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1. E M d 5 AJ 44T SERIES RACK CONVEYOR DISHMACHINE TECHNICAL MANUAL INSTALLATION MANUAL FOR EXPORT UNITS SERVICE MANUAL FOR DOMESTIC UNITS 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 gt Jackson Jackson MSC LLC P O Box 1060 Barbourville KY 40906 606 523 9795 April 19 2007 Fax 606 523 9196 P N 7610 003 07 21 Revision C www jacksonmsc com REVISION MADE APPLICABLE A 08 03 2005 7442 Initial release of manual BY Added gas exhaust fan schematic updated electric exhaust fan 7600 7558 schematic Replaced rinse drain weldment 05700 021 68 28 with 02 13 2006 MAW 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 AW 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 NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Jackson an Encdisce mpany AJ 44TS AJ Ad 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 Serial No Installation Date Service Rep Na
2. PLUMBING THE DISHMACHINE 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 should be a maximum of 6 grains per gallon Harder water should be treated prior to using the machine Iron in the water supply can cause staining A filter 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 gt must be a minimum 1 1 2 NPT and shall 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 EN EN Locking nut a 4B WATER SUPPLY CONNECTION Ensure that you have read the section enti tled PLUMBING THE DISHMACHINE above before proceeding The
3. SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED STEAM LINE CONNECTIONS Some machines covered in this manual are designed to use low pressure steam as a Source of heat for wash tank water The machines come with lines by which outside source steam needs to be connected Connect all incoming steam lines in accordance with the steam booster manufacturer s instructions Ensure that all applicable codes and regulations are adhered to See machine data plate for information concerning steam flow pressure GAS CONNECTIONS Some machines covered in this manual are designed to use gas as an outside source of heat for wash tank water The machines come with connections by which an 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 work
4. Deo 2 6 Q mr VHT ILU ao WHT 5 WIRE BLK VHT e Ts SURGE Or ES H BLK AVHT ORG ge WHT LEGEND Es LI L POWER DISTRIBUTION BLOCK GND GROUND RI HEAT CONTACTOR Re DRIVE MOTOR CONTACTOR R3 WASH PUMP NOTOR CONTACTOR GRY VEL ofa WHT R4 FINAL RINSE RELAY 9890 R6 WASH TANK FILL RELAY R7 DOOR SAFETY SWITCH RELAY GRY YEL Hi WASH HEATER 1 DRIVE MOTOR M2 WASH NOTOR CB CONTROL CIRCUIT BREAKER T CONTROL TRANSFORMER DET DETERGENT DISPENSER CONNECTION cvs CONSTANT VOLTAGE SIGNAL S POWER SVITCH se DOOR SAFETY SWITCH morre WHT 53 WASH PUMP SWITCH 1 as 54 WASH SWITCH 2 55 AUTO MAN DELIME SWITCH 56 FINAL RINSE SWITCH ED HEAFER HIGH LIMIT LIGHT RS WFSWI WASH FLOAT SWITCH 1 o WF SWe WASH FLOAT SWITCH 2 HEATER HIGH LIMIT THERMOSTAT Ts2 WASH REGULATING THERMOSTAT TLS TABLE LIMIT SWITCH OPTIONAL WFS WASH FILL SOLENOID RS FINAL RINSE SOLENOID 9905 031 72 94 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 107 SECTION 7 ELECTRICAL SCHEMATICS Bee AJ 44TE 208 230 VOLT 60 2 3 PHASE 8 GREEN ELK VHT QLK WHT 06 30 WHT GR Stu VFSWE P ORE BLU RK RED BLK VET BLEWHT Jh wc Pen br VS WT 3 3 8 ZRED 2 WHT i E BLK WHT a uve 1510 91 TG 520 ois JUMPER se WIRE ILK WVHT TLS Oo ose BLU ILK ag ALK VHT o GREY GREY o rei ORG
5. 96 18 1 OL AIEVL 08 uke AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION SIDE LOADER LEFT 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 4 1 2 25 1 2 DISHWASHER SECTION lt 12 1 2 CENTER LINE DISHMACHINE VENT CONNECTION OPENING CONVEYOR DISHMACHINE SPLASH SHIELD 14 1 2 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE LENGTH 1 1 2 TABLE ROLL CONVEYOR F DISHWASHER 23 30 depending on 20 3 4 OPENING 7 the width of the side loader UE 29 _ 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 9 SECTION 1 SPECIFICATION INFORMATION SIDE LOADER RIGHT TO LEFT DIMENSIONS DISHTABLE 1 2 A 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 DISHWASHER MINIMUM SECTION Sap CENTER LINE DISHMACHINE VENT CONNECTION OPENING CONVEYOR SS DISHMACHINE GER m SPLASH 8 m 2 N SHI
6. Actuator Switch Replacement Kit 06401 003 10 14 Replacement Kit Notes Right to Left Assembly The replacement kits for the actuator switches come with the switch two spacers and the mounting hardware Rack Guide Spacer 8 per 05700 011 71 44 Actuator Switch Replacement Kit 06401 003 10 86 Rack Rail Weldment 05700 031 76 28 Opposite Rack Rail 05700 041 69 54 Actuator Switch Replacement Kit 06401 003 10 14 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 93 eme SECTION 6 PARTS SECTION eg AJ 80T RACK RAIL ASSEMBLIES Left to Right Assembly Rack Guide Spacer 05700 011 71 44 Rack Guide Weldment Left to Right 05700 031 81 53 Opposite Rail 05700 041 74 13 Actuator Switch Replacment Kit 06401 003 10 83 Actuator Switch Replacement Kit 06401 003 10 14 Right to Left Assembly Replacement Kit Notes The replacement kits for the actu ator switches come with the switch two spacers and the mounting hardware Actuator Switch Replacement Kit 06401 003 10 85 Rack Guide Spacer 05700 011 71 44 Rack Guide Weldment Right to Left 05700 031 81 54 Opposite Rail 05700 041 74 14 Actuator Switch Replacment Kit 06401 003 10 14 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 94 Uns SECTION 6 PARTS SECTION STRAINERS Back Strainer Weldment 05700 021 85 11 Fr
7. a CONTROL CIRCUIT BREAKER CONTROL TRANSFORMER JETERGENT DISPENSER CONNECTION CONSTANT VOLTAGE SIGNAL POWER SWITCH o MEE SWITCH 8 a RINSE SWITCH o PRE VASH PUMP SWITCH 2 POWER LIGHT WASH FLOAT SWITCH 1 WASH FLOAT SWITCH 2 den PRE VASH FLDAT SVITCH 1 ex PRE VASH FLOAT SWITCH 2 WASH REGULATING THERMOS TAT COLD VATER THERMOSTAT OPTIONAL In WATER ABLE LIMIT SWIT TENA D WASH FILL SOLENOCD SY wax wr WASH HEAT SOLENOCD PWFS PRE WASH FILL SOLENOID RS FINAL RINSE SDLENDUI 9903 031 80 8B ir CL 5 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 123 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TS amp AJ 80TS 460 VOLT 60 HZ 3 PHASE H D vic 5 5 Kent D Greet H ors ot E Kr M LEGEND POWER DISTRIBUTION BLOCK GREY n ano GROUND DRIVE MOTOR CONTACTOR WASH PUMP MOTOR CONTACTOR FINAL RINSE RELAY PRE VASH PUMP MOTOR CONTACTOR WASH TANK FILL RELAY PRE VASH TANK FILL RELAY 2 34 DOOR SAFETY SWITCH RELAY 9 aec d 8 8 2 PRE VASH PUMP MOTOR DVERLDAI CONTROL GIRCUIT BREAKER Vin CONTROL TRANSFORMER 9 DETERGENT DISPENSER CONNECTION CONSTANT VOLTAGE SIGNAL POWER SWITCH DOOR SAFETY SWITCH 1 gt DOOR SAFETY SVITCH d 56238 5 Les FINAL RINSE PRE VASH PUMP SWITCH ey POWER LIGHT T WASH FLOAT SWITCH 1 WA
8. 112132 POWER DISTRIBUTION BLOCK DND GROUND Re ORIVE MOTOR CONTACTOR R3 VASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY PRE VASH PUMP MOTOR CONTACTOR VASH TANK FILL RELAY PRE VASH TANK FILL RELAY ODOR SAFETY SWITCH RELAY NASH RECIRCULATING RELAY WASTER SOLENOCD RELAY ORIVE MOTOR RINSE RECIRCULATING PUMP ORIVE MOTOR OVERLOAD VASH PUMP MOTOR OVERLOAR PRE VASH PUMP MOTOR OVERLOAI CONTROL CIRCUIT BREAKER CONTROL TRANSFORMER POWER SWITCH ODOR SAFETY SVITCH 1 ODOR SAFETY SVITCH 2 VASH PUMP SWITCH 1 VASH PUMP SWITCH 2 ALTO MAN DELIME SWITCH FINAL RINSE SWITCH PRE VASH PUMP SWITCH POWER LIGHT VASH FLOAT SWITCH WASH FLOAT SWITCH 2 PWF SWI PRE VASH FLOAT SWITCH Pwr Swe PRE WASH FLOAT SWITCH amp Pee DSaORGZHRG2LSD TSL VASH REGULATING THERMOSTAT up COLI WATER THERMOSTAT OPTIONAL COLI VATER VALVE lt OP TIONAL Tes TABLE LIMIT SWITCH OPTIONAL WFS VASH FILL SDLENCID PRE VASH FILL SOLENOID RS FINAL RINSE SOLENOID MS MASTER SOLENOCD ow 9905 002 33 6 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 120 SECTION 7 ELECTRICAL SCHEMATICS _ _ AJ 66T amp AJ 80TG 460 VOLTS 60 HZ 3 PHASE D 5 2 Lum WE LO AE LO RID La POWER DISTRIBUTION BLOCK GROUND DRIVE MOTOR CONTACTOR MASH PUMP MOTOR CONTACTOR FINAL RINSE RELAY PRE WASH PUMP MOTOR CONTACTOR W
9. 118 SECTION 7 ELECTRICAL SCHEMATICS _ AJ 66TG amp AJ 80TG 208 230 VOLTS 60 2 1 PHASE Q rh 8 ORG ORs Ri LEGEND w Al Sms Lt Le POWER DISTRIBUTION BLOCK ev ee GND GROUND DRIVE MOTOR CONTACTOR WASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY 88 R3 PRE WASH PUMP MOTOR CONTACTOR R7 WASH TANK FILL RELAY PRE WASH TANK FILL RELAY DOOR SAFETY SWITCH RELAY WASH RECIRCULATING RELAY MASTER SOLENOID RELAY ML DRIVE MOTOR WASH PUMP MOTOR PRE WASH PUMP M4 RINSE RECIRCULATING PUMP CB CONTROL CIRCUIT BREAKER Tt CONTROL TRANSFORMER POWER SWITCH se DOOR SAFETY SWITCH 1 53 DOOR SAFETY SWITCH 2 54 WASH PUMP SWITCH 1 ss WASH PUMP SWITCH 2 56 AUTO MAN DELIME SWITCH 57 FINAL RINSE SWITCH 58 PRE WASH PUMP SWITCH Et POWER LIGHT WFSW1 WASH FLOAT SWITCH 1 NFSwe WASH FLDAT SWITCH 2 PWESW1 PRE WASH FLOAT SWITCH PWFSWe PRE WASH FLOAT SWITCH 2 TSL WASH REGULATING THERMOSTAT 5 COLD WATER THERMOSTAT OPTIONAL COLD WATER VALVE OPTIONAL TLS TABLE LIMIT SWITCH lt OPTIONALD NES WASH FILL SOLENOID PRE WASH FILL SOLENO 3 RS FINAL RINSE SOLENOID MS MASTER SOLENOID ajia m 941 9905 0028 53 26 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 119 SECTION 7 ELECTRICAL SCHEMATICS _ _ AJ 66TG amp AJ 80TG 208 230 VOLTS 60 2 3 PHASE 4 Wenger LEGEND fe
10. SECTION 1 SPECIFICATION INFORMATION AJ 66T RIGHT TO LEFT DIMENSIONS TIVM V8 SI 4 SHOOQ LHSISH 1 NOLLO3NNOO NIVHG Sdl E NOLLO3NNOO H31VM HSVM3Hd Sdl NOLLO3NNOO H31VM NOILOANNOO VOIHLIO3 3 V QN3931 401 u8 S 69 FE ZP IL E 1 R elei 3 d 422 318V OL 31801 99 408 218 1 01 3781 99 m See AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION AJ 80T LEFT TO RIGHT DIMENSIONS 1 19 4 1 94 Alavl OL 3 18V 08 96 Alavi OL 3180 08 0 8 6 69 8 SI N3dO HOOQ LHOI3H 1 NOLLO3NNOO NOLLO3NNOO YALVM HSVM3Hd 9 Sdl NOLLO3NNOO H31VM ONINIOONI 8 NOILOANNOO VOIHLO3T13 V aN3931 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION AJ 80T RIGHT TO LEFT DIMENSIONS 8 SI N3dO HOOQ amp 1 NOLLO3NNOO 2 NOLLO3NNOO H31VM 2 Sdl H3 1VM DNINOONI 8 80 NOILO3NNOO 1VOIHIO3 3 V 937 AL E 0 Li Li LIRE 81871 OL 3 18V 08
11. T 98 9 8980 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 54 22 SECTION 6 PARTS SECTION AJ 66 amp AJ 80 CONTROL BOX ASSEMBLY CONTINUED ITEM DESCRIPTION 1 1 Electrical Box Weldment 2 1 Decal L1 L2 L3 3 1 Terminal Block 4 1 Terminal Board 5 1 Decal Gauge 6 1 Light Amber 7 1 Wire Lug 2 AWG to 14 AWG 8 1 Light Red 9 1 Din Rail 10 2 Thermometer 96 Lead Rinse Decal 180 F 11 1 Thermometer 48 Lead 1 Wash Decal 160 F 12 1 Decal Ground 13 1 Terminal Board 14 3 Motor Contactor 15 1 Circuit Breaker 200 208 230 360 Volt 60 Hz Models Only 15 1 Circuit Breaker TG Models Only 16 1 Overload 17 1 Switch ON FILL amp OFF DRAIN 18 1 Overload 19 1 Overload 20 1 Heater Contactor for non steam units 21 2 Relay 22 1 Transformer 200 Volt Models Only Transformer 208 220 230 460 Models Only Transformer 208 220 230 460 Volt TG Models Transformer 380 415 Volt Models Only Transformer 600 Volt Models Only 23 2 Control Relay 24 1 Fuse Holder 380 60 Hz 460 600 Volt Models Only 25 1 Fuse 380 50 Hz 460 Volt Models Only 1 Fuse 600 Volt Models Only 26 2 Control Relay TG Models Only Not Shown MISCELLANEOUS PARTS NOT SHOWN Manual Delime Switch Manual Delime Switch Decal Decal Operation Decal High Limit Warning Light Control Box Cover Control Box Leg Conduit Bracket Mfg No 05700 04 1 88 50 09905 101 12 66 05940 011 48 27 05940 02
12. Heater Nuts 16 In Ibs Terminal Block 50 In Ibs AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 30 SECTION 5 SERVICE PROCEDURES SECTION 5 SERVICE PROCEDURES REPLACING THE PUMP GASKET amp SEAL These rack conveyor machines come equipped with powerful motors and pumps to ensure ware washing results Occasionally some of the parts on these components may need replacing to maintain optimum performance Two com ponents in particular are the wash pump gasket and the mechanical seal 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 Only autho rized personnel should ever perform any maintenance procedure 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 Ensure that incoming water to the machine is secured either by use of a shut off valve or disconnecting the incoming water line 3 Ensure that the dishmachine has been completely drained of water and has been allowed to cool down prior to beginning this maintenance procedure TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 1 7 16 socket and ratchet wit
13. found in the unit s installation manual Before beginning any step that involves working with wiring ensure that the steps located in the section entitled Preparation have been per formed Power must be secured to the machine at the service breaker Failure to do so could result in severe injury to main tenance personnel AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT CONTINUED Prying open the coil wire cover 4 When replacing the coil ensure that when removing the coil wire cover that care is taken not to damage the wires inside Using the medium flathead screwdriver gently use it to open the cover enough to where it could be pulled off Straightening the wires 5 Once the coil wire cover has been removed and set to the side take the internal wires and pull them out straight Removing the wire nuts 6 Remove the wire nuts from the wires and separate them Loosening the conduit nut 7 Using a pair of channel locks gently loosen the conduit retaining ring for the conduit nut Once it is loosened use your fingers to unscrew and remove it 8 Pull the conduit away and discard the bad coil Take the new coil and attach the conduit reinstall amp tighten the conduit nut and pull the wires through so that you will be able to wire the valve back up 9 Reconnect the wires from the conduit to the wires from th
14. 0 161 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 27 SECTION 4 TROUBLESHOOTING SECTION s SECTION 4 TROUBLESHOOTING 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 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 connecte
15. 1 Union 3 4 NPT Black Iron 04730 912 01 00 3 3 Nipple Close 3 4 NPT Black Iron 04730 907 01 00 4 1 Valve Steam Solenoid 3 4 NPT 120V 04820 01 1 87 39 5 1 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 6 1 Elbow Street 90 3 4 NPT Black Iron 04730 01 1 87 37 7 1 Y Strainer 3 4 NPT Black Iron 04730 217 01 32 8 1 Valve Gate Steam 3 4 NPT 04820 100 19 00 9 1 Plug 3 8 NPT Black Iron 04730 909 02 34 10 1 Nipple 3 4 NPT x 32 Long 04730 002 21 27 11 1 Reducer 3 4 NPT to 1 2 NPT Black Iron 04730 91 1 02 34 12 1 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 13 1 Elbow Street 3 4 NPT Black Iron 04730 01 1 87 37 14 1 Union 3 4 NPT Black Iron 04730 912 01 00 15 1 Nipple Close 3 4 NPT Black Iron 04730 907 01 00 16 1 Steam Trap 3 4 NPT 06680 500 02 77 17 1 Pipe 3 4 NPT x 10 Long Black Iron 04730 907 06 34 STEAM OUTLET PLUMBING 17 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 68 SECTION 6 PARTS SECTION STEAM PLUMBING RIGHT LEFT STEAM INLET PLUMBING 5 3 4 10 0 8 3 9 1 ITEM QTY DESCRIPTION Mfg No 1 1 Reducer 3 4 NPT to 1 2 NPT Black Iron 04730 91 1 02 34 2 1 Union 3 4 NPT Black Iron 04730 912 01 00 3 3 Nipple Close 3 4 NPT Black Iron 04730 907 01 00 4 1 Valve Steam Solenoid 3 4 NPT 120V 04820 011 87 39 5 1 Elbow 90 3 4 FNPT Black Iron 04
16. 2006 Revised N A 24 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 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
17. 6 PARTS SECTION CURTAINS TUB MAGNETS Curtain 12 Long x 20 1 2 Wide 08415 131 73 44 Curtain 21 Long x 20 1 2 Wide 08415 131 73 45 SHORT LONG Curtain 24 1 2 Long x 20 1 2 Wide Short Curtain Decal TG MODELS ONLY 09905 011 73 82 08415 002 47 37 Long Curtain Decal 09905 01 1 73 84 LONG Extra Long Curtain Decal Curtain Hook TG MODELS ONLY 05700 01 1 83 54 Middle Curtain Hook 09905 002 52 69 05700 011 72 65 Curtain Rod 05700 021 73 43 Conveyor Switch Replacement Kit 06401 003 11 79 LA Replacement Kit Note The conveyor switch replacement kit comes with the switch a terminal and lt gt wire nut SS Limit Switch Bracket 05700 021 71 18 Service Note The cord for the conveyor switch needs to be cut to length in the field and have the pink terminal applied there AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 98 SECTION 6 PARTS SECTION __ VENT COWL ASSEMBLY VENT SCOOP OPTION Vent Cowl Cover Weldment Gasket Top Vent Cowl 05700 011 74 67 05330 031 83 47 Locknut 1 4 20 Hex with Nylon Insert 4 per 05310 374 01 00 Gasket Side Vent Cowl 05330 031 83 48 Vent Cowl Weldment 05700 041 86 94 VENT SCOOP OPTION Vent Scoop Assembly 05700 002 04 08 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 99 SECTION 6 PARTS SECTION MISCELLANEOUS PARTS
