUIREMENTS CFM 100 CAP INPUT END 200
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16. 6 uuige Zog uedo sioog d uwez 8 Jeng ejqeisn pe 400 SUOISUBWIIP EUSA IN 4 081 LAN PE N uonoeuuoo 0 LAN v 1 uoreuuoo ejesuepuoo PI uonoeuuoo WEIS uoreuuoo eoujoeje WES H jeuondo LdN uonoeuuoo Buiquunjd 9 0 0 J9 M 4 5 3 jeuondo 1ejoo LAN uogoeuuoo 9 uonoeuuoo eou99r3 9 Or 3081 LAN 1 437 o1 WD AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 21 TS SECTION 1 SPECIFICATION INFORMATION SIDE LOADER LEFT TO RIGHT DIMENSIONS NOTE ALL DIMENSIONS ARE TYPICAL 1 2 DISHTABLE MINIMUM USE SILICONE BETWEEN TABLE AND LIP OF SIDE WALL OF SIDE LOADER TO LOADER PREVENT LEAK AGE 1 2 _ 41 25 5 MINIMUM DISHWASHER 5 SECTION A A lt 12 1 27 DISHMACHINE VENT CONNECTION m OPENING T T CONVEYOR z 4 gt lt 2 gt 5 DISHMACHINE SPLASH SHIELD Fe 2 Q 2 D 5 5 25 S ge 52 NES Sa
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18. AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 10 SPECIFICATION INFORMATION SECTION 1 AJ 66T ELECTRIC RIGHT TO LEFT epis 1 M9IA 11044 epis fo 1 1 8 wwogz 01 ul 9 wwzez ee PEE i d 11 i 9 IU pe uu019 rz ua 2 Vi D 7 Jo wwoest 09 amp ysiad 9 os 229 799 10 S o BA 2 7 Ge 4 al e 06 a z q V uueozlg 9 ww6 tues 12 bp e E A 9 9 amp uu901 zt 6 6 Ger uedo 1004 419802 28 8 eur 92 5 0 AALL 9 99 881 eje d 19400 peddius 45 ureq JO UIs 20014 ysemeald 9 yun ese IEEE 907 91 X 201 699 zz DOC uuo e 019 ue d
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23. Lubricant selections are provided by the lubricant manufacturer based on AGMA recommended viscosity grades Viscosity grades are based on Lubrication Standard ANSI AGMA 9005 D94 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 39 SECTION 4 TROUBLESHOOTING SECTION SECTION 4 TROUBLESHOOTING T 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 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 ma
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29. 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 P WP Problem Spotting of silverware glasses and dishes 1 Incorrect final rinse temperature Verify that the rinse water temperature matches that which is listed on the machine data plate 2 Clogged wash and or rinse nozzles and arms Remove the arms and verify that they and their nozzles are from debris 3 Excessively hard water Install a water softener to reduce hardness 4 Loss of water pressure due to clogged obstructed wash pump Turn the power off to the machine at the source Drain the wash tank of water and verify that the pump intake is free from debris 5 Improper scrapping procedures Review the paragraph entitled Ware Preparation in Operating Instructions 6 incorrect detergent chemical 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 specifica tions ITEMS TORQUE SPEC Relays 16 In Ibs Heater Contactor 35 In lbs Heater Nuts 16 In Ibs
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33. ALL DIMENSIONS ARE TYPICAL 10 4 34 23 or 30 depending on the width of the side gt loader lt lt lt Refer to chart above gt FREE AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 24 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 A 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 re
34. LAN v IN uonoeuuoo 4 01 L LAN 1 uonoeuuoo 7 2 uonoeuuoo WEAS LAN uonoeuuoo eoujoeje ureels H ejesuepuo2 LN v 9 uogoeuuoo WEIS LAN 3 moo 3 Jeuondo 2 uogoeuuoo 9 uonoeuuoo duiej MO7 OF L duie1 IH 3081 LAN 19JUI V 1 01 497 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 20 SPECIFICATION INFORMATION SECTION 1 AJ 80T STEAM RIGHT TO LEFT epis 1 1298 9 1 4798 pe 9 450 sz 799 41 08 zt uuges 12 9 sz 10019 4 00v 6 wupgz 01 uiusez ez P 299 unge 9 wwz 291 9 i 1 11 1 i uerg 7 EM 4 Gel x 5 9 CH d mmm Ze 5 d SAI 59 SAA 4 d trop Za 1 Ger a Jo 2601 v is wwezst 09 1 Zeg 4 8 v
