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AJ-44 Series Installation/Operation & Service Manual

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2. K x n 1 5 U gu s NOTE dimensions are in inches and are for reference only CC 11 1 f 26 SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS 3 4 NPT STEAM SUPPLY LINE TO DISHWASHER 11 2 NPT STEAM X 3 SUPPLY LINE 1 NF LINE TO STEAM T Steam Booster Piping Single Tank Machine T ALL CONDENSATE RETURNS TO JNDENSATE RETURN LINE Z d 3 4 NPT CONDENSATE RETURN 3 4 CONDENSATE RETURN Steam Booster Piping Double Tank Machine 27 MY SECTION 1 SPECIFICATION INFORMATION TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS Electric Booster Dimensions Typical
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4. Recirculating Pump Assembly Rinse Header Plumbing Assembly HOSE ASSEMBLIES Gas Coil Weldment D Wash Fill Plumbing Assembly AJ 44CGP L R amp R L AJ 66CGP L R Each hose assembly includes 2 3 4 Pushlock Fittings part number 04730 011 94 00 A Hose Recirculating Discharge B Hose Recirculating Pump Suction C Hose Wash Coil Assembly D Hose Recirculating Discharge 8 1 2 05700 002 52 74 18 1 2 05700 002 52 75 34 05700 002 52 76 L R 48 05700 003 03 95 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 82 18 05700 002 51 38 26 05700 002 51 37 36 05700 002 51 39 60 05700 003 03 97 Rinse Booster Tank AJ 66CGP R L 8 1 2 05700 002 52 74 18 1 2 05700 002 52 75 50 05700 002 57 58 60 05700 003 03 97 SECTION 5 PARTS SECTION WASH FILL PLUMBING ASSEMBLY CGP MODELS Tube Length Chart Item 2 Length Inches 3 4 x 2 13 16 3 4 x 3 7 16 3 4 x 3 3 4 x 2 5 6 Replacement Kits Notes The rinse injector and fill injector replacement kits come with the injector weldments the gaskets and hardware for mounting In the case of Item 1 below it also co
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6. BLACK 1054 us RED 106 ellc RED 106A 4 gt FLFLFLETTI acum ff i 1 BLUE 1064 dl BLUE 1064 5 228 4 gt BLACK 1406 A H BLACK 14GA RI 14GA 4 BLUE 1 gx BLUE 14G MOL I 41 BLACK 1 REI 2 oo ED 1 GA DEI DETERGENT DET RED 18GA PMOL DISPENSER CONNEL 125 ser CVS S1 Se 53 54 FI SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 380 460 600 VOLTS 60 HZ 3 PHASE SECONDARY SIDE HT URG BLU T 3LK WH er SWITC HIGH LIMIT EGULATING MIT SWITCH LENI THERMOS HERMIISTA CUP TIONAL 1D 126 _ SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 380 415 VOLTS 50 HZ 3 PHASE PRIMARY SIDE 17 58 ee q BLACK 100 10 id LUE 10 5 LUE Fg ns 4 7 1 RE mal ate RE BLUE B 1 1 GE SI UNI Fi Mal DET RED R3 1 NSER Ci 127 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 380 415 VOLTS 50 HZ 3 PHASE SECONDARY SIDE lt 4 Bl HT 541 ORG BLL e