18. CFM 100 CAP INPUT END 200 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 2045 FLOWRATE GPM AJ 44 66 80TE TG TS 3 1 STEAM COIL TANK HEAT TS MODELS ONLY STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG Ibs hr 60 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 WASH MOTOR HP 2 POWER RINSE MOTOR HP 2 PREWASH MOTOR HP AJ 66TE TG TS MODELS 1 AJ 80TE TG TS MODELS 2 NOTE Always refer to the machine data plate for specific electrical and water requirements The material provided on this page is for reference only and may be subject to change without notice 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
19. Lo 9 5 Ane elt LEGEND 18 7 L1 L2 L3 POWER DISTRIRUTIEN BLOCK 2 GND GROUND BREY ad R1 HEAT CONTACTOR OO RIE T o Ho R2 DRIVE MOTOR CONTACTOR ane 96 95 R3 WASH PUMP MOTOR CONTACTOR LM R4 FINAL RINSE RELAY Q R6 MASH TANK FILL RELAY R7 TOOR SAFETY SWITCH RELAY Hi WASH HEATER M1 DRIVE MOTOR D I WASH PUMP MOTOR Q 1M L DRIVE MOTOR OVERLOAD CHL WASH PUMP MOTOR OVERLOAD CB CONTROL CIRCUIT BREAKER CONTROL TRANSFORMER 5 DET DETERGENT DISPENSER CONN OF lt lt VHT cvs CONSTANT VOLTAGE SIGNAL POWER DOOR SAFETY SWITCH 3 WASH PUMP SVITCH 1 4 WASH PLMP SVITCH 2 5 m 55 AUTO MAN DELIME SWITCH oro VERG 56 FINAL RINSE SVITCH E1 POWER LIGHT EZ HEATER HIGH LIMIT LIGHT WFSW1 WASH FLOAT SWITCH 1 WFSWe WASH FLOAT SVITCH 2 TS1 HEATER HIGH LINIT THERMOSTAT TSe WASH REGULATING THERMDSTAT TLS TABLE LIMIT SWITCH lt gt VFS WASH FILL SOLENOID RS FINAL RINSE SOLENOID 9905 031 70 79 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 108 SECTION 7 ELECTRICAL SCHEMATICS _ _ AJ 44TE 460 VOLT 60 2 3 PHASE BU VHT ILK WHT 8 Va DnG 3LU 0 WHT 8 TLK VHT A 0 U aon Na TAK VHT meer of VHT YEL od Lo S1 A WHT q ILU RED WHT BUK VHT otto 3LU YEL 6 ro SOU Vn
20. Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 72 SECTION 6 PARTS SECTION HOSE CONNECTIONS TG MODELS ONLY Recirculating Pump Assembly Rinse Booster Tank ei Rinse Header Plumbing Assembly Wash Fill Plumbing Assembly HOSE ASSEMBLIES AJ 44TG L R amp R L AJ 66TG L R AJ 66TG R L hose assembly includes 2 3 4 Pushlock Fittings part number 04730 01 1 94 00 A Hose Recirculating Discharge 8 1 2 05700 002 52 74 18 05700 002 51 38 8 1 2 05700 002 52 74 B Hose Recirculating Pump Suction 18 1 2 05700 002 52 75 26 05700 002 51 37 18 1 2 05700 002 52 75 C Hose Wash Coil Assembly 34 05700 002 52 76 36 05700 002 51 39 50 05700 002 57 58 D Hose Recirculating Discharge L R 48 05700 003 03 95 60 05700 003 03 97 60 05700 003 03 97 R L 60 05700 003 03 97 E Hose connection to existing gas booster outlet fitting F Hose connection to existing gas booster inlet fitting Gas Booster Connection Kit 05700 002 51 73 includes 18 Feet of 3 4 Hose 4 3 4 Push Lock Fittings AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 73 SECTION 6 PARTS SECTION eg AJ 44T SERIES DRAIN PLUMBING ASSEMBLIES Fitting Barbed 1 1 2 NPT x 1 1 2 1 AJ 44TE TS Ball Valve Handle Assembly 04730 011 69 92 Nipple Rinse Weldment 06401 021 83 53 05700 021 84 61 AJ 44TG Ball Valve Handle Assembly 06401 021 8
21. Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 51 95 F up to 450 FPM 680 8 Compounded Extra Hecla Super AGMA 8 Gear Oil Tribol 1105 8 Cylinder Oil W680 Inca Oil 680 Spartan EP 680 SPO 288 Valvata J 680 Vanguard 680 51 95 F above 450 FPM 460 7 Compounded 600W Super Cylinder AGMA 7 Gear Oil Tribol 1105 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 800 680 Tegra 680 N A Teresstic SHP 680 N A Omala RL 680 Pinnacle 680 96 131 F above 450 FPM 460 75 SHC 634 N A Tribol 800 460 Tegra 460 Syncon R amp O 460 Teresstic SHP 460 N A Omala RL 460 Pinnacle 460 1 The sliding velocity in feet per minute FPM for standard ratios is determined by multiplying the speed of the worm in RPM by the factor from the table below For selecting proper lubricant use the speed of the worm in the final stage input RPM divided by the first stage ratio AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 87 SECTION 6 PARTS SECTION DOOR ASSEMBLIES 3 Left Door Guide Weldment TRU 05700 002 32 51 Right Door Guide Weldment 05700 031 76 44 1 2 6 7 8 5 9 Door Catch Weldment Locknut 1 4 20 with Nylon Insert 05700 031 84 80 05310 374 01 00 ED Wash Door Hood Support 05700 031 84 13 wa
22. Replacment Kit 12 E 06401 003 10 15 Bottom Guide Block EQ AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A Top Guide Block Service Note It is highly recommended that when changing out one guide block that the other be changed out as well along with the gasket 89 emer SECTION 6 PARTS SECTION AJ 44T amp AJ 66T PAWL BAR ASSEMBLIES Pawl Bar Dog Casting AJ 44T Complete Assembly with Hardware 12 per 05700 021 69 00 06401 131 81 00 AJ 44T Prison Assembly with Hardware Af 2 06401 231 81 00 7 o SA 29 5 2 9 AS ei Bar Spacer 24 per 05700 011 71 45 ES Pawl Bar Weldment LN 05700 031 72 77 f e AJ 66T Complete Assembly with Hardware 2 5i 5720 4 06401 141 74 64 W af o AJ 66T Prison Assembly with Hardware 2 5 06401 241 74 64 7 2 Pawl Bar Dog Casting ef 2 18 per K CH 7 05700 021 69 00 Pawl Bar Spacer 36 per 05700 011 71 45 Pawl bar Weldment 05700 031 72 78 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 90 SECTION 6 PARTS SECTION es AJ 80T PAWL BAR ASSEMBLIES Left to Right Assembly 06401 141 81 06 d Bolt 3 8 16 x 1 3 4 Long RA 05306 011 36 94 Pawl Bar Weldment dei Pawl Bar Dog Casting ky 05700 031 74 19 05700 021 69 00 Pawl Bar Spacer 05700 011 71 45 Locknut 3 8 16 with Nylon Insert 05700 011 72 55
23. T BLU WHT AMPER VIRE ALK VHT TLS moe R7 JALK VHT O GREY GREY 095 PAN 2 oy MH Lk ALN AZ 56 LEGEND Pe aile 111213 POWER DISTRIBUTION BLOCK GND GROUND E R1 HEAT CONTACTOR ORY YEL wi R2 DRIVE MOTOR CONTACTOR 9 lt R3 WASH PUMP MOTOR CONTACTOR s4 R4 FINAL RINSE RELAY ww He WASH TANK FILL RELAY R7 DOOR SAFETY SWITCH RELAY WASH HEATER 1 DRIVE MOTOR WASH PUMP MOTOR ORY YEL 1MOL DRIVE MOTOR OVERLOAD 9 WASH OVERLOAD FUSE CONTROL CIRCUIT TRANSFORMER FUSE CONTROL TRANSFORMER DETERGENT DISPENSER CONNECTION GREY PS wr CNS CONSTANT VOLTAGE SIGNAL 51 POVER SVITCH anes 52 DOOR SAFETY SWITCH 3 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 55 AUTO MAN DELIME SWITCH E o 6 FINAL RINSE SWITCH 4 El POVER LIGHT E2 HEATER HIGH LIMIT LIGHT 1 WASH FLOAT SWITCH 1 WFSW2 WASH FLOAT SWITCH 2 51 HEATER HIGH LIMIT THERMOSTAT 152 WASH REGULATING THERMOSTAT TLS TABLE LIMIT SWITCH OPTIONAL WFS WASH FILL SOLENDID RS FINAL RINSE SOLENOID 9905 031 72 90 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 109 SECTION 7 ELECTRICAL SCHEMATICS _ AJ 44TG 208 230 VOLT 60 HZ 1 PHASE ule POWER DISTRIBUTION BLOCK DND GROUND R2 DRIVE MOTOR CONTACTOR R3 WASH PUMP NOTOR CONTACTOR R4 FINAL RINSE RELAY R WAS
24. TRANSFORMER DETERGENT DISPENSER CONNECTION CONSTANT VOLTAGE SIGNAL POWER SWITCH DOOR SAFETY SWITCH 1 DOOR SAFETY SWITCH 2 op LJ WASH PUMP SWITCH 1 oe ofan WASH PUMP SWITCH 2 AUTO MAN UELIME SWITCH FINAL RINSE SVJTCH PRE WASH PUMP SWITCH POWER LIGHT RY o WFSWL WASH FLOAT SWITCH 1 oD L Age WF Swe WASH FLOAT SWITCH 2 t PVFSWL PRE WASH FLOAT SWITCH 1 PWFSW2 PRE WASH FLDAT SVETCH 2 por EAS TS1 WASH REGULATING THERMOSTAT __ AE cef 2 CVTS COLD WATER THERMOSTAT OPTIONAL COLD WATER VALVE DPTIDNAL TLS TABLE LIMIT SWITCH COPTIDNAL WASH FILL SULENGID WHS WASH HEAT SOLENOID PNFS PRE WASH FILL SOLENOID RS FINAL RINSE SOLENOID 9905 102 37 15 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 122 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TS amp AJ 80TS 208 230 VOLT 60 HZ 3 PHASE 1 08 aucem eg EI m EE K is on Mo om 1 FON LEGEND 111212 PONER DISTRIBUTION BLOCK GNO CROUND JRIVE MOTOR CONTACTIR WASH PUMP MOTOR CONTACTOR FINAL RINSE RELAY BLUE o PRE WASH PUMP MOTOR CONTACTOR SECH WASH TANK FILL RELAY GY o PRE WASH TANK FILL RELAY 1008 SAFETY SWITCH RELAY PRE WASH PUMP NOTOR CH JRIVE MOTOR DA e WASH PUMP MOTOR OVERLOAD op PRE WASH PUMP MOTOR
25. VENT COWL ASSEMBLY FOR HOODED SIDE LOADER OPTION 05700 003 05 66 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 104 SECTION 6 PARTS SECTION RINSE FILL OPTION ITEM QTY DESCRIPTION Mfg No 1 Rinse Fill Motor Assembly 05700 002 40 25 1 Rinse Fill Motor Assembly AJ 66 Left to Right Models Only 05700 002 48 22 1 1 Motor 06105 002 72 71 2 1 Bracket Pump Mounting 05700 002 63 59 3 1 Clamp Hose 5 5 8 to 6 04730 011 34 90 4 1 Reducer Bushing 1 1 4 to 1 04730 002 73 62 5 1 Reducer Bushing 1 to 3 4 04730 011 65 14 6 1 Elbow 90 Deg 1 Street 04730 002 11 99 7 1 Nipple 1 NPT x 6 Long Brass 04730 002 12 00 8 1 Elbow 90 Deg Brass Female 04730 002 12 55 9 4 Lockwasher 1 4 05311 274 01 00 10 4 Bolt 1 4 20 x 1 2 Long 05305 274 02 00 11 4 Nut Hex S S 1 4 20 05310 274 01 00 12 1 Rinse Motor Mounting Bracket 05700 002 38 90 12 1 Rinse Motor Mounting Bracket AJ 66 Left to Right Models Only 05700 002 39 33 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 105 SECTION 7 ELECTRICAL SCHEMATICS 106 SECTION 7 ELECTRICAL SCHEMATICS AJ 44TE 208 230 VOLT 60 HZ 1 PHASE NIRO CONNECTION Q 3LK ORG WHT WHT E 9 320 VAC BLK VHT BLK WHT WUT dek gLK V MT gLK V MT ORG BLU De wat GRN aa BLK V HT BLK WHT MHT YEL ORG WHT ORG WHT WHT C Q o Q O O Q BLU RED a Eck WHT TSL BLK WHT o au K
26. WASH FILL SOLENOID WHS WASH HEAT SOLENOID RS FINAL RINSE SOLENOID 9905 031 60 24 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 114 N3335 DISPENSER CONNECTION SECTION 7 ELECTRICAL SCHEMATICS AJ 44TS 460 VOLT 60 2 3 PHASE BLK WHT BLK WHT Eo WHT BLK WHT BLK WHT aS ORG BLU WHT muk wur JLU VHT ORG BLU RED 4 7 Q BLK WHT Syr Jr wHT YEL od Lo ferm HI mat TZ VHT E a WES og 9 D LO O JUMPER WIRE ZLK WHT y se BLU BLK WHT BLK WHT aM GREY GREY P oe A9 oM 13 14 5 LEGEND L1 Le L3 POWER DISTRIBUTION BLOCK 9 GND GROUND Re DRIVE MOTOR CONTACTOR R3 WASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY R6 WASH TANK FILL RELAY An R7 DOOR SAFETY SWITCH RELAY GREY GT aar 1 DRIVE MOTOR qan 21 WASH PUMP MOTOR Gi S4 1MDL DRIVE MOTOR OVERLOAD GRY YEL WASH PUMP MOTOR OVERLOAD H FUSE CONTROL FUSE 1 CONTROL TRANSFORMER DET DETERGENT DISPENSER CONNECTION cvs CONSTANT VOLTAGE SIGNAL GREY GRY YEL 51 POWER SWITCH n se DOOR SAFETY SWITCH 53 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 55 AUTO MAN DELIME SWITCH GREY 56 56 FINAL RINSE SVITCH D VHT E1 POWER LIGHT WFSV1 WASH FLOAT SWITCH 1 5 2 WASH FLOAT SWITCH 2 51 WASH REGULATING THERMOSTAT TLS TABLE LIMIT SVITCH lt OPTION
27. 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 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 17 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
28. 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 ranly This units covered in this manual have the following exhaust requirements Load End 200 CFM Unload End 400 CFM The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 14 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 The 1 8 brass plu
29. down the screws for securing it 17 The drive motor now needs to be reattached to the gear reducer There are two methods for doing this The first is to try and and reinsert the drive motor shaft into the gear reduc er with it gear reducer still attached to the unit This is diffi cult but possible Ensure that the key is in the keyway when you mate the parts The second method and perhaps the eas iest is to remove the gear reducer mate the two parts and bolt them together and then put them on the unit at one time This method takes a little more time If you wish to remove the gear SECTION 5 SERVICE PROCEDURES bg R REPLACEMENT CONTINUED reducer and assemble the two components continue on to step 27 Removing the drive hub bolt AJ 44T Series Technic al Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 44 SECTION 5 SERVICE PROCEDURES DRIVE MOTOR GEAR REDUCER REPLACEMENT CONTINUED 18 Once the motor and gear reducer are mated secure them with the locknuts and bolts Ensure the bolts are tight Removing the nuts holding the gear reducer on Removing the gear reducer Note Because of the way the covers for the drive assembly are designed it is imperative that you position the motor on the gear reducer so that the conduit fitting is facing towards the front of the dishmachine If it is facing away from the machine the covers may not go back on Removing the drive hub 19 Reat
30. 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 op
31. immediately shut off the unit and secure power and water There is a seri ous problem that must be addressed If any problems arise you can contact Jackson Technical Service SPECIAL NOTES Work performed on Jackson dishmachines by unau thorized or unqualified personnel may void the warranty Before beginning this or any other maintenance evolution on a unit under warranty you should contact a certified Jackson technician or Jackson Technical Service You can find a list of qualified service agencies in the back of you unit s installation manual SPECIAL PARTS AJ 44 66 80 Machines Gear Reducer 06105 011 71 88 Drive Motor Replacement Kit 50 Hz 06401 003 08 41 60Hz 1 Ph 06401 003 08 42 60 Hz 3 Ph 06401 003 08 40 600V 60 Hz 3 Ph 06401 003 08 43 CONTACT INFORMATION Jackson MSC Inc provides technical support for all of the dishmachines detailed in this manual We strongly rec ommend 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 proper 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 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES REPLACING THE WASH HEATER Jackson rack conv
32. need to be taken This will save time in the long run STEPS 1 Note These instructions only apply to vacuum breakers 1 2 NPT and 3 4 NPT as pictured below The repair kits indicated in these instructions will only work on those style of back flow preventers If you have a machine with a different style of vacuum breaker contact your Ecolab representative about replacement components Vacuum breaker 2 Note Even though the photos in these instructions show a vacuum breaker that has been removed from the plumbing assembly these maintenance steps could be performed with it installed so long as the requirements in the section entitled PREPARATION have been met 3 Remove the top cap by gripping firmly and turning to the left The cap should come off after a few turns Removing the cap 4 Set the cap to the side 5 Using the needle nose pliers gently lift out the plunger and set to the side Examine the brass seating surface inside the vacuum breaker The plunger is required to sit flat on this sur face so it must be free of defects imperfections and the like If there is debris remove it If it is chipped or cracked then the vacuum breaker must be replaced Failure to do so may result in the vacuum breaker not working according to its design and could result in damage to the dishmachine AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES eg V
33. put another rack in OPERATIONAL INSPECTION Based upon usage the pan strainers may become clogged with soil and debris as the work day progresses Operators should regularly inspect the pan strainers to ensure they have not become clogged If the strainers do they will reduce the washing capability of the machine Instruct operators to clean out the pan strainers at regular intervals or as required by work load NOTE On units equipped with prewash sections AJ 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 19 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 w