35. OUTPUT END 400 TOTAL 600 CONVEYOR SPEED FPM AJ 44 66 80TE TG TS MACHINES 5 7 GALLONS PER RACK AJ 44 66 80TE TG TS MACHINES 69 WATER TEMPERATURES AJ 44 66 80TE TG TS MODELS PREWASH RECOMMENDED 66 amp AJ 80 110 140 F WASH MINIMUM 160 F RINSE MINIMUM 180 F FLOW PRESSURE PSI 20 5 FLOWRATE GPM AJ 44 66 80TE TG TS 3 1 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 2 SECTION 1 SPECIFICATION INFORMATION ELECTRICAL REQUIREMENTS NOTE Typical Electrical Circuit is based upon 1 125 of the full amperage load of the machine and 2 typical fixed trip circuit breaker sizes as listed in the NEC 2002 Edition Local codes may require more stringent protection than what is displayed here Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes These numbers are provided in this manual simply for reference and may change without notice at any given time RINSE TYPICAL HEATER TOTAL ELECTRICAL MODEL VOLTS PH HZ RATINGS AMPS CIRCUIT AJ 44TE 208 1 60 N A 97A 125 AMP AJ 44TE 230 1 60 N A 89A 125 AMP AJ 44TE 208 60 N A 57 80 AJ 44TE 230 60 N A 49A 70 AMP AJ 44TE 460 60 N A 25A 35 AMP AJ 44TG 208 1 60 N A 12A 15 AMP AJ 44TG 230 1 60 N A 12A 15 AMP AJ 44TG 208 60 8A 15 AMP AJ 44TG 230 60 N A 8A 15 AMP AJ 44TG 460 3 60 N A 15 AJ 44TS 20
36. Op L duer IH 08 LAN V pue6e1 0 191 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION SECTION 1 AJ 44T GAS RIGHT TO LEFT epis 6 M8IA 14043 epis uus Oe e 1 ug 12 5 uus i Da d Y 61 22 M E PM i 1 ve SAU iN 1 T uu70v 91 2 quurtel jo jeeg 9 uut 1 9 9 ysiad 9 sz ES woes 709 1 799 L D Y 82 V 4 B 1 4106 Zeg 4 V uugzol v z 0 21 a Feb m 1 Zog uuges 12 H Ses uuggo sz wuizor 81 p 6161 uedo 100 KO luwvesH 09 19409 peddius game JO wus 1004 68 j 1nojno eng ejqeisn pe
37. Terminal Block 50 In Ibs AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 42
38. Y wwott fe fer ene 5 dene wwgy Ze ET n 8 I vue ee a 9 4 1 i e a M ERES wwees 12 A sir c 4 Boa X e yi uuig96 8 N f 27772 2 Z T 91 6 WW Sit 7 H XEN A ant 919810514 enoqv ul M 559 12 1 ue d USeMaJd A4 61 Ae pue MALA euooiis esf m A 259 ae N S zhon 8 4 dn a ase KI ejqe eur ueq 92 E 10 10014 uu ipp pm uuigeze 88 or aqe 02 08 eje d 19 09 peddius 45 use ds Mo Buoj 9 1deooy qn L 91oN uoneouqeJ ue z 8 jong ejgeisn pe 1004 2 1 910 feuondo LdN PI uonoeuuoo O 091 011 E N OUIYDELUYSIP 01 4 081
39. 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 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 har
40. e HI zs Ke 5 ae AZ UE X Tm A 2 14 1 2 gt 1 1 2 DRAIN CONNECTED 1 SIS TO DISHMACHINE DRAIN lt 29 gt LINE 8 or 15 depending on the width of the side loader AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 22 TS SECTION 1 SPECIFICATION INFORMATION SIDE LOADER RIGHT TO LEFT DIMENSIONS v O epis JO uo Buipuedep 02 10 52 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 Mu m DISHWASHER gt MINIMUM SECTION A A 1 2 gt TERT uif NC DISHMACHINE VENT CONNECTION OPENING CONVEYOR 5 Q I DISHMACHINE Zee n SPLASH z 2 a SHIELD gt 3 rx m UJ r i Bo 14 1 27 58 1 1 2 DRAIN CONNECTED TO Le 29 9 DISHMACHINE DRAIN LINE 3 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 23 SECTION 1 SPECIFICATION INFORMATION SIDE LOADER INSTALLED DIMENSIONS 23 SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ 44T 75 AJ 66T 97 AJ 80T 111 Left to Right installation shown for reference 30 SIDE LOADER DIMENSIONS MODEL AJ 44T AJ 66T AJ 80T DIMENSIONS 82 104 118 NOTE
41. operation or every 6 months whichever occurs first Under severe conditions rapid temperature changes moist dirty or cor rosive environment it may be necessary to change oil at intervals of one to three months Periodic examination of oil samples taken from the unit will help establish the appropriate interval Synthetic oils Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable have a much longer life and operate over a wider temperature range These oils are appropriate for any application but are especially useful when units are subjected to low start up temperatures or high operating temperatures However continuous operation above 225 F may cause damage to seals or other components It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation to remove metal particles that accumulate during break in Subsequent oil changes should be made after 5000 hours operation if units are operating in a clean environment This can be extended to 10 000 hours if using new reformulated Mobil SHC lubricants orange in color and the lubricant remains free of contamination over this period See comments under Subsequent oil changes for discussion of severe ambient conditions Long term storage or infrequent operation If a speed reducer is to stand idle for an extended period of time either prior to installation or during use it is recommended that the unit be filled comp