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11. jeuondo 199 ue d Y A 4 umb d qni e qejusiq e oqv uot ees JO dr1 1 0 5 Pue lqel 99 4598 uonoeuuoo eouper g Ay Ja eag sn 4 09 4 3 08 LAN V 4 229 8 2 72014 wey 8 user Zor 86 8 4 e 1deoov qN 0 883 54 214 1 ye 01140611 22 SECTION 1 SPECIFICATION INFORMATION SIDE LOADER LEFT TO RIGHT DIMENSIONS NOTE ALL DIMENSIONS ARE TYPICAL 4 1 2 MINIMUM CONVEYOR lt DISHWASHER LENGTH 23 lt lt 8 gt E n S 15 on 30 model 30 on 30 model LEE T a 25 DISHWASHER gt lt 12 1 2 gt CONVEYOR DISHMACHINE 1 2 DISHTABLE MINIMUM USE SILICONE BETWEEN TABLE AND LIP OF SIDE WALL OF SIDE LOADER TO LOADER PREVENT LEAK AGE 172 5 SECTION DISHMACHINE VENT CONNECTION OPENING LLI SPLASH SHIELD EE N 20 3 4 OPENING 14 1 27 2
12. 1 505456 ne qni e oqv 9 12 9 qe 0 y pue jqe ueewjeg 5 61 BUOdIIIS esf MEAN i E 269 68981 a 8 4 0 uus g Zor 4 ejqe e 1deooy JoN uoneonqeJ ejqejsnfpe enp 4008 Woy 211 SUOISUBLUIP 9 0 49 6 408 LAN IN uonoeuuoo 4 011 LAN Uonoeuuoo ejesuepuo2 2 uonoeuuoo WEIS uonoeuuoo H jeuondo 7 2 uonoeuuoo 9 40 v 19 U 4 pJepuejs 3 jeuondo Je oo uonoeuuoo O uonoeuuoo e2u199 3 4 081 3 08 LAN 3914 v ye 0 14611 16 SPECIFICATION INFORMATION SECTION 1 AJ 80 ELECTRIC LEFT TO RIGHT epis 1 614 12 8 41989 99 Y 06 uuges iz
13. 98 19 02 5 vg 8522 88 ul r ul 9 97 9191 OF 98891 og 2 JO 10014 9558 1 E umor fe 5 19 61 9 TEL suoisuauip IV 9 0 te 5 9 93ON 4 18 4 081 14 9 6 11 g uonoeuuoo 4 01 v 9 sz IK gt i uono uuoo ejesuepuoo v 3 0029 69 WEIS LAN ul m r 4 T uonoeuuoo WEIS H 2 Goal NN 63119 896890 LdN 5 2 zit P N 9 7 4 091 4 011 22724 7 22272 lt elu 4 5 3 DOO aboes
14. 18 lt 30 1 2 gt 24 OUTLET NN 34 NPT Coupling for I 4g Temperature Pressure ay 21 4 He 12 Relief Valve 57 mm 83 mm INLET 2 Electical ti U U connection 1 from side or below Nipple SIDE VIEW REAR VIEW 36 gt lt 20 3 4 gt 1 1 Alternate TPRV Location Electrical Electrical 25 1 8 G Water Wal Water Outlet aes as Water Water Inlet Outlet Inlet Water Inlet 2 Gas Inlet E E 0 Y LEFT SIDE VIEW FRONT VIEW Gas Booster Dimensions Typical Alternate e Flue 4 102 mm TPRV Location Vent Adapter y Water Outlet e Water Water Gas Inlet Outlet Inlet Water Inlet SA RIGHT SIDE VIEW REAR VIEW 28 SECTION 2 INSTALLATION amp OPERATION INSTRUCTIONS SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS NOTE THE INSTRUCTIONS PROVIDED HEREIN UNLESS OTHERWISE SPECIFIED ARE FOR THE DISHMA CHINES ONLY THERE ARE SEPARATE DIRECTIONS FOR THE GAS BOOSTER VISUAL INSPECTION Before installing the unit check the container and machine for damage A damaged container is an indi cator that there may be some damage to the machine