34. run without water in those sections This can cause damage to components WARE PREPARATION Proper preparation of ware will help ensure good results and less re washes If not done properly ware may not come out clean and the efficiency of the dishmachine will be reduced It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are good ideas especially for silverware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to sanitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine DAILY MACHINE PREPARATION Refer to the section entitled PREPARATION at the top of this page and follow the instruc tions there Afterwards check that all of the chemical levels are correct and or that there is plenty of detergent available for the expected workload WASHING A RACK OF WARE To wash a rack simply slide a rack of soiled ware into the load end of the machine Once the the machine is started it should pull the rack through the machine and push it out the unload end Once a rack has started through you may
35. 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 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 sanitiz
36. strainers if necessary 3 Worn prewash pump impeller Verify status of impeller replace if necessary Problem Inadequate rinse 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Pawl bar moves with no load but does not move when loaded 1 Clutch on drive assembly is out of adjustment Adjust as required AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 29 SECTION 4 TROUBLESHOOTING U n 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 re
37. 05945 002 65 98 05945 111 68 40 208 50 3 05945 01 1 84 59 05945 002 24 70 05945 11 1 68 40 220 50 3 05945 01 1 84 59 05945 002 24 70 05945 11 1 68 40 230 50 3 05945 01 1 84 59 05945 002 24 70 05945 11 1 68 40 380 50 3 05945 002 71 09 05945 002 24 70 05945 11 1 68 40 415 50 3 05945 111 69 12 05945 002 24 70 05945 111 81 33 440 50 3 05945 111 69 12 05945 002 24 70 05945 111 81 33 208 60 N A N A N A 230 60 N A N A N A 200 60 3 05945 002 66 00 05945 002 66 02 05945 002 65 99 208 60 3 05945 11 1 68 39 05945 11 1 68 41 05945 11 1 68 40 230 60 3 05945 11 1 68 39 05945 11 1 68 41 05945 11 1 68 40 380 60 3 05945 111 69 12 05945 002 24 70 05945 111 81 33 460 60 3 05945 111 68 39 05945 11 1 68 41 05945 11 1 68 40 600 60 3 05945 111 69 12 05945 111 81 33 05945 111 81 33 AJ 80T S 200 50 3 05945 011 84 59 05945 111 68 40 05945 111 68 40 208 50 3 05945 01 1 84 59 05945 11 1 68 40 05945 11 1 68 40 220 50 3 05945 01 1 84 59 05945 11 1 68 40 05945 11 1 68 40 230 50 3 05945 01 1 84 59 05945 11 1 68 40 05945 11 1 68 40 380 50 3 05945 002 71 09 05945 11 1 68 40 05945 11 1 68 40 415 50 3 05945 111 69 12 05945 111 81 33 05945 111 81 33 440 50 3 05945 111 69 12 05945 111 81 33 05945 111 81 33 208 60 N A N A N A 230 60 N A N A N A 200 60 3 05945 002 66 00 05945 002 65 99 05945 002 65 99 208 60 3 05945 11 1 68 39 05945 11 1 68 40 05945 11 1 68 40 230 60 3 05945 11 1 68 39 05945 11 1 68 40 05945 11 1 68 40 380 60 3 05945 111 69 12 05945 111 81 33 05945 111 81 33 460 60 3 059
38. 1 22 21 22 21 22 22 27 7 6 3 22 28 t sm 8 8 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 52 SECTION 6 PARTS SECTION AJ 44 CONTROL BOX ASSEMBLY CONTINUED ITEM DESCRIPTION Electrical Box Weldment 1 2 1 Terminal Block 3 Pole 3 1 Rinse Thermometer 96 Lead 1 Rinse Decal 180 F 4 6 Star Washer External Tooth 10 24 5 6 Screw 10 32 x 3 4 Long Phillips Trusshead 6 1 Decal Gauge 7 1 Wash Thermometer 48 Lead 1 Wash Decal 160 F 8 1 Wire Lug 2 AWG to 14 AWG 9 1 Decal Ground 10 2 Screw 10 32 x 1 2 Long Phillips Trusshead 11 1 Decal L1 L2 L3 12 1 Light Amber 13 1 Light Red 14 1 Din Rail 15 1 Circuit Breaker 200 380 Volt 60 Hz Models Only 15 1 Circuit Breaker TG Models Only 16 1 Switch ON FILL OFF DRAIN 17 2 Motor Contactor 18 1 Heater Contactor 19 1 Overload 20 1 Overload 21 1 Control Relay 21 2 Control Relay 22 10 Screw 6 32 x 3 8 Long Round Phillipshead 23 1 Fuse 380 Volt 460 Volt all 60 Hz Models Only 1 Fuse 600 Volt Models Only 24 1 Fuse Holder for 23 Above 25 1 Transformer 200 Volt Model 208 220 230 460 Volt Models 208 220 230 460 Volt TG Models 380 415 Volt Models 600 Volt Model 26 4 Locknut 10 24 with Nylon Insert 27 1 Terminal Board 28 1 Terminal Board 29 2 Control Relay TG Models Only Not Shown MISCELLANEOUS PARTS NOT SHOWN Grommet 1 2 OD x 3 8 ID Bushing Heyco SB100 Plug Heyco 2700 G 875 Con
39. 1 89 41 09905 021 72 30 05945 111 44 44 05940 200 76 00 05945 111 44 45 05700 021 72 75 06685 111 68 49 09905 002 97 62 06685 111 68 48 09905 003 00 69 09905 011 86 86 05940 002 78 97 05945 111 68 38 05925 011 68 34 05925 111 64 18 48 05930 301 46 00 48 48 05945 002 24 70 05945 111 72 51 05950 002 41 47 05950 011 68 35 05950 002 46 10 05950 011 75 59 05950 002 23 77 05945 111 35 19 05920 011 72 89 05920 011 72 88 05920 002 75 95 05945 111 72 51 05930 301 22 18 09905 011 74 61 09905 002 82 33 09905 002 49 48 05700 031 66 88 05700 011 71 47 05700 021 70 88 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 55 SECTION 6 PARTS SECTION MOTOR OVERLOAD CHART Model Volts Hz Phase Drive Motor Prewash Motor Wash Motor AJ 44T S 208 50 3 05945 01 1 84 59 N A 05945 11 1 68 40 220 50 3 05945 01 1 84 59 N A 05945 11 1 68 40 230 50 3 05945 01 1 84 59 N A 05945 11 1 68 40 380 50 3 05945 002 71 09 N A 05945 11 1 68 40 415 50 3 05945 111 69 12 N A 05945 111 81 33 440 50 3 05945 111 69 12 N A 05945 111 81 33 208 60 N A N A N A 230 60 N A N A N A 200 60 3 05945 002 66 00 N A 05945 002 65 99 208 60 3 05945 11 1 68 39 N A 05945 11 1 68 40 230 60 3 05945 11 1 68 39 N A 05945 11 1 68 40 380 60 3 05945 111 69 12 N A 05945 111 81 33 460 60 3 05945 11 1 68 39 N A 05945 1 11 68 40 600 60 3 05945 111 69 12 N A 05945 111 81 33 AJ 66T S 200 50 3 05945 011 84 59
40. 10 003 07 21 Issued 03 21 2006 Revised N A 101 Bees SECTION 6 PARTS SECTION SIDE LOADER PAWL ASSEMBLIES STRAINER MAGNET D Replacement Kit Note The kits for the pawl bars come with the bar weldment 3 dogs and the hardware Pawl Dog Wing Weldment 05700 021 86 79 Pawl Bar Spacer 05700 011 71 45 Kit Pawl Bar Replacement 06401 131 86 90 Kit 30 Pawl Bar Replacement 06401 231 86 90 Drive Linkage Replacment Kit L R 06401 003 11 59 Replacement Kit Note The replacement kits for the drive linkages come also with the hardware for mounting them to the pawl bars Drive Linkage Replacement R L 06401 003 1 1 60 Replacement Kit Note The conveyor switch replacement kit comes with the switch a termi nal and a wire nut Conveyor Switch Replacement Kit 06401 003 11 79 x Service Note The cord for the conveyor switch needs to be cut to length in the field and have the Front Strainer Weldment pink terminal applied there 05700 021 85 10 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 102 SECTION 6 PARTS SECTION SIDE LOADER PAWL ASSOCIATED PARTS Pawl Bar Roller Bracket 05700 031 77 94 Associated Hardware Washer 1 4 20 I D 05311 174 01 00 Locknut 1 4 20 S S Hex w Nylon Insert 05310 374 01 00 Pawl Bar Roller Replacement Kit 06401 003 11 80 Replacement Kit Notes The replacement kit for the pawl
41. 4 74 Ball Valve 1 1 2 NPT 04820 111 71 46 Tee 1 1 2 Brass Nipple 1 1 2 Brass Close Elbow 1 1 2 Brass 90 Street 04730 01 1 69 93 04730 207 40 00 04730 206 32 00 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 74 SECTION 6 PARTS SECTION AJ 66T DRAIN PLUMBING ASSEMBLIES Left to Right Plumbing Nipple Brass Close 3 Nipple Brass Close 1 1 2 NPT 04730 207 40 00 Assembly 04730 01 1 87 04 Tube Copper 1 1 2 x 8 1 4 Long 05700 021 70 06 Tube Copper 1 1 2 x 4 3 4 Long 05700 01 1 70 08 Adapter Male to Female 1 1 2 04730 401 25 01 Elbow 1 1 2 FNPT 90 Brass Tube Copper 1 1 2 x 4 1 4 Long 04730 01 1 73 77 05700 01 1 70 07 Connector No Hub 1 1 2 04720 604 06 00 Right to Left Plumbing Tube Copper 1 1 2 x 8 1 4 Long 05700 021 70 06 Assembly _____ Tee Brass 1 1 2 x 1 1 2 x 1 1 2 04730 01 1 69 93 Nipple Rinse Weldment d 05700 021 84 61 ANY K i OUA Tube Copper 1 1 2 4 1 4 Long Valve Handle Assembly 05700 021 84 74 Elbow Brass Street 1 1 2 NPT 04730 206 32 00 Tube Copper 1 1 2 x 4 3 4 Long V pU alve Ball 1 1 2 05700 011 70 08 04820 111 71 46 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 75 SECTION 6 PARTS SECTION eg AJ 80T DRAIN PLUMBING ASSEMBLIES Tube Coppe
42. 401 003 08 40 Drive Motor 460 Volt 60 Hz Three Phase Models 06401 003 08 43 Drive Motor 600 Volt 60 Hz Three Phase Models 06401 002 48 32 9 1 Gear Drive 06105 011 71 88 10 1 Roller Bearing 03120 011 71 81 11 1 Drive Hub 05700 011 67 97 Complete Drive Assembly 05700 003 06 83 Decal Drive Adjuster 09905 021 72 24 OUTPUT SHAFT OF GEAR REDUCER Front Drive Motor Cover Rear Drive Motor Cover Replacement Kit Replacment Kit 06401 003 1 1 64 06401 003 10 18 Replacement Kits Notes Detail A The replacement kits for the drive motor covers come with the weldments and the mounting hardware AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 86 SECTION 6 PARTS SECTION 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 R amp O 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 7 Cylinder Oil W460 Inca
43. 45 111 68 39 05945 11 1 68 40 05945 111 68 40 600 60 3 05945 111 69 12 05945 111 81 33 05945 111 81 33 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 56 SECTION 6 PARTS SECTION eg HEATER BOX ASSEMBLY ITEM DESCRIPTION Mfg No 1 1 Heater Box Cover 05700 002 02 04 2 1 Heater Box Weldment 05700 002 98 38 3 1 Thermostat High Limit 05930 01 1 49 43 1 Fitting 1 4 Imperial Brass 05310 924 02 05 4 1 See Next Page N A 5 1 Gasket 05330 200 02 70 6 1 Terminal Board 05940 002 78 97 7 1 Kit Wash Regulating Thermostat TE Series 06401 003 18 20 7 1 Kit Wash Regulating Thermostat TS Series 06401 003 18 21 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 57 SECTION 6 PARTS SECTION eg HEATER BOX ASSEMBLY CONTINUED 5 16 18 Hex Nut See Heater Chart Below 05310 275 01 00 Heater Gasket 05330 200 02 70 SO S 5 16 Lockwasher 05311 275 01 00 Heater Chart Model Volts Phase KW Part Number 208 1 18 04540 121 79 30 230 1 18 04540 121 79 31 200 3 18 04540 121 79 30 208 3 18 04540 121 79 30 220 3 18 04540 121 79 31 230 3 18 04540 121 79 31 380 3 18 04540 003 08 51 415 3 18 04540 003 08 52 440 3 18 04540 003 08 53 460 3 18 04540 121 79 32 575 3 18 04540 003 06 22 600 3 18 04540 003 06 22 Gas and steam models do not use electric heaters in the wash tank or power rinse tank SERVICE NOTE When replacing the tub h
44. 7 Hi ff f To Drain From the existing drain attach the two additional Tees 7 using the 1 1 2 NPT Close Nipples 8 Tighten the Reducers Items 6 amp 9 into the Tees as shown above Attach the Modified Compression Fitting Item 10 into the 1 1 2 to 1 4 Reducer 9 Position the bulb of the thermostat Item 1 so that it rests approximately 1 4 from the bottom of the Tee Item 7 Tighten the Modified Compression Fitting Item 10 as required Mount the Thermostat Item 1 to the tub using the Thermostat Bracket Item 2 and set it for 120 F 140 F Install the Solenoid Valve Item 3 to the second Tee 7 and then attach to the incoming cold water line Use pipe dope or thread tape as required to prevent any leaks ITEM QTY DESCRIPTION Mfg No 1 1 Thermostat 05930 121 67 72 2 1 Thermostat Bracket 05700 01 1 81 64 3 1 Solenoid Valve 04810 100 09 18 4 2 Nipple Close 1 2 NPT Brass 04730 207 15 00 5 1 Valve Check 1 2 04820 002 55 77 6 1 Reducer 1 1 2 to 1 2 04730 002 55 75 7 2 Tee 1 1 2 x 1 1 2 x 1 1 2 04730 011 69 93 8 2 Nipple 1 1 2 Close Brass 04730 207 40 00 9 1 Reducer 1 1 2 to 1 4 04730 002 55 76 10 1 Modified Compression Fitting 05700 001 16 52 1 Complete Kit 06401 002 44 07 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 79 See Motor Chart Below 05700 01 1 89 17 Cap Screw 3 8 16 x 2 05305 011
45. 730 906 10 34 6 1 Elbow Street 90 3 4 NPT Black Iron 04730 01 1 87 37 7 1 Y Strainer 3 4 NPT Black Iron 04730 217 01 32 8 1 Valve Gate Steam 3 4 NPT 04820 100 19 00 9 1 Plug 3 8 NPT Black Iron 04730 909 02 34 10 1 Nipple 3 4 NPT x 10 Long 04730 907 06 34 11 1 Reducer 3 4 NPT to 1 2 NPT Black Iron 04730 91 1 02 34 12 1 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 13 1 Elbow Street 3 4 NPT Black Iron 04730 01 1 87 37 14 1 Union 3 4 NPT Black Iron 04730 912 01 00 15 1 Nipple Close 3 4 NPT Black Iron 04730 907 01 00 16 1 Steam Trap 3 4 NPT 06680 500 02 77 17 1 Pipe 3 4 NPT x 10 Long Black Iron 04730 907 06 34 STEAM OUTLET PLUMBING AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 69 SECTION 6 PARTS SECTION GAS COIL ASSEMBLY TG MODELS Gas Coil Weldment 05700 002 44 23 Connection point for Hose Recirculating Discharge See Hose Connections page Connects with 3 4 90 Elbow Brass 04730 206 13 00 3 4 Close Brass Nipple 04730 207 34 00 Connection point for Hose Wash Coil Assembly See Hose Connections page Connects with 3 4 90 Elbow Brass 04730 206 13 00 3 4 Close Brass Nipple 04730 207 34 00 Coil Box Weldment 05700 002 50 94 Gas Coil Box Cover Replacement Kit 06401 003 10 37 Other items used but not shown ITEM QTY DESCRIPTION Mfg No 1 1 Thermostat High L
46. 74 98 Motor Mounting Clamp 4 1 8 7 Not Shown 04730 002 32 15 Complete Assembly 05700 021 73 42 Upper Support Bracket Model s 05700 021 73 68 AJ 66T s AJ 80T s Nut 1 4 20 Serrated 05310 011 66 49 Lower Support Bracket 05700 021 73 71 s Motor Mounting Gasket 05330 01 1 71 62 Key 3 16 x 1 Long Volts 200 440 208 230 200 230 380 460 600 Volts 208 230 380 415 440 208 230 200 230 380 460 600 208 230 380 415 440 208 230 200 230 380 460 600 Pump Plate 05700 021 71 83 Pump Seal 05330 011 71 98 Phase C2 CO SECTION 6 PARTS SECTION MOTOR ASSEMBLIES Impeller AJ 44T s 05700 031 67 45 Impeller AJ 66T s 8 AJ 80T s WASH MOTOR CHART Hz Part Number 50 06105 121 81 34 60 06105 021 70 57 60 06105 121 70 58 60 06105 121 81 34 60 06105 121 70 58 60 06105 002 48 31 PREWASH MOTOR CHART Hz Part Number 50 06105 121 70 56 50 06105 121 81 34 50 06105 121 81 34 50 06105 121 70 56 60 06105 121 70 55 60 06105 121 70 56 60 06105 121 70 56 60 06105 121 70 56 60 06105 002 48 31 50 06105 121 81 34 50 06105 121 81 34 50 06105 121 81 34 50 06105 121 81 34 60 06105 121 70 57 60 06105 121 70 58 60 06105 121 81 34 60 06105 121 70 58 60 06105 002 48 31 05700 031 71 78 Impeller Washer 05700 011 71 95 Bolt 1 4 20 x 3 4 05305 274 04 00 Kit P
47. 80T MODELS ONLY SERVICE NOTE When replacing the 10 32 screws in the End Caps it is recommended that a thread locking fluid be used to ensure that the screws do not back out during normal operation ITEM DESCRIPTION Mfg No 1 1 Wash Arm Weldment 05700 002 95 25 2 1 Lanyard 05340 01 1 72 46 3 1 Cap Threaded 04730 603 12 00 Items 1 through 3 Hardware 05700 002 95 19 1 O ring Not Shown 05330 400 12 08 4 1 Prewash Manifold Weldment 05700 003 01 66 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 82 Bee SECTION 6 PARTS SECTION WASH ARM MANIFOLD ASSEMBLY ITEM DESCRIPTION 9 Wash Arm Assembly 9 Screw 10 32 x 3 8 Long Phillips Truss Head 9 Locknut 10 24 S S Hex with Nylon Insert 9 Wash Arm Weldment 9 Lanyard 9 End Cap Wash Tube 9 O ring 1 Wash Manifold Weldment Left to Right Right to Left Hose 2 X 6 75 Manifold Pump 2 Clamp Hose 1 9 16 TO 2 1 2 OO E A Mfg No 05700 002 95 19 05305 173 12 00 05310 373 01 00 05700 002 95 25 05340 011 72 46 05700 011 67 11 05330 400 12 08 05700 002 95 20 05700 002 95 66 05700 002 90 79 04730 011 34 89 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 83 SECTION 6 PARTS SECTION FINAL RINSE ASSEMBLY Gasket 05330 111 42 81 E Rinse Arm Support Bracket 05700 002 06 24 End Caps P oE 9 Upper Rinse Arm 05700 002 02 18
48. 80TG 460 3 60 N A 7A 15 AMP AJ 80TS 208 1 60 N A 19A 25 AMP AJ 80TS 230 1 60 N A 19A 25 AMP AJ 80TS 208 3 60 N A 13A 20 AMP AJ 80TS 230 3 60 N A 13A 20 AMP AJ 80TS 460 3 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 DIMENSIONS s 78 NHdO HOOQ LHOI3H 1334 1915 OL ANG HOO 14 WOH X 3NIHOVIAHSIO SNOISNAWIG TVOLLH3A TTV HOO lJ dAO8V 268 ATALVWIXOUddV NOILOANNOO IWOIHLOATA O NOLLO3NNOO L 8 dOOTs Q3HSINIJ 3AOSV 469 ATALVNIXOUdd V NOLLO3NNOO 197 H31VM 41 qN3931 SZ 409 1 09 409 18 1 OL 318V L St 52 r4 ALISOddO AHL NO SI NOILOANNOO H3 VM OSNIINOONI FHL 57900 13310 LHOIH NO NMOHS 13GOW 1H9I8 OL 1391 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION AJ 66T LEFT TO RIGHT DIMENSIONS 6 4 9 48 8 69 a seen 21871 OL 3189 99 408 8 SI N3dO TIVM 2181 OL 3187 99 Sdl NOLLOANNOO Sdl NOLLO3NNOO YALVM ONINOONI HSVM3Hd 5 Sdl NOLLO3NNOO H31VM SNIINOONI 8 NOILOANNOO VOIHLIO313 V aN3931 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A