42. series of rack conveyors 44 44 wide machine 66 66 wide machine 80 80 wide machine TE Electrically heated hot water sanitizing machine TG Gas heated hot water sanitizing machine TS Steam heated hot water sanitizing machine Model Jackson MSC LLC provides technical support for all of the dishmachines detailed in this manual We Serial No strongly recommend that you refer to this manual before making a call to our technical support staff Installation Date Please have this manual with you when you call so that our staff can refer you if necessary to the prop Service Rep Name er page Technical support is available from 8 00 a m to 5 00 p m EST Monday through Friday Phone No Technical support is not available on holidays Contact technical support toll free at 1 888 800 5672 Please remember that technical support is available for service personnel only a TABLE OF CONTENTS SECTION DESCRIPTION PAGE SPECIFICATION INFORMATION Operating Characteristics 2 Electrical Requirements 3 AJ 44T Electric Left to Right 4 AJ 44T Electric Right to Left 5 AJ 44T Gas Left to Right 6 AJ 44T Gas Right to Left 7 AJ 44T Steam Left to Right 8 AJ 44T Steam Right to Left 9 AJ 66T Electric Left to Right 10 AJ 66T Electric Right to Left 11 AJ 66T Gas Left to Right 12 AJ 66T Gas Right to Left 13 AJ 66T Steam Left to Right 14 AJ 66T Steam Right to Left 15 AJ 80T Electric Left to R
43. the terminal block Install the grounding wire into the lug provided Tighten the connections It is recommended that DE OX or another similar anti oxidation agent be used on all power connections Terminal Block VOLTAGE CHECK Ensure that the power switch is in the OFF position and apply power to the dishmachine Check the incom ing power at the terminal block and ensure it corresponds to the voltage listed on the data plate If not contact a qualified service agency to examine the problem Do not run the dishmachine if the voltage is too high or too low Shut off the service breaker and mark it as being for the dishmachine Advise all proper per 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 The exhaust system must be sized to handle this volume for the dishmachine to operate as
44. 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 u
45. 006 Revised N A 28 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CURTAIN INSTALLATION DIAGRAMS Please refer to the chart for placement of the curtains L 5 5 SS LL tc tr tc UW z m LLI Q Q 8 8 ke 5 _ Q ol 2 Aa E _ 2 Em 2 oe foo cc x c ben tc X oan lt E Lu 1 A emm We n a Q 2 5 p I T 2 2 D D Nd NA os L SSS aes os cc 2 I lt e ho 69 lt m c ne Ge AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 29 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 recommen
46. 014 zoe 5 o1 1 nou 8 uugL Li vv ens 1 iz 1 DU _ EN 9 sz o v eO cox Cd wy oh v 996 vt 1 ejqeisn pe enp 100 6 1 e1oN 3 Jeuondo 1u9A 2 L L uonoeuuoo ueq 9 uonoeuuoo 0r Ouer 408 LAN HE 01391 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION SECTION 1 AJ 44T ELECTRIC RIGHT TO LEFT epis 1614 M9IA 11014 5 uwos 4 taz Ol 6 9 1 1 rd Hi 1 1 i IT i Y 9 li wun pe Ru E wwoest 709 mi jo ENTE ysiq wiwo6st teo 411689 sz e 3 x 111 99 99 lt uu6 161 552 69 99 y 1 4 x uugzi z uuisz Leite wwzolly wwoe m V m 1450 8
47. 03 07 21 Issued 03 21 2006 Revised 09 29 2007 SPECIFICATION INFORMATION SECTION 1 AJ 44T GAS LEFT TO RIGHT epis 14614 11044 9piS 971 uu 6 9 ot SS Taree f 9 uwos H j 29 i 2 6 ez 5 E i i i id e ii rii wun lu ju re td ler aN HEN q m SR E wwzg 9 uwose rim E n jo peu usejdsyoeg 6 96 ees Huus sue Md 9 92 01 9 z wwoes 709 V uupgo 799 i uugz Z 14 069 z9 wuz 1 wwzoe Stee 8 a v v Zoo 9 8 wwz69 99 uuges iz 4 7 uruse9 97 28 gel wwe 161 9 Y uedo 5100 18409 peddius pals peta eur ureJq I E9 O ysejdg imog 1ueA 1nojno 97 E 10 4UIS 10014 122 ynos oi EES huett rk 0 8 p o y UM d D Ki _1 69 gt
48. 12 92 E JO US 10014 gt 559 12 A LR ZENO 97 81 m wwipe 09 ww ze 9 oi 09 8 wwo p 5 amp d uu L1 271 v A XEN 2 ww 61 229 8 ve 01 oDue J decoy Qn L 910 Bass 88 n u GE eg _ 11 wwes 79 14996 8 A 91 6 9 1 dr e qeiusiq ejqe xoeu Jejees QUODI IS esf gt Wey uedo Le 78 joe Jong ejqeisn pe enp 10044 6 1 v 210 euigoeulusip 4 081 IN uonoeuuoo Jayem 4 011 LAN v 1 uonoeuuoo uonoeuuoo WEIS uonoeuuoo WSIS H uinjeJ ejesuepuoo LN v 9 uonoeuuoo WSIS LAN U9A 3 jeuondo u2