15. 8 1 IPAA uuzsi g wwe 14 FZ 66 9 1 0 y uuo 1 Y 06296 e qeiusiq e o 401995 me 6 90 14 eutuoey 10 4 qni Iqeiusiq 61 PUB 91981 5 esf juo x Y s 9 794 86 514 91951 e 91 1deooy 20 91481 uollo99uuoO 520 Jenjoejnueui Aq pepi o4d uonoeuuo UO uonoeuuoo 45081 LAN v 9 48 500 seb 10 1 49 M 07 1 45011 LAN d piepuels MOO 3 jeuondo 46109 2 1 uonoeuuoo O uonoeuuoo 2 8 OF 0 40 v 6 1uBiti 20 SPECIFICATION INFORMATION SECTION 1 AJ 80 STEAM LEFT TO RIGHT epis 14 uwz 89 1 6 uwz 2 8 1 Bees gu 1 294 9 1 1 5 ni D 5 2 X f
16. 989 2 _ H 459 uuigig u i juuz60il uu wwoest 09 3 199 14 1 229 E 9 4141065 29 luu 0 zi v uuges 12 96691 fez 92694 99 sg 9 c uu901 19409 peddius 98116 37200 9 0 28 2 78 eur 97 41 lt lt gt 81 o 2421 uu791 99 907 94 epi ZOL 1 09 n ules JO 10014 ysemald yun 9588 29 uu 4 wwess zz L o 0 8 i f fe ge mi l 5 H 1 i 2 1 6 9 92 2 4 i wees 12 3 Y 415 wg H f oli 1 982 111 699 9 21 v 996 86 N Z I 46 1010000 y 9 9 USEA 1d T X
17. L jo 1uBi H 44 8 1 1 uonoeuuoo 9 lt 61 g 92 91981 uonoeuuoo 5112813 49898 955 A dui 1 AO1 OY L duier IH 269 0119 15 0 d pue6e1 8 2 ON rey oDue J 5 qn L 210 01 497 SPECIFICATION INFORMATION AJ 44 GAS RIGHT TO LEFT SECTION 1 epis 14014 2 e wig 21 1 4 pe Y utet Hi L 9 98 H 4 9 91 i jo 1984 9 usiq 1659 sz 3 wwoest 709 a 1 99 1 wig 1 iN 0691 9 l 4 421 uuzoe zim 8
18. 5 n R l J BLK K WHTE PWFSW GRY WHT H XRSJO w rS s B PWFS R8 K WHT PWFSW2 GRY RED m GRY WH AF 9 BLK BLK WHI NI BLUE WHT ole 2119 DOOR SWITCH LEADS JUMPER se 83 E E BLK WHT REY GR JN HT SIRIBU TOR CUN SH PUMP SE RI PUMP M SAFETY SW HEATER RIVE MOTOR W PUMP PRE WASH PUMP M TOR OVE SH PUMP UIT ISI MSPENSER C CONSTANT VOLTAGE 51 CH CH CH 1 CH 2 M S R LIGHT R HIGH LIMI LOA AT SW SH FLOA FLOAT IGH LIMI EGULATING COLD WA COLD ER WATER VAL IMIT SW SOLED F WAS RINSE 50 MOTOR IDN B CLIN 11115 FILL RELAY H TANK FILL ICK ACTOR CONTACTOR RELAY TCH RELAY MOTOR 1111 RL PUMP MOTOR MOTOR TRANSFORMER PUMP SWITC IVERLUAD INNECT ION NAL LIGHT CH 1 WI CH 1 WITCH 2 THERMOSTAT ERMOSTAT THERMOS A lt OPTION VE OPTIONAL DID P TIONAL FILL SOLENOID ENDID FUSE ORC RED 5 5 ORG YEL 2 JH SE 2 RED GRN 1 gt 5 09905 031 73 39 146 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CS CSL amp AJ 80CS CSL 200 208 220 230 VOLTS 50 60 HZ 1 PHASE PRIMARY SIDE j box 1468 ite LD SES malt s eee Ree 215