49. ACUUM BREAKER REPAIR PARTS KIT CONTINUED 7 H any of these conditions are present replace the old plunger with the new one from your kit Verify that the new plunger is also free from defects If it is not contact your Ecolab representative immediately 8 The plunger should drop into the vacuum breaker and seat Ensure it is not flipped upside down the orange seal ring should be up towards the top of the vacuum breaker 9 Pick up the cap and examine it With a soft towel remove any grit grime or debris that may have gotten caught in the threads of both the cap retainer or the vacuum breaker body There is an O ring that should be present on the cap retainer as well Regardless of the condition of the plunger this O ring Removing the plunger should be replaced once the cap is removed Using a small flathead screwdriver remove the old O ring 6 Your repair kit comes with a new plunger Examine the old one and ensure that the mating surface is not damaged or cut Also inspect the rubber seal on the top of the plunger to ensure it is in good condition and not torn Replacing the O ring 10 With the new O ring in place screw the cap back on the vacuum breaker body The cap needs to only be hand tight snug Examining the seal ring on the plunger AFTER MAINTENANCE ACTIONS 1 Reconnect the incoming water if disconnected and turn on Then restore power to the unit Run the unit for at least 10 minutes to
50. AL gt Bt WFS WASH FILL SOLENOID WHS WASH HEAT SOLENOID RS FINAL RINSE SOLENOID 9905 031 80 26 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 115 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TE amp AJ 80TE 208 230 VOLT 60 HZ 1 PHASE 4 LEGEND LL Le L3 POWER DISTROMUTION BLOCK CND CROUND RL HEAT CONTACTOR Re DRIVE MOTOR CONTACTOR R3 VASH PUMP MOTOR CONTAC TOR R4 FINAL RINSE RELAY R3 PRE WASH PUMP MOTOR CONTACTOR R7 WASH TANK FILL RELAY Ro FRE WASH TANK FILL RELAY R9 DOOR SAFETY SWITCH RELAY HL MASH HEATER ML DRIVE MOTOR ME WASH PUMP MOTOR M3 PRE NVASH PUMP MOTOR DRIVE MOTOR OVERLOAD WASH PUMP MOTOR OVERLOAD 3m PRE WASH PUMP MOTOR OVERLOAD cp CONTROL CIRCUIT BREAKER TL CONTROL TRANSFORMER DETERGENT DISPENSER CONNECTION CVS CONSTANT VOLTAGE SIGNAL St POWER SWITCH DOOR SAFETY SWITCH 1 53 DOOR SAFETY SWITCH 2 54 WASH PUMP 1 55 WASH PUMP SVITCH 2 56 AUTO MAN DELIME SWITCH 57 FINAL RINSE SWITCH ER PRE WASH PUMP SVITCH EL LIGHT EB HEATER HIGH LIMIT LIGHT WESW1 WASH FLOAT SWITCH L MASH FLOAT SWITCH 2 PVFSW PRE WASH FLOAT SWITCH L PvFswe PRE WASH FLOAT SWITCH 2 TER LIMIT THERMOSTAT WASH REGULATING THERMDSTAT CVTS COLO WATER THERMOSTAT OPTIONAL CNN COLO WATER VALVE COPTIDNAL gt TLS TABLE LIMET SWITCH OPTIONAL WFS VASH FILL SOLENOID PVFS PRE WASH FILL RS FINAL RINSE SOLENOID 9905 031 70 76d AJ 44T
51. AND WELDMENTS o D o 0 o Plate Left Water Plate Right Water Directional Directional 05700 021 79 27 05700 021 79 23 Run Off Sheet Weldment Splash Shield Weldment 05700 031 85 16 05700 021 71 39 Replacment Kit Note The kit for the hole direction plate comes with the plate a new gasket and the mounting hardware Hole M Kit Pipe Clamp 05700 000 35 05 Rinse Drain Plate Replacment Kit Rinse Drain Plug Replacement Kit TG Models Only 06401 003 10 07 06401 003 10 06 Rinse Drain Weldment Replacement Kit Replacement Kits Notes OBO DOs 18 08 The kits for the drain weldments and drain plugs with the weldments parts a new gasket and the mounting hardware Rinse Drain Plate Gasket Shoulder Bolt Wingnut Weldment 05330 011 72 27 05700 002 46 02 Wash Fill Tube Weldment 05700 021 71 21 Vellumoid Gasket Prewash Fill Tube Weldment 05330 111 42 81 AJ 66 amp AJ 80 Models Only 05700 021 74 76 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 95 Delay Timer 05945 011 65 44 SECTION 6 PARTS SECTION EXHAUST FAN CONTROL TABLE LIMIT SWITCH OPTIONS 2 Din Rail 77 7 05700 002 36 09 Terminal Board 05940 011 84 41 FAN LOAD ON TIMER OUTPUT 5A 1 4HP 240 V AC MAX Kit Exhaust Fan Electric amp Steam Models 05700 031 90 53 Decal Fan Load 09905 003 32 20 Kit Exhaust Fan
52. ARTS SECTION PREWASH INCOMING PLUMBING ASSEMBLY 1 5 ITEM DESCRIPTION Mfg No 1 1 Fill Line Injector Weldment 05700 002 04 71 1 Gasket 05330 111 42 81 2 1 Tube Copper 1 2 x 5 645 Long 05700 002 04 90 3 2 Adapter Male 04730 401 03 01 4 1 Vacuum Breaker 04820 003 06 13 5 1 Elbow 607 1 2 CTOC 04730 406 01 01 6 2 Adapter 1 2 FTG x Male 04730 011 59 53 7 1 Valve Solenoid 1 2 NPT 110 Volt 04810 100 12 18 8 1 Nipple 1 2 Close Brass 04730 207 15 00 9 1 Y Strainer 1 2 NPT 04730 217 01 10 10 1 Elbow 1 2 S CU to Ftg 04730 406 31 01 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 61 SECTION 6 PARTS SECTION INCOMING RINSE PLUMBING ASSEMBLY Tube Length Chart Item Length Inches 27 8 1 2 x 2 10 1 2 x 3 06 11 1 2 x 2 08 12 1 2 x 4 13 1 2 x 5 27 17 1 2 x 4 185 19 1 2 x 5 92 25 1 2 x 5 75 26 1 2 x 4 75 27 1 2 x 40 28 22 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 62 ITEM SECTION 6 PARTS SECTION INCOMING RINSE PLUMBING ASSEMBLY CONTINUED DESCRIPTION Plug 1 8 NPT Brass Rinse Injector Weldment Gasket Vacuum Breaker 1 2 NPT Adapter 1 2 Fitting x Male Elbow 607 1 2 Copper to Copper Valve Solenoid 1 2 NPT 110 Volt Union 1 2 Copper to Copper Tube Copper Tee Copper 1 2 Tube Copper Tube Copper Tu
53. ASH TANK FILL RELAY PRE WASH TANK FILL RELAY RELAY MASTER SOLENOID RELAY DRIVE MOTOR MASH PUMP MOTOR PRE WASH PUMP MOTOR RINSE RECIRCULATING PUMP DRIVE MOTOR OVERLOAD 3 5 8852819254 E a Sei VASH PLMP MOTOR DER Dad SC PRE VASH PUMP MOTOR OVERLOAD FUSE CONTROL FUSE n CONTROL TRANSFORMER E POWER SWITCH se DOOR SAFETY SWITCH 1 53 IR SAFETY SWITCH E 54 WASH PUMP SWITCH 1 WASH PLMP SWITCH 2 56 AUTO HAN DELIME SWITCH 57 FINAL RINSE SWITCH 58 PRE WASH PUMP SWITCH E1 POWER LIGHT WASH FLOAT SWITCH 1 VFSwe MASH FLOAT SVITCH Z PRE WASH FLOAT SWITCH 1 PRE WASH FLOAT SWITCH 2 TS WASH REGULATING THERMOSTAT CVTS COLP WATER THERMOSTAT OPT ONAL gt COLO WATER VALVE OPTIONAL TLS TABLE LIMIT SVITCH OPTIONAL VFS WASH FILL SOLENDIO PRE VASH FILL SOLENOID RS FINAL RINSE SOLENOID MS MASTER 2 2 2 33 23 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 121 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TS amp AJ 80TS 208 230 VOLT 60 HZ 1 PHASE i t vet oo Ser t mka LEGEND L L3 L3 POWER DISTRCBUT UN PLOCK GROUND DRIVE MOTOR CONTACTOR WASH PUMP MOTOR CONTACTOR FINAL RINSE RELAY PRE WASH PUMP MOTOR CONTACTOR WASH TANK FILL RELAY PRE WASH TANK FILL RELAY DOOR SAFETY SWITCH RELAY DRIVE MOTOR WASH PUMP MOTOR PRE WASH PUMP MOTOR CONTROL CIRCUIT BREAKER CONTROL
54. ED MODELS To energize the unit turn on the power at the service breaker The volt age should have been previously verified as being correct If not the voltage will have to be verified POWER UP 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
55. ELD WEI m gt UJ Lx A gt EE mo cto ze o Z 8 Ta ween S 99 y 9 Qo T Sg X NENG ae Ee Nes o2 O 14 1 2 os 1 1 2 DRAIN CONNECTED TO 29 99 DISHMACHINE DRAIN LINE AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 10 M 2 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 DIMENSIONS AJ 44T 82 AJ 66T 104 AJ 80T 118 NOTE ALL DIMENSIONS ARE TYPICAL E 23 or 30 depending on 7 width of the side loader Refer to chart above AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 11 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 dishmac
56. Final Rinse Manifold Weldment ITEM QTY 05700 002 97 41 1 4 Lower Rinse Nozzle 05700 002 96 04 Lower Rinse Arm 2 4 Upper Rinse Nozzle 8 05700 002 03 13 Rinse Drain Control Plate 05700 01 1 68 70 Rinse Pan Strainer Weldment 05700 041 85 09 Right Rinse Pan Locator Bracket 05700 021 Locknut 1 4 20 with Nylon Insert 05310 374 01 00 Rinse Tray Weldment 05700 031 66 75 Ys Left Rinse Pan Locator Bracket 05700 021 92 38 Optional Parts for TG Models Rinse Drain Control Plate 05700 011 68 70 Rinse Drain Overflow Plate 05700 002 53 62 Rinse Tray Weldment TG models only 05700 002 51 18 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 84 SECTION 6 PARTS SECTION DRIVE ASSEMBLY See Detail A AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 85 SECTION 6 PARTS SECTION DRIVE ASSEMBLY CONTINUED ITEM DESCRIPTION Mfg No 1 1 Drive Plate and Rod Weldment 05700 003 06 84 2 2 Coupling amp Expansion Leg Weldment 05700 021 67 50 3 1 Pawl Bar Drive Linkage Casting 09515 021 87 73 4 2 Pillow Block 06401 003 08 50 5 2 Shaft Collar 05700 011 89 18 6 1 Drive Spring 05315 01 1 83 51 7 1 Drive Motor Mounting Bracket 05700 031 73 56 8 1 Drive Motor 50 Hz Models 06401 003 08 41 1 Drive Motor 208 230 Volt 60 Hz Single Phase 06401 003 08 42 Drive Motor 208 230 Volt 60 Hz Three Phase Models 06
57. Gas Models 05700 003 14 59 Whisker Switch Assembly Whisker Limit Switch 05700 002 23 94 Mounting Bracket 05700 000 14 55 Whisker Limit Switch amp Lever 05930 303 40 01 Photoelectric Limit Switch Assembly Proximity Limit 05700 002 93 81 Switch Sensor 06685 002 94 15 Limit Switch 05930 002 62 81 2 S a Y Striker Plate Limit Switch Assembly Bracket Proximity Switch 05700 002 62 94 05700 002 94 93 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised 04 19 2007 100 Bees SECTION 6 PARTS SECTION SIDE LOADER TRACK ASSEMBLY LEG REPLACEMENTS Side loader track assembly left to right model shown ITEM QTY DESCRIPTION Mfg No 1 1 Track Weldment Left to Right 24 05700 031 78 98 1 Track Weldment Right to Left 24 05700 031 95 20 1 Track Weldment Left to Right 30 05700 003 04 57 1 Track Weldment Right to Left 30 05700 003 04 58 2 1 Actuator Switch Replacement Kit 06401 003 10 64 3 2 Spacer 05700 011 71 44 4 1 Leg Socket Replacement Kit 06401 003 09 79 5 1 Leg Support Replacement Kit 06401 003 09 80 6 1 Bullet Foot 05340 108 01 03 Replacement Kits Notes The actuator switch replacement kit comes with the actuator weldment mounting hardware and 2 spacers The leg socket replacement kit has the leg socket mounting hardware and set screw The leg support replacement kit has the leg and the bullet foot included AJ 44T Series Technical Manual 76
58. H TANK FILL RELAY R7 DOOR SAFETY SWITCH RELAY R8 WASH RECIRCULATING RELAY R11 MASTER SOLENOID RELAY ML DRIVE MOTOR Me WASH PUMP MOTOR M3 RINSE RECIRCULATING PUMP CR CONTROL CIRCUIT BREAKER Ti CONTROL TRANSFORMER DET DETERGENT DISPENSER CONNECTION cvs CONSTANT VOLTAGE SIGNAL 51 POWER SWITCH 5 DOOR SAFETY SWITCH 53 WASH PUMP SWITCI S4 WASH PUMP SWITCH 2 55 AUTO MAN DELIME SWITCH 56 FINAL RINSE SWITCH POWER_LIGHT WFSW1 WASH FLOAT SWITCH 1 WFSVe WASH FLOAT SWITCH 2 TSL WASH REGULATING THERMOSTAT TLS TABLE LIMIT SWITCH lt OPTIONAL WFS WASH FILL SOLENDID RS FINAL RINSE SOLENDID MS MASTER SOLENOID 9905 002 58 42 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 110 SECTION 7 ELECTRICAL SCHEMATICS _ _ AJ 44TG 208 230 VOLT 60 HZ 3 PHASE GRY ORG LEGEND L1 12 L3 POVER DISTRIBUTION BLOCK GND GROUND DRIVE MOTOR CONTACTOR wg WA R3 WASH PUMP MOTOR CONTACTOR ok oho R4 FINAL RINSE RELAY s Ke w R6 WASH TANK FILL RELAY Lid 9 ERY YCL R7 DOOR SAFETY SWITCH RELAY 9 WASH RECIRCULATING RELAY Rit MASTER 5 RELAY DRIVE MOTOR 55 WASH PUMP MOTOR RINSE RECIRCULATING PUNP DRIVE MOTOR OVERLOAD EK WASH PUMP MOTOR OVERLOAD CB CONTROL CIRCUIT BREAKER oer xe n CONTROL TRANSFORMER o em DET DETERGENT DISPENSER CONNECTION CVS CONSTANT VOLTAGE SIGNAL 51 POWER SWITCH se DOOR SAFET
59. Ki E e AJ 80T Complete L R Assembly S e 06401 141 81 06 AJ 80T Complete R L Assembly 06401 241 81 06 AJ 80 Prison Assembly 06401 341 81 06 All associated hardware spacers and castings may be ordered using the part numbers indicated in the above assem bly Pawl Bar Weldment 05700 041 82 01 Both assemblies contain 40 pawl bar dog castings Please note the direction of installation as indicated on the above drawings When replacing pawl bar dog castings ensure to re install in the appropriate direction If you do not then the rack will not be pulled through the machine during operation AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 91 SECTION 6 PARTS SECTION AJ 44T RACK RAIL ASSEMBLY Rack Rail Weldment 05700 031 67 59 Opposite Rack Rail 05700 031 69 48 05700 011 71 44 Actuator Switch Replacement Kit 06401 003 10 14 Replacement Kit Note The replacement kit for the actuator switch comes with the switch two spac ers and the mounting hardware AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 92 SECTION 6 PARTS SECTION AJ 66T RACK RAIL ASSEMBLIES Left to Right Assembly Rack Rail Weldment 05700 031 76 27 Opposite Rack Rail 05700 041 71 37 Actuator Switch Replacement Kit Rack Guide Spacer 06401 003 10 99 8 per 05700 011 71 44
60. NAL BOARD 0 L2 CUSTOMER PROVIDED FAN CONTACTOR COIL R10 9 56 TO R8 9 44 TO TO R14 9 86 2 9905 003 14 580 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 126
61. SECTION eg HEATER BOX ASSEMBLY CONTINUED FRAME ASSEMBLY DRESS PANELS THERMOSTATS The thermostat range is from 140 F to 240 F with a maximum bulb exposure temperature of 300 F Calibration Wash Thermostat Set Point 165 F Adjustable range Hi Llmit Thermostat Fixed set point 210 F Non adjustable The hi limit thermostat is used to protect the heater element in the event of a run away regulating thermostat or a dry fire situ ation It is set 210 F 0 F or 10 F with a fixed set point This part is not adjustable The wash tank regulating thermostat will maintain the correct wash water temperature to meet NSF requirements These spec ify that the wash be no lower than 140 F on chemical sanitizing models and no lower than 160 F on hot water sanitizing machines FRAME WELDMENTS Model Left to Right Part Number Right to Left Part Number AJ 44T s 05700 031 67 15 05700 031 67 15 AJ 66T s 05700 002 49 28 05700 002 57 57 AJ 80T s 05700 031 74 07 05700 002 32 14 Bullet Feet 4 per model order using part number 05340 01 1 71 74 FRONT DRESS PANELS Model Left to Right Part Number Right to Left Part Number AJ 44T s 05700 031 72 22 05700 031 72 22 AJ 44TG 05700 002 52 77 05700 002 52 77 AJ 66T s 05700 002 51 22 05700 002 57 84 AJ 66TG 05700 002 51 22 05700 002 57 84 AJ 80T s 05700 031 74 06 05700 031 77 10 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 60 10 3 SECTION 6 P
62. SH FLOAT SWITCH 2 Pwesw PRE WASH FLOAT SWITCH L TA SERMOS ge Si EE COLD WATER THERMOSTAT OPTIONAL COLD WATER VALVE OPTIONAL W TABLE LIMIT SVITEH lt P TIONAL WHS vase HEAT u PWFS PRE VASH FILL SOLENDUD mu Sale NEM RS FINAL RINSE SOLENOID 9905 031 80 28 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 124 SECTION 7 ELECTRICAL SCHEMATICS n CONVEYOR SIDE LOADER amp DRAIN QUENCH DIAGRAM CONVEYOR SIDE LOADER AJ 44T SERIES SWITCH GRY IQ u E GRY YEL TO TB 4 AJ 66T amp AJ 80T SERIES SWITCH GRY TO TB 4 e WHI RED mg 4 9905 002 56 84a DRAIN QUENCH SCHEMATIC L1 Le THERMOSTAT SOLENOID 4 RED CONNECT BLACK WIRE TO MOTOR CONTACTOR L1 WITH PIGGYBACK TERMINAL PROVIDED CONNECT WHITE WIRE TO MOTOR CONTACTOR Le WITH PIGGYBACK TERMINAL PROVIDED AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 125 SECTION 7 ELECTRICAL SCHEMATICS 2 EXHAUST HOOK UP SCHEMATIC CONVEYOR EXHAUST FAN HOOKUP CUSTOMER SUPPLIED GRY VOLTAGE TO 2 13 250V LEGEND iN T TIMER TB TERMINAL BOARD CUSTOMER PROVIDED FAN CONTACTOR COIL 9905 002 55 88b GAS CONVEYOR EXHAUST FAN HOOKUP L1 TO RB 6 44 TO R10 6 66 CUSTOMER SUPPLIED TO 14 6 86 VOLTAGE 250V LEGEND A T TIMER TB TERMI
63. Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 116 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TE amp AJ 80TE 208 230 VOLT 60 HZ 3 PHASE H Q 7 AER 30 ot BLACK RED 1GA gt i GK 4 POWER DISTRIBUTION BLOCK CROUND HEAT CONTACTOR LJ MOTOR CONTACTOR WASH BUMP MOTOR CONTACTOR FINAL RINSE RELAY Ri PRE WASH PUMP MOTOR CONTACTOR WASH TANK FILL RELAY omy PRE WASH TANK FILL RELAY fp XL oho 3008 SAFETY SWITCH RELAY Ae WASH HEATER 3RIVE m WASH PUMP MOTOR PRE VASH PUMP MOTOR JRIVE MOTOR OVERLOAD WASH PUMP MOTOR Dei ES e PRE WASH PUMP MOTOR OVERLOAD CONTROL Depu BREAKER D CONTROL TRANSFORMER ori JETEREENT DISPENSER CONNECTION o wina CONSTANT VOLTAGE SIGNAL POWER SWITCH JOOR SAFETY SWITCH JOOR SAFETY SWITCH 2 WASH PUMP SWITCH 1 57 WASH PUMP SWITCH 2 e v AUTO MAN IELME SWITCH FINAL RINSE SWITCH PRE VASH PUMP SWITCH POWER HEATER HIGH LIMIT LIGHT ony WASH FLDAT SWITCH 1 WASH FLOAT SWITCH 2 PRE WASH FLOAT SVITLH J PRE VASH FLOAT SWLTCH 2 HEATER HIGH LIMIT THERMOSTAT WASH REGULATING THERMOSTAT vie COLD VATER THERMOSTAT OPTIONAL COLD VATER VALVE OPTIONAL TABLE LIMIT SWITCH OPTIONAL WASH FILL SOLENOD PRE WASH FILL SOLENOID FINAL RINSE S LENDII BEB LAGS GU SHA Eet 81828828 Za HAK ver 9903 031 70 76d AJ 44T Ser