49. 8 1 60 N A 15 AJ 44TS 230 1 60 N A 11A 15 AMP AJ 44TS 208 60 N A 15 AJ 44TS 230 60 N A 15 AJ 44TS 460 3 60 N A 4A 15 AMP AJ 66TE 208 1 60 N A 103A 150 AMP AJ 66TE 230 1 60 N A 95 125 AMP AJ 66TE 208 60 N A 61 80 AJ 66TE 230 60 N A 52A 70 AMP AJ 66TE 460 3 60 N A 26A 35 AMP AJ 66TG 208 1 60 N A 18A 25 AMP AJ 66TG 230 1 60 N A 18A 25 AMP AJ 66TG 208 60 N A 12A 15 AMP AJ 66TG 230 60 N A 12A 15 AMP AJ 66TG 460 60 7A 15 AMP AJ 66TS 208 1 60 N A 17A 25 AMP AJ 66TS 230 1 60 N A 17A 25 AMP AJ 66TS 208 3 60 N A 15 AJ 66TS 230 60 N A 15 AJ 66TS 460 60 N A 6A 15 AMP AJ 80TE 208 1 60 N A 106A 150 AMP AJ 80TE 230 1 60 N A 97 A 125 AMP AJ 80TE 208 60 N A 63 A 80 AMP AJ 80TE 230 3 60 N A 58 80 AMP AJ 80TE 460 60 29 40 AJ 80TG 208 1 60 N A 19A 25 AMP AJ 80TG 230 1 60 N A 19A 25 AMP AJ 80TG 208 3 60 N A 13A 20 AMP AJ 80TG 230 3 60 N A 13A 20 AMP AJ 80TG 460 3 60 N A 15 AJ 80TS 208 1 60 N A 19A 25 AMP AJ 80TS 230 1 60 N A 19A 25 AMP AJ 80TS 208 60 N A 13A 20 AMP AJ 80TS 230 60 N A 13A 20 AMP AJ 80TS 460 60 N A 7A 15 AMP AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 3 SPECIFICATION INFORMATION SECTION 1 AJ 44T ELECTRIC LEFT TO RIGHT
50. 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 Wipe out strainers with a rag and rinse under a faucet if necessary For stubborn debris a toothpick should be able to dislodge any obstructions from the perforations Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub You may wish to also refer to the page entitled Detergent Control in order to learn more about how your water hardness will effect the perfo
51. boat travel without prior authorization 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 thermosta
52. chine 2 Dishmachine doors are not closed Close doors completely 3 Incoming water solenoid valve damaged faulty Verify that the valve is operating If not replace 4 Tank floats faulty Verify the wiring of the floats Verify that no debris is jamming the floats Replace if necessary Problem Machine fills but fill is weak 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Low wash tank temperature 1 Low incoming water temperature Verify that the incoming water temperature matches what is indicated on the machine data plate 2 Heater not energizing Verify that the wash tank heater is operating If not replace 3 Low incoming voltage Have an electrician verify that the power coming to the machine is the same as indicated on the data plate Problem Low wash arm pressure poor spray pattern 1 Clogged wash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged wash tank or wash pump strainers Clean out strainers if necessary 3 Worn wash pump impeller Verify status of impeller replace if necessary Problem Low prewash arm pressure poor spray pattern 1 Clogged prewash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged prewash tank or prewash pump strainers Clean out strainers
53. d 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 Even after the water hardness problems have been solved there still must be proper training of dishmachine operators in how much detergent is to be used per cycle Talk with your water treatment specialist and detergent vendor and come up with a complete training program for operators Using too much detergent has as detrimental effects as using too little The proper amount of detergent must be used for job It is impo
54. ded 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 NORMAL DELIME switch on the back of the control box to the DELIME position 2 Disconnect or turn off all chemical feeder pumps 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 6 Wait five minutes then inspect the inside of the machine If the machine is not delimed run another time cycle as per the deliming solution s instructions 7 When clean drain and re fill the machine 8 Run in MANUAL for 10 minutes to remove residual deliming solution 9 Drain and re fill the machine This equipment is not recommend for use with deionized water or other aggressive fluids Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components Use of deionized water or other aggressive fluids will void the manufacturer s warranty AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 30 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