19. 8 V 4141505 8 12 Buiquunid 9 629 9 oS 091 4 011 Oer AL LAN v Ysemald 4 4 usse 2 2 lt jeuondo 46109 uonoeuuoo O Y spees oa y 91 9 uonoeuuoo E21329 3 g M A XEN 2 da j 0r L duiey iH 669 12 pue 6 051 PEN 4 081 v 1 498 v lt 61 Y 02115 esf zeo 14611 01 497 8 2 0 88 14 e 1deooy e3oN 46 17 SPECIFICATION INFORMATION SECTION 1 AJ 80 ELECTRIC RIGHT TO LEFT epis 14614 lge 8 2 14014 9 1 441798 ve 99UEBJE9 9 sz 1 799 uwzoe 9 2 uuseg s eur 97 JO 0914 z 8 1 EN ZEN ww LOL ere 9 62 OF 1 1 1 1 141
20. 0 8 uuuup0Z 8 9 uuggs 12 wwzorl 8 8 se l 81 9 84000 nuu peddius z ve 92 2 useldS IwoO 3nojno 10 JUIS 20014 7 09 90 91 X 201 en 6 04 lunur09 fec 12541 29 I ejgejsn pe Bo use e aide 9081 198 2 1 suoisueuiip JEDA ON i 8 uugL LI uiuoz 8 5 a 4 08 LAN IN 18 uonoeuuoo a 41 69 sz 4 011 LAN 2 8g 7 uonoeuuoo 2 M amp 8 wwiges 12 uonoeuuoo 5 14 H j 1o i 0839 03 8 4439 H b 4169 9 yt 9 N 414996 86 uonoeuuoo WEIS LdN 4 2 mod 3 jeuondo 48105 z V v m uut LAN uonpeuuoo 9 Y y 91 9 uogoeuuoo g T A XEN PiE euet 9 Jo dr1 qni aiqe
21. 147 RED 18GA SECTION 6 ELECTRICAL SCHEMATICS a AJ 66CS CSL amp AJ 80CS CSL 200 208 220 230 VOLTS 50 60 HZ 1 PHASE SECONDARY SIDE lt j BLK ORG p WHT WHT BLK WHT WHT e BLK W BLK WH WHI 4 BLK WH BLK WH BLK WH WHT 9 BLK WHT HT o BLK W HT GRY WH BLK WH 10 JUMPER WIRE TLS NE q BLU BLK wit R9 R3 BLK WHT 11 ORG WHT GREY 5 ORG 2115 R5 GEND om 112 L8 POWER DISTRIBUTION BLOCK n HEN 54 uam 25 R E R7 s RS 71 v2 3 MOTOR GREY CB BREAKER BRYA Ti RMER DET SER CONNECTION CVS SIGN 1 2 1 3 4 ORG YEL cy Y wHT 55 S6 SWITCH CH GREY WHT RED WHI CH 1 ICH 2 BLK Y WHT 7 ERMOSTAT 20 lt OPTIONALD NAL 2 S GREY WHT BLK gt WHT E 9905 002 37 15 148 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CS CSL amp AJ 80CS CSL 200 208 220 230 VOLT 50 60 HZ 3 PHASE PRIMARY SIDE BLACK 14 d JP 3 3 423 l 4 3 4 DIR gt Oso 15 ESSA 149 SECTION 6 ELECTRICAL SCHEMATIC
22. RED E T e 21 Se 3L K S CK RI 2 AC ode Rie x TUR C gt u 43 5 P UMP TOR lt 5 lt 2 gt S T TOR GREY Bd X TUR X 4 TUR US NLIL x JS 1 NS 52 SES 223 25 So X 2 2 S S S S S1 5 S SMOUS S S S S SE S 132 35 9 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 200 208 220 230 VOLTS 50 60HZ 1 PHASE PRIMARY SIDE 1 4 BLAC AC RE G 57118 eus CONSTANT 18GA CYS VOLTAGE SIGNAL ITH CONVEYOR RUNNING 12 R3 R3 BLACK 146 RED 1464 T LEET Te We BLK 1864 DET DETERGENT RED 18GA DISPENSER CONNECTION BLACK 18GA 1 RED 133 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 200 208 220 230 VOLTS 50 60HZ 1 PHASE SECONDARY SIDE Al JUMPER 46 5 H g E 1 RE 134 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 200 208 220 230 VOLTS 50 60HZ 3PHASE PRIMARY SIDE iff A AF E T RS d ev 4 DETERGE m 4 F 3 135 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 200 208 220 230 VOLTS 50 60HZ 3PHASE SECON