64. THERMOSTAT MS TLS TABLE LIMIT SWITCH OPTIONAL St oto BEN m WES WASH FILL SOLENOID TE RS FINAL RINSE SDLENDID NS MASTER SOLENOID 9905 002 53 24 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 112 SECTION 7 ELECTRICAL SCHEMATICS _ AJ 44TS 208 230 VOLT 60 HZ 1 PHASE 8 B CON STANT CONVEYOR RUNNING BLACK 1464 LACK 1864 s Q BLK ORG WHT WHT O 120 vac BLK WHT BLK VHT d WHT ZLK VHT ZLK WHT MS DRG BLU WHT WHT DRN A B Q BLK WHT WDE BLU WHT ol La ORG BLU BLK FER BLK WHT BLK WHT BR VHT odi met ak BLU YEL mo vis Q LENS JUMPER WIRE ELK VHT 52 ot BLU ILK TUS B 3LK VHT Be GREY REY PH oe oe WHT 5 MAP L E G E N D 5 ORG L1 Le L3 POWER DISTRIBUTION BLOCK 5 GND GROUND R2 DRIVE MOTOR CONTACTOR R3 WASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY R6 WASH TANK FILL RELAY R7 DOOR SAFETY SWITCH RELAY Mi DRIVE MOTOR SEE WASH PUMP MOTOR cB CONTROL CIRCUIT BREAKER GRY YEL 1 CONTROL TRANSFORMER DET DETERGENT DISPENSER CONNECTION Cvs CONSTANT VOLTAGE SIGNAL 51 POWER SWITCH Se DOOR SAFETY SWITCH GRY YEL 53 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 55 AUTO MAN DELIME SWITCH 56 FINAL RINSE SWITCH El POWER LIGHT SW1 WASH FLOAT SWITCH 1 IRE YEL wer WF Swe WASH FLOAT SWITCH 2 ams 51 WASH REGULATING THERMOSTAT TLS TABLE LIMIT SWITCH OPTIONAL WES
65. WASH FILL SOLENOID RS WHS WASH HEAT SOLENOID WHT BLK RS FINAL RINSE SOLENOID 9905 031 80 23 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 113 SECTION 7 ELECTRICAL SCHEMATICS AJ 44TS 208 230 VOLT 60 HZ 3 PHASE ILACK 1404 TACK 1404 52 BLK ORG WHT WHT a Q O 120 BLK WHT EE Oo BLK WHT ad ORC BLU deck d GR A BLK WHT art waren 27 Rv fi pont MES Ss 3 4 e R6 BLK WHT Q SLU YEL D vuan JUMPER VIRE BLUK VHT Ts se ort BLU BLK WHT A D BLK WHT Bu GREY GREY T tec oen WHT 1 t ee 96 g LEGEND Am Li Le L3 POWER DISTRIBUTION BLOCK G GND GROUND Re DRIVE MOTOR CONTACTOR R3 WASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY R6 WASH TANK FILL RELAY ua R7 DR SAFETY SWITCH RELAY Mi DRIVE MOTOR o oe Meg WASH PUMP MOTOR N 54 DRIVE MOTOR OVERLOAD GRY YEL eMOL WASH PUMP MOTOR OVERLOAD 9 CONTROL CIRCUIT BREAKER CONTROL TRANSFORMER DET DETERGENT DISPENSER CONNECTION 55 CVS CONSTANT VOLTAGE SIGNAL GREY Ser 1 POWER SWITCH 9 52 DOUR SAFETY SWITCH 3 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 55 AUTO MAN DELIME SWITCH GREY 56 FINAL RINSE SWITCH o REL MAT El POWER LIGHT anvo WFSW1 WASH FLOAT SWITCH 1 WFSW2 WASH FLOAT SWITCH 2 151 WASH REGULATING THERMOSTAT R4 RS TLS TABLE LIMIT SWITCH OPTIONAL Ser WHT BLK WFS
66. Y SWITCH oi 53 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 E AUTO NAN DELIME SWITCH x 6 FINAL RINSE SWITCH SAND w Ei POWER LIGHT 3 WFSWL FLOAT SWITCH 1 WFSWE WASH FLOAT SWITCH 2 TSL WASH_ REGULATING THERMOSTAT TLS TABLE LIMIT SWITCH lt OPTIONAL gt w AL o ve WFS VASH FILL SOLENOID RS FINAL RINSE SOLENDID MS MASTER SOLENOID oflo 3N 4 17 9905 008 33 110 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 111 SECTION 7 ELECTRICAL SCHEMATICS _ AJ 44TG 460 VOLT 60 2 3 PHASE FUSE GR el un LEGEND Li L2 L3 POWER DISTRIBUTION BLOCK M DRIVE MOTOR CONTACTOR Gry 210 R3 WASH PUMP CONTACTOR VT FINAL RINSE RELAY WASH TANK FILL RELAY SY ig Bre R7 DOOR SAFETY SWITCH RELAY 9 WASH RECIRCULATING RELAY R11 MASTER SOLENOID RELAY M DRIVE MOTOR WASH PUMP MOTOR RINSE RECIRCULATING PUMP 1001 DRIVE MOTOR OVERLOAD Eh WASH PUMP MOTOR OVERLOAD FUSE CONTROL FUSE on 5 n CONTROL TRANSFORMER ome mW IET DETERGENT DISPENSER CONNECTION 5 CONSTANT VOLTAGE SIGNAL St POWER SWITCH sa DOOR SAFETY SWITCH oe 53 WASH PUMP SWITCH 1 54 WASH PUMP SWITCH 2 55 E SWITCH m Ge 56 FINAL RINSE SWITCH oilo VHT BLK 1 POWER LIGHT 4 7 WFSW1 WASH FLOAT SWITCH 1 WFSW2 WASH FLDAT SWITCH 2 TS WASH REGULATING
67. al Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 64 QTY lt hihi P hihi EA SECTION 6 PARTS SECTION TG SERIES INCOMING RINSE PLUMBING ASSEMBLY CONTINUED DESCRIPTION Rinse Injector Weldment Replacement Kit Gasket Plug 1 8 NPT Brass Vacuum Breaker 3 4 NPT Valve Solenoid 3 4 NPT 110 Volt Elbow 3 4 Street Brass Nipple Close Brass 3 4 NPT Union 3 4 NPT Copper to Copper Adapter 3 4 Fitting x Male Elbow 90 3 4 Copper to MSPS Tee 3 4 CU x CU x CU Tee 3 4 x 3 4 x 1 2 Fitting Adapter 1 2 to 1 4 Plug 1 4 NPT Brass Test Cock Valve Ball 1 4 NPT Gauge Pressure 0 100 PSI Elbow 3 4 NPT 90 Brass Tube Copper Union 3 4 Copper to Copper Elbow 90 1 2 Copper to MSPS Fill Line Injector Weldment Gasket Plate Deflector Mfg No 06401 003 11 84 05330 111 42 81 04730 209 07 37 04820 002 53 77 04810 100 53 00 04730 206 04 34 04730 207 34 00 04730 212 05 00 04730 401 11 01 04730 406 42 01 04730 411 46 01 04730 41 1 03 01 04730 401 41 01 04730 209 01 00 04810 011 72 67 06685 11 1 88 34 04730 206 13 00 See Chart 04730 412 06 01 04730 406 32 01 05700 002 04 71 05330 111 42 81 05700 002 62 49 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 65 P SECTION 6 PARTS SECTION en RINSE SOLENOID VALVE amp VACUUM BREAKER REPAIR PARTS KITS 8
68. art Number 06401 003 09 96 06401 003 09 97 06401 003 09 98 06401 003 09 96 06401 003 09 98 06401 003 09 99 Kit Part Number 06401 003 10 38 06401 003 10 39 06401 003 10 39 06401 003 10 38 06401 003 10 40 06401 003 10 38 06401 003 10 38 06401 003 10 38 06401 003 10 41 06401 003 10 39 06401 003 10 39 06401 003 10 39 06401 003 10 39 06401 003 10 42 06401 003 10 43 06401 003 10 39 06401 003 10 43 06401 003 10 41 AJ 44T Series Technical Manual 7610 003 07 21 80 Issued 03 21 2006 Revised N A SECTION 6 PARTS SECTION PREWASH amp WASH PUMP WELDMENTS Wash Pump Prewash Intake Strainer Weldment 05700 021 74 96 Weldment Intake Suction Scoop Weldment 05700 041 68 88 05700 021 87 60 D Prewash Strainer 60 i 05700 021 74 94 Scoop Intake Suction Wash Prewash Pump Weldment Prewash Pump Weldment AJ 66 AJ 80 Left to Right models AJ 66 AJ 80 Right to Left models 05700 002 10 62 05700 002 1 1 96 Gasket 05330 002 54 55 Pump Discharge Weldment 05700 002 90 05 Wash Pump Weldment 700 002 51 2 05700 002 50 92 Prewash Pump Weldment Prewash Pump Weldment AJ 66TG Left to Right model AJ 66TG Right to Left model 05700 002 43 56 05700 002 42 69 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 81 Bees SECTION 6 PARTS SECTION men PREWASH 0 ASSEMBLY AJ 66T amp AJ
69. ater Wipe out the inside of the unit and then reassemble with the components previously removed SHUTDOWN AND CLEANING GAS HEATED MODELS At the end of the work day shut down the gas booster in accor dance with manufacturer s instructions Place the power switch in the OFF position secure the flow to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the 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 fro
70. bar roller comes with the roller roller shaft hardware and locknut as shown Pawl Bar Gutter Weldment Replacement Kit Drive Gutter Gasket 06401 003 09 95 05330 011 68 55 Guide Block Replacment 06401 003 10 15 Replacement Kit Notes Top Guide Block The pawl bar gutter kit includes the weldment lock nuts and the gasket The guide block kits includes the blocks and the gasket Service Note Because of wear patterns that develop over time it is highly rec ommended that when replacing either of the guide blocks that Bottom Guide Block the other be replaced as well from the kit AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 103 SECTION 6 PARTS SECTION SIDE LOADER VENT COWL OPTION Vent Cowl Replacement Kit Left to Right Vent Cowl Replacement Kit Right to Left 06401 003 11 81 06401 003 11 83 Service Note One of the side gaskets that come in the kit will need to be cut to length in order to fit prop erly on the unit when replaced Replacement Kit Note Vent Cowl Gasket Top 05330 031 83 47 The replacement kit s for the vent cowls come with Vent Cowl Gasket Side 05330 031 83 48 the cowls the gaskets and mounting hardware VENT SCOOP OPTION STANDARD ASSEMBLY Replacement Kit Note The cover kit contains the cover Vent Scoop Assembly Vent Cowl Cover Replacement Kit 05700 002 04 08 06401 003 10 16 and the hardware for mounting it
71. be Copper Tube Copper Tee 1 2 x 1 2 x 1 4 Gauge Pressure 0 100 PSI Decal 15 25 PSI Test Cock Valve Ball 1 4 NPT Tube Copper Plug 1 4 NPT Brass Tube Copper Regulator Watts 1 2 Not used on GP units Elbow 90 1 2 Street Brass GP units only Plate Rinse Plumbing Gasket Elbow 90 1 2 Copper to MSPS Adapter Male Tube Copper Tube Copper Tube Copper Plate Deflector Mfg No 04730 209 07 37 05700 002 03 42 05330 111 42 81 04820 003 06 13 04730 011 59 53 04730 406 01 01 04810 100 12 18 04730 412 05 01 See Chart 04730 411 01 01 See Chart See Chart See Chart See Chart 04730 411 25 01 06685 1 11 88 34 09905 002 97 74 04810 011 72 67 See Chart 04730 209 01 00 See Chart 04820 100 04 07 04730 206 08 00 05700 01 1 82 86 05330 111 42 81 04730 406 32 01 04730 401 03 01 See Chart See Chart See Chart 05700 002 62 49 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 63 SECTION 6 PARTS SECTION TG SERIES INCOMING RINSE PLUMBING ASSEMBLY Tube Length Chart R Item Length Inches 17 3 4 x 2 13 16 18 3 4 x 3 7 16 19 3 4 x 2 5 8 20 3 4 x 3 21 3 4 x 4 3 4 22 3 4 x 5 3 4 23 3 4 x 40 26 27 28 Replacement Kits Notes The rinse injector replacement kit comes with the injector weldment the gasket 3 brass plugs and M hardware for mounting 25 RN AJ 44T Series Technic
72. cal Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 35 SECTION 5 SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT These dishmachines are equipped with electrical solenoid valves to allow for automatic fill and rinse These valves are designed to specific tolerances and design aspects that must be met in order to function properly Ecolab offers repair kits for replacing some of the wear items associated with solenoid valves which will allow you to save money in that replacement of these parts can take place without removing the solenoid valve from the plumbing assembly 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 Only autho rized personnel should ever perform any maintenance procedure 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 Ensure that incoming water to the machine is secured either by use of a shut off valve or disconnecting the incoming water line TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 1 Small flathead screwdriver 2 Medium flathead screwdriver 2 Needle nose pliers 3 5 16 nutdriver 4 C
73. cket and ratchet with extension 7 16 combination wrench 9 16 combination wrench 3 4 combination wrench 1 8 Allen wrench 1 4 nutdriver Large flathead screwdriver Medium phillipshead screwdriver 10 Medium hammer 11 Rubber mallet TIME REQUIRED P It is estimated that it will take 1 person and a quarter hours to replace the drive motor one and a quarter hours to just replace the gear reducer or two hours to do both at one time not including all of the items indicated in the sec tion entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempting this maintenance procedure Become familiar with the parts and what actions need to be taken This will save time in the long run 2 The procedures demonstrated in this manual are shown being performed on an AJ 44 rack conveyor dishma chine The actual maintenance steps however apply to any drive motor or gear reducer found on a Jackson rack convey or dishmachine STEPS 1 Remove the 2 screws that secure the top drive assembly cover in place Removing the screws from the top cover 2 Remove the top cover to expose the drive assembly Removing the top cover 3 Set the top cover to the side and out of the way so that it does not become a trip hazard From here the next step will be to remove the bottom cover This will require using the 7 16 socket with ratchet and mo
74. d to the machine 2 Dishmachine doors are not closed Close doors completely 3 Incoming water solenoid valve damaged faulty Verify that the valve is operating If not replace 4 Tank floats faulty Verify the wiring of the floats Verify that no debris is jamming the floats Replace if necessary Problem Machine fills but fill is weak 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Low wash tank temperature 1 Low incoming water temperature Verify that the incoming water temperature matches what is indicated on the machine data plate 2 Heater not energizing Verify that the wash tank heater is operating If not replace 3 Low incoming voltage Have an electrician verify that the power coming to the machine is the same as indicated on the data plate Problem Low wash arm pressure poor spray pattern 1 Clogged wash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged wash tank or wash pump strainers Clean out strainers if necessary 3 Worn wash pump impeller Verify status of impeller replace if necessary Problem Low prewash arm pressure poor spray pattern 1 Clogged prewash arm nozzles Verify that nozzles are not clogged with debris If so remove debris 2 Clogged prewash tank or prewash pump strainers Clean out
75. de of the 3 4 hole 3 Mount the switch bracket to the outside of the dishtable using the 1 4 20 hardware supplied The cable entering the switch body should be pointing upwards so that the switch sensitivity adjust ment screw is downward for adjusting from the underside of the table 4 Wiring instructions White wire from the conveyor control panel to red black wire from proximity switch Door switch wire from the conveyor control panel to the black wire from the proximity switch Black white wire from the conveyor control panel to the red white wire from the proximity switch 5 Adjust the sensitivity of the proximity switch by turning the adjustment screw on the switch The proper setting is reached when the switch will sense an object approximately 12 from the switch 20 28 20 75 SCALE 1 1 Unless noted all dimensions are in inches AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 22 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions 1 Wiring The switch is wired common and nor mally open because of the hinge design By interrupting the line in series with the door switches the dishmachine ceases to operate Refer to the machine schematic for details on how to wire the switch 2 Parts of the table switch are mounted in the dishtable at the end of the table and under the tab
76. druff key back into the groove of the motor shaft and re install the impeller being careful to align the woodruff key with the slot in the impeller Replace the bolt and washer then tighten 16 Install the motor by placing it on the studs and sliding it for ward until it is against the wash tank wall Replace the nuts and washers and tighten 17 Re install the pump motor support bracket and tighten down the nuts used to secure it to the tub 18 Replace the band clamp on the motor and support brack et tighten until snug AFTER MAINTENANCE ACTIONS Reconnect the incoming water if disconnected and turn on Then restore power to the unit Run the unit for at least 10 minutes to ensure there are no leaks If you hear any grinding sounds while the motor is running immediately shut off the unit and secure power and water There is a serious problem that must be addressed If any problems arise you can contact your Ecolab representative SPECIAL PARTS Mechanical Seal Part number 06401 003 06 73 Motor Mounting Gasket Part number 06401 003 06 75 Motor Support Clamp Part number 04730 002 32 15 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 34 SECTION 5 SERVICE PROCEDURES eg RACK RAIL STABILIZER KIT First remove three bolts locknuts and flat washers at middle hood tub junction Next remove door splash shield Rack Rail Stabilizer 05700 01 1 34 63 AJ 44T Series Techni