55. e d S AJ 44T SERIES RACK CONVEYOR DISHMACHINE INSTALLATION OPERATION amp TECHNICAL MANUAL AJ 44T SERIES AJ 66T SERIES AJ 80T SERIES AJ 44TE AJ 66TE AJ 80TE AJ 44TG AJ 66TG AJ 80TS AJ 44TS AJ 66TS AND ASSOCIATED OPTION PACKAGES INCLUDING SIDE LOADER Jackson MSC LLC P O Box 1060 Barbourville KY 40906 606 523 9795 September 29 2007 Fax 606 523 9196 P N 7610 003 07 21 Revision C 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 rep
56. er level for the standard mounting position that you will find it in on the unit The oil level should be checked and adjusted if necessary prior to operation using the oil level plug provided and while the unit is oriented in its operating position Ambient temperature If the operating ambient temperature is other than 51 95 F then refer to the lubrication chart and refill the unit with the correct grade based on actual ambient temperature and operating speed See Oil changing below for additional information Oil changing When changing the oil for any reason it should be remembered that oils of various types may not be compatible Therefore when changing to a different oil it is recommended that the housing be completely drained and thoroughly flushed with a light flushing oil prior to refilling with the appropriate lubricant The oil level should be rechecked after a short period of operation and adjusted if necessary When changing double reduction models each housing should be drained and filled independently even though there may be a common level Initial oil change The new oil in a speed reducer should be changed at the end of 250 hours of operation This is equivalent to 30 days of operation 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
57. ervice breaker The volt age should have been previously verified as being correct If not the voltage will have to be verified 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 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 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 damage
58. es Drain Plumbing Assemblies AJ 66T Series Drain Plumbing Assemblies AJ 80T Series Drain Plumbing Assemblies AJ 66TG Series Left to Right Drain Plumbing Assembly AJ 66TG Series Right to Left Drain Plumbing Assembly Drain Quench Assembly Motor Assemblies Prewash amp Wash Pump Weldments Prewash Arm Manifold Assembly Wash Arm Manifold Assembly Final Rinse Assembly Drive Assembly Door Assemblies Pawl Bar Roller Bracket AJ 44T amp AJ 66T Pawl Bar Assemblies AJ 80T Pawl Bar Assemblies AJ 44T Rack Rail Assembly AJ 66T Rack Rail Assemblies AJ 80T Rack Rail Assemblies Miscellaneous Parts amp Weldments Strainers Float Switch Components Scrap Baskets Curtains Tub Magnets Vent Cowl Assembly Vent Scoop Option Exhaust Fan Control Limit Switch Options SIDE LOADER SECTION Side Loader Track Assembly Leg Replacements Side Loader Pawl Bar Assemblies Strainer Magnet Side Loader Pawl Bar Associated Parts Side Loader Vent Cowl Option Rinse Fill Option ELECTRICAL SCHEMATICS AJ 44TE 208 230 Volt 60 Hz 1 Phase 208 230 Volt 60 Hz 3 Phase 460 Volt 60 Hz 3 Phase AJ 44TG 208 230 Volt 60 Hz 1 Phase 208 230 Volt 60 Hz 3 Phase 460 Volt 60 Hz 3 Phase AJ 44TS 208 230 Volt 60 Hz 1 Phase 208 230 Volt 60 Hz 3 Phase 460 Volt 60 Hz 3 Phase AJ 66TE amp AJ 80TE 208 230 Volt 60 Hz 1 Phase 208 230 Volt 60 Hz 3 Phase 460 Volt 60 Hz 3 Phase 98 100 101 102 103 104 105 106 107 108 109
59. ever 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 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 34 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions 1 Wiring The switch is wired common and nor mally open because of the hinge design By interrupting the line in series with the door switches the dishmachine ceases to operate Refer to the machine schematic for details on 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 relat
60. g 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 OO Om AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 37 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 Comp
61. if necessary 3 Worn prewash pump impeller Verify status of impeller replace if necessary Problem Inadequate rinse 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Pawl bar moves with no load but does not move when loaded 1 Clutch on drive assembly is out of adjustment Adjust as required AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 41 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