23. uonoeuuoo 9 uornoeuuoo eoui 9r 8 j LAN 19 UI 01191 9 v8 13 SPECIFICATION INFORMATION AJ 66 GAS RIGHT TO LEFT SECTION 1 epis 19614 N IA 14044 9818 o ez uwz iz uwos for i wwesil9 1 I 1 wwe9 1 5 3 141 l 1 d b 0191 pz ng H 35 TES 0 9 9 292 Lai 82 89 0 uupez 18 441659 sz uu L6 9 3 N wwoest 09 9 799 j9 lt _ ue 1d 066 1 29 2 H uwzos zi H 5 2 a y ugoe 8 uu uuees iz luwees tec uw 01 9 6 61 52 v 1 99 52 191 2 E uedo 8000 9802 28 pue ITI DE uupeiz 98 amp 4 eur 90 94 epi 201
24. 9 299 9 iz uueg 2 uuz9p e uere uws 164 88 8 00 19 00 paddiys eur 1nojno 92 1 09 ww 90p 91 201 JO 40014 za uBnoi 9151 1 49 8 L1 1 8 2 1 9594 9 ejqeisnfpe enp 1001 1 p 2 20 e 92 uses 12 Aq sepoo 290 eq 9 0 uonoeuuoo edid 21 1 uonoeuuo 880 dN 6 H 6 502 2 4enjoejnueui gt gt Z 1 Z 2712 Aq esou 39 02 21 TID 1 UO L L finest usse v 19M 3081 w e 9 9811 14 vst yayeay 1915004 526 8 vt JOM 4091 4011 LAN d i 8 91 5 7 EN 1 eigeiusiq reuondo ees 12
25. 98 N y H 2601 soueles D USIq 4141989 sz 799 gz eur 1044 5 2 ez 221 uusz 0 6 PED luus 9 01 d 7 996 85 17 ju y 3 0 9 6122 4 1 J E 10 usejdsxyoeg Laon OL 3 0 94 109 pa J o H 1 x 1 Am 122 5 4 g Y N 2019 90218 N 991 81 ve v mon 4141009 262 t 6 01 Ly 8 000 92 5 ureJg 10 AUIS 40914 uuyogltez Ep 1 i c i oo 2 11 TEL 49 9 H nua 682 uu1996 8 W 1ejsouueu JejeA yun eseg 7
26. 99 g uuseg gz 10013 epis r luuuzgz ez ae 119 0921 01 9 9 1 1 1 1 4 lun 996 9 1 6 6 LP 18 9565 SAU 1 LY rL 1 E Jo 9 8 95 588 unus 91981 93 8 28 usiq OL 441689 82 3 441056 109 1 IN 2 6 fsz i 9 2 4 3 uuo v E 64 sss Eo uuo09l ly 84000 z 8 ww yz 96 7 97 88 91981 91981 660 10 Je 02 peddius yse ds jmog ur JO AUIS 49914 yun 9558 907 9 X ZOL wwe jejsouueu J9jeM 8138 01298 SUOISUBLUIP 20 2 iE ys eee 4669 sz Jeuondo uonoeuuoo 3 F TT
27. 6c 1 1 1 I l 1 1 1 Y uuzg 9 41598 pe 54 709 017991 259 93 8489 9 SZ uuze9 299 5 L H _ 8 9 2 p e uwopuun 91 s 61 y 669 229 YZ 0 dn 91981 e 1deooy 20 4 Ww9 v i jo pue Jejeeg uool is esp 513 Y 1981 UN 91 29 201 021 8 ww L6L 5 fer eur 9 JO 40014 uwgoz 8 _ 09 JOAOD 5 ui 81981 8 vv 9 sz uuees LZ 3 5 08 y 909 201