77. e solenoid as they had been connected previously Ensure that the wire nuts are on tight 10 Slide the coil wire cover back on taking care not to dam age the wires 11 If you are done performing maintenance on the valve con tinue on to step 23 Otherwise please go on to step 12 L Loosening the valve bonnet 12 To remove the valve bonnet grasp it with the jaws of the pipe wrench and turn to the left Note on some models you may have to remove the valve in order to perform this and any further steps Be careful not to damage the plumbing assem bly Only use the pipe wrench enough to where you can spin the valve bonnet off with your hand AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT CONTINUED Removing the valve bonnet 13 Slowly remove the valve bonnet Note The spring for the plunger is located directly under the bonnet and may come free if you are not careful Remove the plunger spring and valve bonnet and place to the side Removing the O ring 14 Remove the O ring and inspect it If it has any tears or cuts or excessive flat spaces it should be replaced 15 Examine the threads for the valve bonnet Check them for scoring or signs of damage Take a cloth and clean them out to remove any foreign particles that might get lodged in the threads and cause a leak Severely damage threads should not be re
78. e 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 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 18 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 HEAT
79. eaters it is HIGHLY recommended that you also change out the gasket as well Once installed gaskets become compressed and are subjected to extreme temperature changes Replacing the gasket with a new one when replacing the heater may prevent future leaks SERVICE NOTE The nuts used to secure the heater to the tub should be torqued to 16 in lbs After tightening the unit should be allowed to heat up and operate normally for approximately 30 minutes Secure power to the machine and check the nuts once more to ensure that they are torqued to 16 in lbs AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 58 emer SECTION 6 PARTS SECTION HEATER BOX ASSEMBLY CONTINUED The wash tank heater system is electrically connected in the circuit so that they are dependent upon the dishwasher being prop erly filled with and maintaining a safe water level two thermostats mounted in the heater box behind the dress panel float switch mounted in the wash tank and the heater relay mounted in control box with the heater being activated by the ther mostats Once the dishwasher has been filled to the correct level the heater should operate automatically Should the tank heat be too high too low or no indication of temperatures at all the following checkout should be made Note The following checkout should be made by either a qualified service person or electrician A Checkout of the heater system 1 If the temperat
80. 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 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 21 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS PHOTOELECTRIC LIMIT SWITCH INSTALLATION INSTRUCTIONS CONVEYOR DIRECTION CORNER OF CLEAN DISHTABLE V i SECTION BRACKET MOUNTING TEMPLATE Installation Instructions 1 Locate and drill a 3 4 diameter hole through the back of the dishtable 4 from the end and 3 above the surface of the table 2 Using the switch mounting bracket template a photocopy of it may prove beneficial locate and drill the 9 32 diameter hole on either si
81. ensure there are no leaks If any prob lems arise please contact your Ecolab representative SPECIAL PARTS Vacuum breaker repair kit For 1 2 NPT order 06401 003 06 23 Complete Vacuum Breaker Assembly Part number 04820 003 06 13 1 2 Examining the plunger seating surface AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 41 SECTION 5 SERVICE PROCEDURES DRIVE MOTOR GEAR REDUCER REPLACEMENT The drive motor and the gear reducer of your Jackson rack conveyor are responsible for moving racks of ware through the dishmachine If needed to be replaced these instructions will show you how to get your machine up and running in the shortest possible time Jackson offers all of the repair parts necessary for performing this task 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 Only autho rized personnel should ever perform any maintenance procedure on the dishmachine PREPARATION 1 Power must be turned off to the unit at the service breaker Tag or lock out the service breaker to prevent acci dental or unauthorized energizing of the machine TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 7 16 socket and ratchet with extension 9 16 so
82. er 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 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
83. er to remove the wiring access cover on the back of the motor Removing the bolts holding the drive motor to the gear reducer 9 Once the cover is removed and the wiring is exposed you AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 43 DRIVE MOTOR GEAR REDUCE may want to jot down how your motor is wired You can also refer to the schematic located on the motor itself because how the motor is wired when you remove it is how you will wire it when you replace it If you have any questions regarding the wiring of your motor do not hesitate to contact Jackson Technical Service Removing the wire nuts 10 pull the bundled wires out and remove the wire nuts Set the wire nuts to the side as you will need them when you wire up the new motor 11 Once the wire nuts are removed separate the wires 12 With the flathead screwdriver and the hammer loosen the conduit nut Once loosened pull the conduit away from the motor The motor may now be disposed of 13 Remove the access cover off of the new motor 14 Attach the conduit and pull the wires through the hole pro vided Tighten the conduit nut 15 Using the wire nuts wire the motor back the same way the old one had been Refer to the schematic on the motor itself or contact Jackson Technical Service if you any questions 16 Once the wiring is done carefully push wires back into the motor and put the access cover back on Tighten
84. erances and design aspects that must be met in order to function properly Ecolab offers repair kits for replacing some of the wear items associated with vacuum breakers which will allow you to save money in that replacement of these parts can take place without removing the vacuum breaker from the plumb ing assembly 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 Only autho rized personnel should ever perform any maintenance procedure 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 Ensure that incoming water to the machine is secured either by use of a shut off valve or disconnecting the incoming water line TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 1 Small flathead screwdriver 2 Needle nose pliers TIME REQUIRED It is estimated that it will take 1 person twenty min utes to perform this task not including all of the items indicat ed in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance evolution Become familiar with the parts and what actions
85. eration 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 c
86. eyor machines come equipped with heaters to ensure proper ware washing results Occasionally some of these components may need replacing to maintain optimum performance Jackson offers all of the repair parts necessary for performing this task 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 Only autho rized personnel should ever perform any maintenance procedure 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 Ensure that incoming water to the machine is secured either by use of a shut off valve or disconnecting the incoming water line 3 The unit must be drained completely TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 3 8 Nutdriver Ratchet 1 2 Socket 3 8 Socket Phillipshead Screwdriver Needlenose Pliers Torque Wrench Siliconee Sealant Amp Meter TIME REQUIRED It is estimated that it will take 1 person ninety min utes to perform this task not including all of the items indicat ed in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thorough
87. f you are not going to replace the seal go to step 16 Removing the woodruff key Removing the pump gasket AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 33 SECTION 5 SERVICE PROCEDURES REPLACING THE PUMP GASKET amp SEAL CONTINUED 10 Note that the mechanical seal will consist of the following parts 1 A rubber seal with a ceramic ring set inside it that will seat in the center of the mounting plate 2 A rubber seal with a stainless steel covering on the outside that seals the motor shaft and seats against the ceramic ring 3 A spring 4 A stainless steel spring cap to capture the top of the spring and hold it in place 11 Most of the mechanical seal should simply come off leav ing the rubber seal with the ceramic ring inside the pump mounting plate 12 Using a screwdriver pry out the remaining part of the mechanical seal taking care not to score or damage the motor shaft 13 Once the hole is free of any parts of the mechanical seal verify that the hole is clean and free of debris 14 Gently press the new seal and ceramic over the shaft and slide down into the mounting plate hole NOTE Do not touch the surface of the seal with your bare fingers place a rag or paper towel between your fingers and the seal Gently slide the shaft seal over the shaft and push it down against the mounting plate seal Place the spring and cap over the shaft 15 Place the woo
88. gs 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 FEX Terminals in the control box marked CVS provide a constant voltage signal whenever the d drive motor is operating Terminals in the control box marked DET provide a voltage signal whenever the wash motor is operating Aid Connection Points AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 15 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CURTAIN INSTALLATION DIAGRAMS Please refer to the chart for placement of the curtains HOODED SIDE LOADER HOODED SIDE LOADER UNHOODED SIDE LOADER UNHOODED SIDE LOADER O lt lt ui N O AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 16 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
89. h extension 2 9 16 socket and ratchet with extension 3 5 16 Allen wrench 4 5 16 nutdriver 5 Large flathead screwdriver TIME REQUIRED It is estimated that it will take 1 person one and a half hours to perform this task not including all of the items indicated in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance procedure Become familiar with the parts and what actions need to be taken This will save time in the long run 2 The procedures demonstrated in this manual are shown being performed on an ES 4400 rack conveyor dish machine The actual maintenance steps however apply to any wash prewash or power rinse motor found on an Ecolab rack conveyor dishmachine STEPS 1 Note in this procedure it is not necessary to always remove the wiring from the motor However the motor should be treated with the greatest of care when being pulled away and set on the floor for maintenance as demonstrated in these instructions 2 Remove the 4 nuts holding the mounting plate in position Removing the mounting plate nuts with the 9 16 socket 3 Loosen the band clamp on the back end of the motor Loosening the band clamp on the back end of the motor 4 With the band clamp loosened carefully remove it from the back end of the motor Once the clamp is removed examine it to determine if it needs to be replaced as well If
90. hannel locks 5 12 pipe wrench TIME REQUIRED It is estimated that it will take 1 person twenty min utes to perform this task not including all of the items indicat ed in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance evolution Become familiar with the parts and what actions need to be taken This will save time in the long run 2 The procedures demonstrated in this manual are shown being performed on an AJ 44C rack conveyor dishma chine The actual maintenance steps however apply to any Parker style solenoid valve found on a Ecolab dishmachine STEPS 1 Remove the top screw with the 5 16 nutdriver Remove the screw and the data plate and set to the side Removing the top screw 2 With the top screw and data plate removed grasp the sole noid coil and gently pull up The coil should slide up allowing you to remove it from the valve bonnet If you are wanting to replace the coil continue on with Step 3 If you are wanting to replace some of the internal components of the valve proceed to step 12 Removing the coil 3 NOTE Replacing the solenoid coil requires working with the wiring of your machine It is important that all wiring main tenance be performed by qualified personnel Always verify the wiring steps presented in this instruction with the schemat ic that shipped with the unit A current schematic can also be
91. he torque wrench to the nuts 10 Before proceeding any further it is important to verify that the tub wall is free of any excess debris so that when the new gasket is applied there are no gaps that could lead to leaking around the heater 11 Apply the new heater gasket from your service kit 12 Slide the heater onto the studs and apply by hand the lock washers and nuts Tighten the nuts by hand and then use the torque wrench set to 154 in lbs to ensure that the nuts are secure Removing the heater AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 48 emeng SECTION 5 SERVICE PROCEDURES eg REPLACING THE WASH HEATER CONTINUED Three phase wiring 13 The thermostat probe needs to be placed into the well of the new heater Again use caution when doing this so that the probe or the capillary tube do not become broken If this occurs then the thermostat will have to be replaced 14 Apply silicone to seal the well and hold the thermostat probe in place 15 Reattach the incoming power lines to the heater ensuring that you wire the heater correctly for either single or three phase operationrightening the nuts holding the power lines 16 Using the torque wrench or a torque nutdriver if available torge the nuts holding the wires jumpers and bus bars to 16 in Ibs Single phase wiring 17 Ensuring that all non essential personnel are clear of the area close the drain valve
92. hine has been inspected and packed at the factory and is expected to arrive to you in new undam aged condition However rough handling by carriers or others may result in damage to the unit while in transit If such a situ ation occurs do not return the unit to Jackson instead contact the carrier and ask them to send a representative to the site to inspect the damage to the unit and to complete an inspection report You must contact the carrier within 48 hours of receiving the machine Also contact the dealer through which you purchased the unit UNPACKING THE DISHMACHINE The machine should be unboxed and removed from shipping pallet prior to being installed Open the front door and remove all of the packing materials Once unpacked ensure that there are no missing parts from the machine This may 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
93. ies Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 117 SECTION 7 ELECTRICAL SCHEMATICS AJ 66TE amp AJ 80TE 460 VOLT 60 HZ 3 PHASE aKo tot ERC gt E Weg menu ao JUk vHT Riet H NI 9 R7 wis Atert mam D H 4 5 vir ato wit Ron D ue e H ee e Aue uer 3 Ser 55 URN a POWER DISTRIBUTION BLOCK GRO L1 L2 L3 UN Ri HEAT CONTACTOR DRIVE MOTOR CONTACTOR WASH PUMP MOTOR CONTACTOR Re FINAL RINSE RELAY RS PRE WASH PLMP MOTOR CONTACTOR R7 VASH TANK FILL RELAY R8 PRE WASH TANK FILL RELAY Fa DOOR SAFETY SWITCH RELAY Hi VASH HEATER MI ORIVE MOTOR WASH PUMP MOTOR PRE WASH PUMP MOTOR wo DRIVE MOTOR OVERLOAD aur ski IML FUSE n se 53 54 se 57 se EI MESVL VASH PUMP MOTOR DVERLDAD 9 PRC WASH PLMP MOTOR OVERLOAD CONTROL CIRCUIT TRANSFORMER FUSE CONTROL TRANSFORMER POWER SWITCH DOOR SAFETY SWITCH 1 DOOR SAFETY SWITCH 2 WASH PUMP SWITCH 1 SWITCH 2 HEATER HOOH LIMIT LIDHT VASH FLOAT SVITCH L WFSV2 VASH FLOAT SVITCH CWTS COLD WATER VALVE COPTIONAL Stt TLS LIMIT SWCTCH OPTIONAL wes WASH FILL SDLENDID PWFS PRE WASH FILL SULENCED RS FINAL RINSE SDLLNDID 9905 091 78 9 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A