62. ight 16 AJ 80T Electric Right to Left 17 AJ 80T Gas Left to Right 18 AJ 80T Gas Right to Left 19 AJ 80T Steam Left to Right 20 AJ 80T Steam Right to Left 21 Side Loader Left to Right Dimensions 22 Side Loader Right to Left Dimensions 23 Side Loader Installed Dimensions 24 INSTALLATION amp OPERATION INSTRUCTIONS Installation Instructions 26 Curtain Installation Diagram 29 Deliming Operations 30 Side Loader Installation amp Operation Instructions 31 Dishmachine Operating Instructions 32 Detergent Control 34 Striker Plate Limit Switch Installation Instructions 35 II PREVENTATIVE MAINTENANCE General Maintenance 37 Lubrication Chart for Drive Gear 38 Drive Motor Gear Reducer Preventative Maintenance 39 IV TROUBLESHOOTING 41 V PARTS SECTION AJ 44T Control Box Assembly 44 AJ 66T AJ 80T Control Box Assembly 46 Motor Overload Chart 48 Heater Box Assembly 49 Frame Weldments Front Dress Panels 52 Prewash Plumbing Assembly 53 Incoming Plumbing Assembly 55 Incoming Plumbing Assembly TG Series 57 Solenoid Valve amp Vacuum Breaker Repair Parts 58 Steam Unit Wash Tank Coil Assembly 59 Steam Plumbing Left to Right Models 60 Steam Plumbing Right to Left Models 61 Gas Coil Assembly TG Models 62 TABLE OF CONTENTS SECTION DESCRIPTION PARTS SECTION CONTINUED Rinse Booster Tank Assembly TG Models Recirculating Pump Assembly TG Models Hose Connections TG Models AJ 44T Seri
63. ionship 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 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 35 SECTION 3 PREVENTATIVE MAINTENANCE 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
64. it was designed to AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 27 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED 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 Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting Remove the bulkhead plug in the side of the tub to install the deter gent concentration probe For more information concerning detergent concerns please refer to the page entitled Detergent Control Detergent Connection Point Machine rear view Brass Plug 78 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 back 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 lis operating Aid Connection Points AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2
65. lacement parts may create a hazard 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
66. le with the components previously removed SHUTDOWN AND CLEANING GAS HEATED MODELS At the end of the work day shut down the gas booster in accor dance with manufacturer s instructions Place the power switch in the OFF position secure the flow to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the 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 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
67. letely with oil to protect interior parts from rust and corrosion due to internal condensation Be sure to drain the oil to the proper level before placing the speed reducer in service Grease fittings Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash These fittings must be lubricated every 3 6 months depending on operating conditions bearing greases must be compatible with the type of gear lubricant being used i e mineral synthetic food grade etc For mineral oils use a high quality lithium base NLGOI 2 bearing grease For synthetic oils use a synthetic bearing grease such as Mobil Synthetic Universal grease Mobilith SHC 100 or a suit able equivalent For food grade lubricants use Chevron FM grease NGLI 2 or equivalent Low input speeds under 1600 RPM When input speeds are less than 1600 RPM grease fittings will be required to lubri cate any bearings not partially covered by the normal oil level Oil temperature Speed reducers in normal operation can generate temperatures up to 200 F depending on the type of reduc er and the severity of the application 9loading duration of service ambient temperatures Excessive oil temperatures may be the result of several factors including overloading overfilling underfilling or inadequate cooling Nominal Ratio Size 5 7 5 10 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
68. mful 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 capability of the machine Instruct operators to clean out the pan strainer at regu lar intervals or as required by work load SHUTDOWN AND CLEANING At the end of the workday remove the pan strainer and clean as required Wipe out the inside of the Side Loader and then reinsert the strainer AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 31 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATING INSTRUCTIONS PREPARATION Before proceeding with the start up of the unit verify the following 1 Close door s on dishmachine 2 Close the drain valve s POWER UP ELECTRICALLY HEATED MODELS To energize the unit turn on the power at the s
69. moved from shipping pallet prior to being installed Open the front door and remove all of the packing materials Once unpacked ensure that there are no missing parts from the machine This may 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 to side and from front to back before making any connections You will be able to adjust the over all height of the unit by turning the bullet feet from between 75 1 2 to 76 1 2 PLUMBING THE DISHMACHINE All plumbing connections must comply with all applicable local state and national plumbing 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 sh
70. ould be a maximum of 6 grains per gallon Harder water should be treated prior to using the machine Iron in the water supply can cause staining A filter designed to remove iron from the supply water is highly recommended for sup plies in excess of 0 1 ppm parts per million CONNECTING THE DRAIN LINE The drain for the models covered in this manual are gravity discharge drains All piping from the machine to the drain Adjusting screw _ must be a minimum 1 1 2 NPT and shall not be reduced There must also be nut E 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 M _ 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 1 2 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 r ncoming Plumbing Connection ommended temperature indicated on the data plate If the water level is too low or too high check the incoming water pressure It should be 20 5 PSI Too high of pre
71. ounded Extra Super AGMA 8 Gear Oil 1105 8 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 Cylinder 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 800 680 Tegra 680 N A Teresstic SHP 680 N A Omala RL 680 Pinnacle 680 96 131 F above 450 FPM 460 7S SHC 634 N A 800 460 Tegra 460 Syncon 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 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 38 SECTION 3 PREVENTATIVE MAINTENANCE o 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 prop
72. pon 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 amp AJ 80 operators should also take the time to inspect the prewash section strainers and clean them as required by workload AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 32 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATION INSTRUCTIONS CONTINUED 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 reassemb
73. rmance 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 maintenance is going to help Acommon problem has to do with temperatures being too low Verify that the water temperatures coming to your dishmachine match the requirements listed on the machine data plate There can be a variety of reasons why your water tem perature could be too low and you should discuss it with Jackson to determine what can be done By following the operating and cleaning instructions in this manual you should get the most efficient results from your machine As a reminder here are some steps to take to ensure that you are using the dishmachine the way it was designed to work Ensure that the water temperatures match those listed on the machine data plate Ensure that all strainers are in place before operating the machine Ensure that all wash and or rinse arms are secure in the machine before operating Ensure that drains are closed sealed before operating Remove as much soil from dishes by hand as possible before loadin