94. imit 05930 01 1 49 43 2 1 Terminal Board 05940 002 78 97 3 1 Thermostat Bracket 05700 01 1 81 64 4 1 Decal Thermostat Regulating 09905 01 1 84 31 5 1 Thermostat Wash Regulating 06401 140 00 32 6 2 Fitting 1 4 Imperial Brass 05310 924 02 05 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 70 Bee SECTION 6 PARTS SECTION eg TANK RINSE BOOSTER TG MODELS ONLY 8 BOTTOM ANGLED VIEW TOP ANGLED VIEW ITEM DESCRIPTION Mfg No 1 2 Plumbing Assembly Inlet Discharge Rinse Tank 05700 002 51 24 2 1 Tube Dispersion Weldment 05700 002 46 16 3 1 Tank GP Rinse 05700 002 45 05 4 1 Bracket Upper Rinse Tank 05700 002 67 13 5 1 Bracket Lower Rinse Tank 05700 002 67 14 6 1 Nipple 3 4 NPT x 4 Long 04730 207 05 00 7 3 Elbow 3 4 NPT 90 Brass 04730 206 13 00 8 1 Nipple 3 4 NPT x Closed Brass 04730 207 34 00 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 71 emer SECTION 6 PARTS SECTION a RECIRCULATING PUMP ASSEMBLY TG MODELS ONLY Elbow 3 4 90 Brass 2 per 04730 206 13 00 Pump Recirculating with Adapters 05700 002 51 28 Nipple 3 4 Close Brass 2 per 04730 207 34 00 Used on AJ 44CGP AJ 66CGP AJ 80CGP units right to Used only on AJ 66CGP AJ 80CGP left to right units left units and the AJ 44CGP left to right unit es um Mounting Bracket Mounting Bracket 05700 002 25 74 05700 002 23 61 AJ 44T Series Technical
95. ing Assembly TG Series 64 Solenoid Valve amp Vacuum Breaker Repair Parts 66 Steam Unit Wash Tank Coil Assembly 67 Steam Plumbing Left to Right Models 68 Steam Plumbing Right to Left Models 69 Gas Coil Assembly TG Models 70 Rinse Booster Tank Assembly TG Models 71 Recirculating Pump Assembly TG Models 72 Hose Connections TG Models 73 AJ 44T Series Drain Plumbing Assemblies 74 TABLE OF CONTENTS P SECTION DESCRIPTION PAGE VII PARTS SECTION CONTINUED AJ 66T Series Drain Plumbing Assemblies 75 AJ 80T Series Drain Plumbing Assemblies 76 AJ 66TG Series Left to Right Drain Plumbing Assembly 77 AJ 66TG Series Right to Left Drain Plumbing Assembly 78 Drain Quench Assembly 79 Motor Assemblies 80 Prewash amp Wash Pump Weldments 81 Prewash Arm Manifold Assembly 82 Wash Arm Manifold Assembly 83 Final Rinse Assembly 84 Drive Assembly 85 Lubrication Chart for Drive Gear 87 Door Assemblies 88 Pawl Bar Roller Bracket 89 AJ 44T amp AJ 66T Pawl Bar Assemblies 90 AJ 80T Pawl Bar Assemblies 91 AJ 44T Rack Rail Assembly 92 AJ 66T Rack Rail Assemblies 93 AJ 80T Rack Rail Assemblies 94 Miscellaneous Parts amp Weldments 95 Strainers 96 Float Switch Components Scrap Baskets 97 Curtains Tub Magnets 98 Vent Cowl Assembly Vent Scoop Option 99 Exhaust Fan Control Limit Switch Options 100 SIDE LOADER SECTION Side Loader Track Assembly Leg Replacements 101 Side Loader Pawl Bar Assemblies Strainer Magnet 102 Side L
96. ing 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 3 phase models To install the incoming power lines open the control box Install ony 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 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 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
97. it is broken in any spots or shows signs of metal fatigue it is best to order a new one The purpose of the clamp and the attached sup port bracket is to keep the weight of the motor from pulling on the tub damaging it It is absolutely necessary that this com ponent be replaced once the maintenance procedure is com pleted AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES REPLACING THE PUMP GASKET amp SEAL CONTINUED 8 Using a large screwdriver flathead preferred but a phillip shead will work just as well and the 7 16 socket loosen and then remove the bolt holding the impeller to motor shaft Refer to the picture below Removing the bolt that holds the impeller to the shaft 9 With the bolt and washer removed grasp the sides of the impeller and pull up gently The impeller should slide off of the shaft Remove the woodruff key as well and set to the side Removing the motor support bracket 6 With the motor support bracket removed gently pull back on the motor You may have to move it from side to side but it should start to move back Pull it completely away from the mounting studs on the tub and set down gently to work on it 7 Remove the gasket from the tub If you are going to replace it with a new one do so at this time Otherwise carefully examine the gasket for tears and other damage If it is accept able set to the side I
98. le 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 1 3 RACK WIDTH INSTALL AT FAR END OF TABLE 6 If you have any difficulty you might have to adjust the connectors to the seal screwing in or screwing out until the installation is straight on the table and the limit switch is actuated correctly by the rack TABLE LIMIT SWITCH THROUGH ROD HOLES TABLE IOUNTING BOLTS TABLE BOTTOM 00 75 Unless noted all dimensions inches 3 00 2 00 1 875 00 25 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 23 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS WHISKER LIMIT SWITCH INSTALLATION INSTRUCTIONS Mounting Bracket Limit Switch and Lever 12 Typ Spacing Limit Switch Dish and Lever Table Side View Top View Installation Instructions 1 Wiring Refer to the machine schematic 2 Mounting Mount the switch as indicated in the drawing s above AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21
99. lt gt Screw Data Plate xu EE Q Cap Screw Coil amp Housing Valve Bonnet Y Spring Plunger CO O Ring Diaphragm Retainer Cen Diaphragm Screen SC Retainer Components of Repair Kit Valve SPECIAL PARTS Solenoid Valve Plunger Kit Includes plunger and s 01 003 06 23 Part number 06401 00 Solenoid Valve Diaphragm Kit mbly 13 1 27 Includes diaphragm an Part number 06401 00 Solenoid Valve 110 Volt Coil anc Part number 06401 00 Complete Solenoid Valve Part number 04810 100 1 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 66 emer SECTION 6 PARTS SECTION men STEAM UNIT WASH TANK COIL ASSEMBLY Coil Weldment 05700 002 84 03 Stand D Weldment 05700 002 74 85 Stand B Weldment 05700 002 74 83 Coil Nut 05310 011 17 85 Stand C Weldment 05700 002 74 84 HIGHLY recommends that the Coil Gaskets be replaced any Order the entire assembly using part number time the Coil Weldment is 05700 002 11 78 y replaced or removed for an extended period of time Flat Washer Coil Gasket 05700 001 17 87 05700 001 17 86 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 67 STEAM INLET PLUMBING SECTION 6 PARTS SECTION STEAM PLUMBING LEFT TO RIGHT 10 3 8 ITEM DESCRIPTION Mfg No 1 1 Reducer 3 4 NPT to 1 2 NPT Black Iron 04730 91 1 02 34 2
100. ly before attempt ing this maintenance task Become familiar with the parts and what actions need to be taken This will save time in the long run STEPS 1 Remove the front dress panel 2 Remove the heater box cover to expose the heater Set the cover and hardware to the side Removing the power lines 3 Remove the incoming electrical lines from the heater Set the hardware to the side Heater without power lines attached 4 Push the incoming electrical lines out of the way 5 The thermostat probe needs to be removed from the well inside the heater The probe is secured in place with silicone that must be peeled away prior to attempting to remove it It is important that you do not damage the probe during this part of the maintenance action If you do then the thermostat will have to be replaced as well AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES REPLACING THE WASH HEATER CONTINUED Removing silicone from thermostat well Removing the gasket 6 Using your hand or needlenose pliers remove the silicone 7 With the thermostat probe out of the way use the 1 2 sock So that the thermostat probe may be gently removed et and ratchet to remove the nuts holding the heater to the tub Remove all nuts and lockwashers 8 Remove the heater from the tub weldment 9 Remove the gasket Removing the nuts and lockwashers Applying t
101. m 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 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 20 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 wa
102. me Phone No TABLE OF CONTENTS SECTION DESCRIPTION PAGE L SPECIFICATION INFORMATION Operating Characteristics 2 Electrical Requirements 3 AJ 44T Dimensions 4 AJ 66T Left to Right Dimensions 5 AJ 66T Right to Left Dimensions 6 AJ 80T Left to Right Dimensions 7 AJ 80T Right to Left Dimensions 8 Side Loader Left to Right Dimensions 9 Side Loader Right to Left Dimensions 10 Side Loader Installed Dimensions 11 Il INSTALLATION amp OPERATION INSTRUCTIONS Installation Instructions 13 Curtain Installation Diagram 16 Deliming Operations 17 Side Loader Installation amp Operation Instructions 18 Dishmachine Operating Instructions 19 Detergent Control 21 Photoelectric Limit Switch Installation Instructions 22 Striker Plate Limit Switch Installation Instructions 23 Whisker Limit Switch Installation Instructions 24 PREVENTATIVE MAINTENANCE General Maintenance 26 Drive Motor Gear Reducer Preventative Maintenance 27 IV TROUBLESHOOTING 29 V SERVICE PROCEDURES Replacing Pump Gasket and Seal 32 Rack Rail Stabilizer Kit 35 Rinse Solenoid Valve Repair Parts Kits 36 Vacuum Breaker Repair Parts Kit 40 Drive Motor Gear Reducer Replacement 42 Wash Heater Replacement 47 VI PARTS SECTION AJ 44T Control Box Assembly 52 AJ 66T AJ 80T Control Box Assembly 54 Motor Overload Chart 56 Heater Box Assembly 57 Frame Weldments Front Dress Panels 60 Prewash Plumbing Assembly 61 Incoming Plumbing Assembly 62 Incoming Plumb
103. ng See Service Note 11 1 Nipple Brass 1 1 2 NPT x 3 Long 04730 011 87 04 Service Note Copper tubing should be purchased locally and cut to length lengths provided in parts list above AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 77 QTY SECTION 6 PARTS SECTION AJ 66TG RIGHT TO LEFT DRAIN PLUMBING ASSEMBLY 3 4 10 4 3 5 6 5 3 4 I 12 Dui 11 gt me lt 14 DESCRIPTION Elbow 1 1 2 NPT Brass Street Valve Ball 1 1 2 FNPT Adapter Male to Female 1 1 2 Tube Copper Tee Brass 1 1 2 FNPT Nipple Brass 1 1 2 NPT Close Tube Copper Tube Copper Elbow Brass 90 1 1 2 FNPT No Hub Connector Nipple Brass 1 1 2 NPT x 3 Long Rinse Nipple Weldment Valve Handle Weldment Assembly Valve Handle Weldment Assembly 10 Tube Length Chart Item Length Inches 4 1 1 2 x 1 7 8 7 1 1 2 x 5 3 16 8 1 1 2 x 8 1 8 Mfg No 04730 206 32 00 04820 011 71 46 04730 401 25 01 See Chart 04730 01 1 69 93 04730 207 40 00 See Chart See Chart 04730 011 73 77 04720 604 06 00 04730 011 87 04 05700 021 84 61 06401 021 84 74 06401 002 57 83 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 78 SECTION 6 PARTS SECTION eg DRAIN QUENCH SYSTEM To Dishmachine Drain
104. oader Pawl Bar Associated Parts 103 Side Loader Vent Cowl Option 104 Rinse Fill Option 105 VI ELECTRICAL SCHEMATICS AJ 44TE 208 230 Volt 60 Hz 1 Phase 107 208 230 Volt 60 Hz 3 Phase 108 460 Volt 60 Hz 3 Phase 109 AJ 44TG 208 230 Volt 60 Hz 1 Phase 110 208 230 Volt 60 Hz 3 Phase 111 460 Volt 60 Hz 3 Phase 112 AJ 44TS 208 230 Volt 60 Hz 1 Phase 113 208 230 Volt 60 Hz 3 Phase 114 460 Volt 60 Hz 3 Phase 115 AJ 66TE amp AJ 80TE 208 230 Volt 60 Hz 1 Phase 116 208 230 Volt 60 Hz 3 Phase 117 460 Volt 60 Hz 3 Phase 118 AJ 66TG amp AJ 80TG 208 230 Volt 60 Hz 1 Phase 119 208 230 Volt 60 Hz 3 Phase 120 460 Volt 60 Hz 3 Phase 121 TABLE OF CONTENTS SECTION Vi DESCRIPTION ELECTRICAL SCHEMATICS AJ 66TS amp AJ 80TS 208 230 Volt 60 Hz 1 Phase 208 230 Volt 60 Hz 3 Phase 460 Volt 60 Hz 3 Phase Conveyor Side Loader Drain Quench Schematics Exhaust Fan Hook Up Schematics PAGE 122 123 124 125 126 SECTION 1 SPECIFICATION INFORMATION SECTION 1 SPECIFICATION INFORMATION OPERATING CHARACTERISTICS RACKS PER HOUR AJ 44 66 80TE TG TS 204 DISHES OR GLASSES PER HOUR AJ 44 66 80TE TG TS 5100 PREWASH TANK CAPACITY GALLONS AJ 66TE TG TS 17 25 AJ 80TE TG TS 17 25 WASH TANK CAPACITY GALLONS AJ 44 66 80TE TG TS 20 4 PREWASH PUMP CAPACITY GPM AJ 66TE TG TS 120 AJ 80TE TG TS 270 WASH PUMP CAPACITY GALLONS PER MINUTE ALL MODELS 270 VENTING REQUIREMENTS
105. ompletely 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
106. ont Strainer Weldment 05700 021 85 10 Overflow Strainer Support Drain Guard 05700 001 96 48 Strainer Weldment 05700 002 09 15 Wash Intake Strainer Weldment TG Models 05700 002 51 52 9p POT ELTE 2 p N L 2 27 55 LEE zi TL Garis ese EE CHI IPE ES ET III Tub Strainer Weldment TG Models _ Screen Strainer 05700 002 03 21 with Handle Weldment 05700 002 09 04 Wash Strainer Separator Weldment 05700 031 84 38 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 96 SECTION 6 PARTS SECTION eg FLOAT SWITCH COMPONENTS SCRAP BASKETS Wash Tank Float Switch Replacment Kit 06401 003 11 75 Prewash Tank Float Switch Replacment Kit 003 11 7 Replacement Kit 0920 E003 06401 003 11 77 Replacment Kit Note The float switch support bracket replace ment kit contains the bracket and asso ciated hardware for mounting Replacment Kit Note The float switch replacement kits contain the float switch with associated terminals the flat washer and the nut Service Agent Note Remember than when reinstalling the float switch that the flat washer goes inside against the tub wall while the nut is on the outside of the tub Float Switch Cover 05700 021 75 71 Scrap Basket Lid e Weldment 05700 002 56 55 Scrap Basket Assembly 06401 002 11 21 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 97 Ss SECTION
107. paired instead it is recommended that the entire valve should be replaced These instructions do not provide information on replacing the solenoid valve 16 Note Even though an O ring may not appear damaged it is a good idea to go ahead and replace it if you have a new one This will help ensure that your valve remains leak free in the future Removing the diaphragm 17 Remove the diaphragm retainer and then the diaphragm itself Many problems associated with a solenoid valve can be traced to a clogged pilot port in the diaphragm Pointing out the extension hole 18 As indicated in the photo above the extension hole can become clogged If it is difficult to clean out you can use a heated straight pin to push through the hole The center hole the pilot port must also be clear If the diaphragm is torn or bent in any way it must be replaced Diaphragm showing 1 pilot port and 2 extension hole AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT CONTINUED Removing the screen retainer 19 Using the small flathead screwdriver lift out the screen retainer Verify that the holes in it are free of clogs and debris Removing the mesh strainer screen 20 Again using the small flathead screwdriver carefully remove the mesh screen from inside the valve body The screen should be taken and rinsed out to remo
108. place 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 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 Ibs
109. 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 97 125 AJ 44TE 230 1 60 N A 89A 125 AMP AJ 44TE 208 3 60 N A 57A 80 AMP AJ 44TE 230 3 60 N A 49 70 AMP AJ 44TE 460 3 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 3 60 N A 8A 15 AMP AJ 44TG 230 3 60 N A 8A 15 AMP AJ 44TG 460 3 60 N A 5A 15 AMP AJ 44TS 208 1 60 N A 11A 15 AMP AJ 44TS 230 1 60 N A 11A 15 AMP AJ 44TS 208 3 60 N A 7A 15 AMP AJ 44TS 230 3 60 N A 7A 15 AMP 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 A 125 AMP AJ 66TE 208 3 60 N A 61A 80 AMP AJ 66TE 230 3 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 3 60 N A 12A 15 AMP AJ 66TG 230 3 60 N A 12A 15 AMP AJ 66TG 460 3 60 N A 15 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 11A 15 AMP AJ 66TS 230 3 60 N A 11A 15 AMP AJ 66TS 460 3 60 N A 6A 15 AMP AJ 80TE 208 1 60 N A 106A 150 AMP AJ 80TE 230 1 60 N A 97 125 AJ 80TE 208 3 60 N A 63 A 80 AMP AJ 80TE 230 3 60 N A 58 A 80 AMP AJ 80TE 460 3 60 N A 29A 40 AMP 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 1 20 230 3 60 N A 13A 20 AMP AJ