74. rtant 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 important factor in ensuring that your dishmachine functions properly The data plate located on each unit details what the minimum temperatures must be for either the incoming water supply the wash tank and the rinse tank depending on what model of dishmachine you have installed These temperatures may also be followed by temperatures that Jackson recommends to ensure the highest performance from you dishmachine How
75. signed 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 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 La 3 phase models To install the incoming power lines open the control box Install oniy 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
76. ssure results in too much water too low of pressure results in too little water To adust the regulator loosen the nut at the top this will allow you to screw or unscrew the adjustment With a screwdriver turn the adjuster clockwise to increase pressure or counter clock wise to decrease it Do not confuse static pressure with flow pressure Static pressure is the line pressure in a no flow condition all valves and services are closed Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle It is also recommended that a shock absorber not supplied be installed in the incoming water line This prevents line hammer hydraulic shock induced by the solenoid valve as it operates from causing damage to the equipment AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 26 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED STEAM LINE CONNECTIONS Some machines covered in this manual are designed to use low pressure steam as a source of heat for wash tank water The machines come with lines by which outside source steam needs to be connected Connect all incoming steam lines in accordance with the steam booster manufacturer s instructions Ensure that all applicable codes and regulations are adhered to See machine data plate for information concerning steam flow pressure GAS CONNECTIONS Some machines covered in this manual are de
77. 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 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 33 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DETERGENT CONTROL Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate Using detergent in the proper amount can become in time a source of substantial savings A qualified water treatment spe cialist can tell you what is needed for maximum efficiency from your detergent but you should still know some basics so you ll understand what they are talking about First you must understand that hard water greatly effects the performance of the dishmachine Water hardness is the amount of dissolved calcium and magnesium in the water supply The more dissolved solids in the water the greater the water hard ness Hard water works against detergent thereby causing the amount of detergent required for washing to increase As you use more detergent your costs for operating the dishmachine will increase and the results will decrease The solids in hard water also may build up as a scale on wash and rinse heaters decreasing their ability to heat water Water temperature is important in removing soil an
78. ts or doors beyond 30 days from the date of installation In addition the warranty will only cover the replacement of wear items such as curtains drain balls door guides or gaskets during the first 30 days after installation Also not covered are conditions caused by the use of incorrect non Commercial grade detergents incorrect water temperature or pressure or hard water conditions STOP PARE ARRET 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 MADE APPLICABLE A 08 03 2005 7442 Initial release of manual Added gas exhaust fan schematic updated electric exhaust fan 7600 7558 schematic Replaced rinse drain weldment 05700 021 68 28 with 02 13 2006 7462 7367 05700 002 51 12 Added wash rinse and psi decals Changed 7463 the door assemblies Added the rinse fill motor assembly Added Gas Models 3 21 2006 7571 to new layout Change themostats and add replacement PG 100 04 19 2007 7898 Added 09905 003 32 20 fan load decal 4 thru 21 91 09 29 2007 Updated dimension pages alternate table limit switch BY MAW MAW MAW MAW AW NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Jackson AJ 44TS AJ AJ
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