110. r 1 1 2 x 15 3 16 Long Nipple Brass Close 1 1 2 NPT 05700 002 06 99 04730 207 40 00 Tube Copper 1 1 2 x 4 15 16 Long 05700 011 87 25 Valve Ball 1 1 2 04820 111 71 46 Left to Right Plumbing Assembly Tube Copper 1 1 2 x 11 3 16 Long 05700 002 07 00 Right to Left Plumbing Assembly Tee Brass 1 1 2 x 1 1 2 x 1 1 2 04730 01 1 69 93 Nipple Rinse Weldment lt 05700 021 84 61 Connector No Hub 1 1 2 04720 604 06 00 Adapter Male to Female 1 1 2 04730 401 25 01 Elbow Brass Street 1 1 2 NPT 04730 206 32 00 Ball Valve Handle Assembly Elbow 1 1 2 FNPT 90 Brass 05700 021 84 74 04730 011 73 77 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 76 SECTION 6 PARTS SECTION AJ 66TG LEFT TO RIGHT DRAIN PLUMBING ASSEMBLY ITEM QTY DESCRIPTION Mfg No 1 6 Adapter Male to Female 1 1 2 04730 401 25 01 2 3 No Hub Connector 04720 604 06 00 3 3 Tee Brass 1 1 2 FNPT 04730 01 1 69 93 4 2 Ball Valve 1 1 2 FNPT 04820 011 71 46 2 Valve Handle Weldment Assembly Not Shown 06401 021 84 74 5 2 Nipple Brass Close 1 1 2 NPT 04730 207 40 00 6 2 Elbow Brass 90 1 1 2 FNPT 04730 011 73 77 7 2 Tube Copper 1 1 2 x 1 3 4 Long See Service Note 8 1 Rinse Nipple Weldment 05700 021 84 61 9 2 Tube Copper 1 1 2 x 3 1 2 Long See Service Note 10 2 Tube Copper 1 1 2 x 7 1 2 Lo
111. r the temperature should rise noticeably in a minute or two If it moves slow ly it would indicate that the element is faulty If it moves constantly higher at a good rate elements should be good Note A check with an amp probe at heater relay R1 terminals should be made to verify the amp draw on each leg This should be appropriate for the voltage and phase indicated on the data plate HEATER PROTECTION amp AUTOMATIC FILL FOR UNITS EQUIPPED WITH AUTOMATIC FILL This control is activated when the power switch is turned ON The primary function is to automatically energize the wash tank heat circuit It will also cutoff the wash tank heat circuit should the water be accidently drained from the machine with the power switch still ON The power switch should always be turned off before draining the unit This water level control consists of two 2 floats that operate when the power switch is turned on and works in conjunction with the thermostats and heater relays When the power switch is turned ON water starts to enter the dishmachine When it reaches the proper level the normally open contacts in the water level float switch close activating the heating circuit for tank heat If the water level below the correct level while power is still on the float switch will sense the lack of water and de activate the heater AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 59 SECTION 6 PARTS
112. s and restore power and water to AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 49 SECTION 5 SERVICE PROCEDURES REPLACING THE WASH HEATER CONTINUED the unit Turn the unit on and allow it to fill normally 18 Verify that there are no leaks around the heater If there are attempt to tighten it down as the tub will change shape slightly as it heats up 19 Use the amp meter to take readings off of the power lines to the heater verifying the amperage draw to the machine data plate 20 Wait until the heater contactor kicks out meaning that the tub has reached the appropriate temperature and place the unit in DELIME mode by flipping the switch on the back of the control box Allow the unit to operate for at least ten minutes to verify that there are no leaks and that the heater is main taining the tank temperature 21 If the unit appears to be operating correctly return it to AUTO mode and turn off 22 Replace the heater box cover 23 Replace the front dress panel AFTER MAINTENANCE ACTIONS Service perosnnel may want to drain the machine and allow it to cool down Secure power to the unit at the ser vice breaker and then verify the torque of all fasteners covered in this instruction SPECIAL NOTES Work performed on Jackson dishmachines by unau thorized or unqualified personnel may void the warranty Before beginning this or any other maintenance evolution on a unit under
113. sh Door Hande weldment 22 Prewash Door Hood Support 05700 031 84 14 05700 011 82 63 Prewash Door Handle Weldment 05700 011 80 45 Door Stiffener Not Shown 05700 031 83 43 ITEM QTY DESCRIPTION Mfg No 1 1 Wash Door Weldment 05700 003 13 47 2 1 Prewash Door Weldment AJ 66 8 80 5 Left to Right Model 05700 003 13 43 Om e Right to Left Model Screw 8 32 x 1 4 Long Door Switch Magnet Door Guide Bracket Right Door Stop Weldment Bracket Left Door Stop Weldment Locknut 10 24 SS Hex with Nylon Insert Bracket Pre Wash Door Stop 05700 003 13 40 05305 172 09 00 05700 111 51 68 05700 111 70 92 05700 002 96 33 05700 002 96 32 05310 373 01 00 05700 002 05 46 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 88 Bee SECTION 6 PARTS SECTION PAWL BAR ROLLER BRACKET Pawl Bar Roller Replacement Kit 06401 003 1 1 80 Replacement Kit Notes The replacement kit for the pawl bar roller comes with the roller roller shaft hardware and locknut as shown Pawl Bar Bracket with studs Weldment Pawl Bar Bracket without tabs Weldment 05700 031 84 68 05700 031 92 36 Replacement Kits Notes The pawl bar gutter weldment replacement kit contains the weld ment a gasket and the mounting hardware The guide block kit con tains both blocks and a gasket Pawl Bar Gutter Weldment Replacement Kit 06401 003 09 95 Guide Block
114. some steps to take to ensure that you are using the dishmachine the way it was designed to work Ensure that the water temperatures match those listed on the machine data plate Ensure that all strainers are in place before operating the machine Ensure that all wash and or rinse arms are secure in the machine before operating Ensure that drains are closed sealed before operating Remove as much soil from dishes by hand as possible before loading into racks Do not overfill racks Ensure that glasses are placed upside down in the rack Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations Clean out the machine at the 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 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 26 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
115. st likely the 7 16 combina tion wrench Do not lose the hardware for the covers as your repair kits do not come with the hardware necessary to replace these If you do require hardware that is not present in your kits do not hesitate to contact Jackson Technical Service for help AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 42 SECTION 5 SERVICE PROCEDURES DRIVE MOTOR GEAR REDUCER REPLACEMENT CONTINUED 5 With the cover removed you may now remove the bolts used to connect the drive motor to the gear reducer Note you need to support the motor as you remove the bolts fail ure to do so could result in the motor falling to the ground and becoming damaged Removing the drive motor 6 Once the bolts are removed the motor should slide out of the gear reducer Remember to support and lay it gently on the floor or some other surface in order to continue working on it Be sure that you get the key checking the keyway on the motor shaft and in the gear reducer Removing the bottom cover 4 Remove the bottom and set to the side so that it does not become a trip hazard Removing the wiring access cover 7 If the purpose of this maintenance action is to replace the drive motor continue to step 8 If you wish to replace the gear reducer continue to step 21 8 With the motor laying on a level surface you need to remove the conduit from it First use the 1 4 nutdriv
116. 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 T 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 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 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 13
117. tach the bottom and top drive assembly covers 20 Proceed to the sections entitled AFTER MAINTENANCE ACTIONS 21 Continuing from step 7 To remove the gear reducer first take the 3 4 combination wrench and remove the drive hub bolt 22 Once the drive hub bolt amp bearing are removed loosen the set screw on the drive hub There is no need to remove it 23 Remove the gear drive by using the 9 16 socket and ratchet as well as the combination wrench as required to remove the nuts holding it to the mounting plate 24 Gently remove the gear reducer careful not to drop it 25 Set the gear reducer on a flat surface The drive hub needs tobe removed You have already loosened the set screw but it may take some more effort to remove it You may have pry it off or give it some taps with a mallet to coax it off of the shaft The liberal use of spray lubricants will also help 26 Once the drive hub is removed place it on the shaft of the new gear reducer Ensure the key is in the keyway Once it is on and flush with the end of the shaft tighten down on the set screw with the 1 8 allen wrench AJ 44 Series Technical Manual 07610 001 76 22 Rev F 01 13 2006 45 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A SECTION 5 SERVICE PROCEDURES DRIVE MOTOR GEAR REDUCER REPLACEMENT CONTINUED 27 As you have both the drive motor and the gear reducer off of the machine it is m
118. ter 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 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 prop
119. trol Box Cover Control Box Cover Hinge Weldment Cotter Pin MANUAL DELIME Switch located on rear of control box MANUAL DELIME Switch Decal located on rear of control box Copper Conductors Only Decal Decal Operation Decal High Limit Light Warning Control Box Leg Component Mounting Plate located inside the control box Conduit Bracket Mfg No 05700 04 1 88 43 05940 011 48 27 06685 11 1 68 49 09905 002 97 62 0531 1 273 02 00 05305 011 62 17 09905 021 72 29 06685 1 11 68 48 09905 003 00 69 05940 200 76 00 09905 011 86 86 05305 011 39 36 09905 101 12 66 05945 111 44 44 05945 111 44 45 05700 021 72 75 05925 011 68 34 05925 111 64 18 05930 301 46 00 05945 1 11 68 38 05700 002 24 70 See Page 48 See Page 48 05945 111 35 19 05945 111 72 51 05305 002 25 91 05920 011 72 88 05920 002 75 95 05920 011 72 89 05950 002 41 47 05950 011 68 35 05950 002 46 10 05950 011 75 59 05950 002 23 77 05310 373 01 00 05940 002 78 97 05940 021 89 41 05945 111 72 51 05325 011 46 73 05975 210 09 00 05975 011 47 81 05700 031 66 88 05700 021 68 57 05315 011 68 56 05930 301 22 18 09905 011 74 61 09905 011 47 35 09905 002 82 33 09905 002 49 48 05700 011 71 47 05700 031 67 03 05700 021 70 88 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 53 14 14 20 24 25 23 23 21 21 SECTION 6 PARTS SECTION AJ 66T amp AJ 80T CONTROL BOX ASSEMBLY H
120. uch simpler to assemble them together prior to mounting them Ensuring that the key for the drive shaft of the drive motor is in the keyway 28 After the motor is mated against the gear reducer turn the motor so that the conduit fitting will face towards the front of the dishmachine once both components are mounted to the frame This is to all the drive assembly covers to go back on If you do not do this then there is a possibility the covers will not fit back on the unit Refer to step 18 and the note follow ing for more details 29 Stand the assembly up and secure them using the lock washers and bolts Use the 9 16 combination wrench to tight en them down Tightening the bolts to secure the drive motor to the gear reducer 30 Once the motor is securely fastened to the gear reducer carefully lift the assembly up and mount it on the fasteners Be sure to use proper lifting techniques to prevent injury 31 Once mounted secure with the lockwashers and locknuts 32 Reinstall the drive hub bearing and drive hub bolt tight ening down with the 7 8 combination wrench 33 Reattach the bottom and top assembly covers AFTER MAINTENANCE ACTIONS Reconnect the incoming water if disconnected and turn on Then restore power to the unit Run the unit for at least 10 minutes running an empty rack through the machine to ensure that it is carried all of the way through If you hear any grinding sounds while the motor is running
121. ure is too high adjust thermostat using instructions in the section entitled Thermostats 2 If temperature is too low adjust thermostat as above then a Turn off power to machine by placing customer s circuit breaker in the OFF position Turn off machine circuit breaker located on right side of control box b Remove cover from control box on top of dishwasher c Make sure water temperature is below 140 F preferably about 130 F d Turn on both circuit breakers Observe heater relay R1 while the power switch is turned ON and OFF If relay contacts move in and out the heater relay is operating correctly if not proceed to C B If heater relay R1 closes 1 Check power supply at incoming terminal board L1 L2 amp L3 It should be the same voltage as indicated on the machine data plate 2 Check power at connections on heater relay R1 The voltage should agree with the voltage on the machine data plate If not check wires for breaks or bad connections 3 Check power at terminals of heater which should agree with the data plate If not check wires for breaks or bad connections 4 Temperatures should rise as explained in C 1 and amperage may be checked according to those instruc tions Replace any defective elements C If heater relay R1 does not close 1 There is an insulated movable insulated movable bar on relay across the top With an insulated probe depress this bar and observe the thermomete
122. ve any debris fouling it View inside the solenoid valve body 21 With the mesh screen removed look down into the valve and verify it is not clogged Remove any foreign objects from the valve body that would obstruct flow 22 Reassemble the valve reversing the steps needed to take it apart Replace defective replacement parts with new parts from ordered kits Ensure that components are sufficiently tightened to prevent leakage AFTER MAINTENANCE ACTIONS Reconnect the incoming water if disconnected and turn on Then restore power to the unit Run the unit for at least 10 minutes to ensure there are no leaks If any problems arise please contact your Ecolab representative SPECIAL PARTS Solenoid Valve Plunger Kit Includes plunger and spring Part number 06401 003 07 40 Solenoid Valve Diaphragm Kit Includes diaphragm and o ring Part number 06401 003 07 41 1 2 NPT Solenoid Valve 110 Volt Coil and Housing Kit Part number 06401 003 07 43 Complete Solenoid Valve Part number 04810 100 12 18 1 2 110 Volt AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 39 SECTION 5 SERVICE PROCEDURES VACUUM BREAKER REPAIR PARTS KIT These dishmachines are equipped with vacuum breakers to serve as back flow prevention devices ASSE requirements specify what type of back flow prevention is nec essary dishmachines Vacuum breakers unlike air gaps have certain parts that have specific tol
123. warranty you should contact a certified Jackson technician or Jackson Technical Service You can find a list of qualified service agencies in the back of you unit s installation manual SPECIAL PARTS Heater Replacement Chart Model Volts Phase KW Part Number All 208 1 18 04540 121 79 30 230 1 18 04540 121 79 31 200 3 18 04540 121 79 30 208 3 18 04540 121 79 30 220 3 18 04540 121 79 31 230 3 18 04540 121 79 31 380 3 18 04540 003 08 51 415 3 18 04540 003 08 52 440 3 18 04540 003 08 53 460 3 18 04540 121 79 32 575 3 18 04540 003 06 22 600 3 18 04540 003 06 22 CONTACT INFORMATION Jackson MSC Inc provides technical support for all of the dishmachines detailed in this manual We strongly rec ommend 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 proper 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 AJ 44T Series Technical Manual 7610 003 07 21 Issued 03 21 2006 Revised N A 50 SECTION 6 PARTS SECTION _ SECTION 6 PARTS SECTION AJ 44T CONTROL BOX ASSEMBLY 2 12 4 5 4 8 9 10 13 14 10 15 16 17 19 20 17 e 4 18 e 22 23 24 25 26 2
124. work in the way it was designed to Wipe out strainers with a rag and rinse under a faucet if necessary For stubborn debris a toothpick should be able to dislodge any obstructions from the perforations Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub You may wish to also refer to the page entitled Detergent Control in order to learn more about how your water hardness will effect the performance of your machine Hard water makes dishmachines work harder and decreases efficiency Again it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larg er problems or even 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 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 reminder here are

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