28. Elbow Street 90 3 4 NPT Black Iron Y Strainer 3 4 NPT Black Iron Valve Gate Steam 3 4 NPT Plug 3 8 NPT Black Iron Nipple 3 4 NPT x 10 Long Reducer 3 4 NPT to 1 2 NPT Black Iron Elbow 90 3 4 FNPT Black Iron Elbow Street 3 4 NPT Black Iron Union 3 4 NPT Black Iron Nipple Close 3 4 NPT Black Steam Trap 3 4 NPT Pipe 3 4 NPT x 10 Long Black 7 AN 2 1 Mfg No 04730 911 02 34 04730 912 01 00 04730 907 01 00 04820 011 87 39 04730 906 10 34 04730 011 87 37 04730 217 01 32 04820 100 19 00 04730 909 02 34 04730 907 06 34 04730 911 02 34 04730 906 10 34 04730 011 87 37 04730 912 01 00 04730 907 01 00 06680 500 02 77 04730 907 06 34 STEAM OUTLET PLUMBING 78 SECTION 5 PARTS SECTION GAS COIL ASSEMBLY CGP MODELS 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 Gas Coil Weldment 08700 002 44 23 Coil Box Weldment 05700 002 50 94 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 Gas Coil Box Cover Replacement Kit 06401 003 10 37 Other items used but not shown QTY N DESCRIPTION Thermostat High Limit
29. R7 WASH TANK FILL RELAY o R8 PRE W AN FILL RELAY R9 OOR VITCH RELAY Hi ASH 4 GREY 2 Me JA R GRY YEL 13 PUMP MOTOR i MDL RIVE MOTOR OVERLOAD GREY WASH PUMP MOTOR OVERLOAD Se WHT RED 3MOL PRE WASH MOTOR OVERLOAD FUSE CONTROL TRANSFORMER FUSE 1 CONTROL T PUWER SW e MOOR SAFE 1 3 OOR SAFE 2 mE ORG YEL T 4 WAS PUMP p NUM 4 5 6 M WITCH 8 GREY 5 8 3801 HT CH 1 BLK YEL WHT 5 7 HERMOSTAT x ERMDSTAT AT OPTIONAL s OP TIONAL GREY o WHT BLK on WHT MIT SWITCH DPTIONAL 4 7 LL SOLENOID H FILL SOLENOID NSE SOLENOID 144 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CE CEL amp AJ 80CE CEL 380 415 440 VOLTS 50 HZ 3 PHASE PRIMARY SIDE BLACK a BLACH BLACK BLACK BLACK BLACK MO N BLACK 4 145 85 3 4 a RED 146 i BLUE 14 i T V DET 1 3M RED 1 ED 1 R5 7 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CE CEL 8 AJ 80CE CEL 380 415 440 VOLTS 50 HZ 3 PHASE SECONDARY SIDE BLK DRC BLK WHT BLKZWI lt A BLK WH BLK Lu BLK ORG BLU HT HT A 1 gt l 7 BLU 5 Sa DRG Rk ISe O 5
30. Close Nipples Item 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 Item 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 Item 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 022 73 72 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 90 SECTION 5 PARTS SECTION MOTOR ASSEMBLIES See Motor Pump Plate Wash Impeller Replacement Kit Chart Below Key 3 16 x 1 Long 05700 021 71 83 06401 003 10 51 Y Pump Seal Prewash Impeller Replacment Kit 06401 003 06 73 06401 003 10 55 Impellar Washer Bolt 1 4 20 x 3 4 Cap Screw 3 8 16
31. 160 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CGP amp AJ 80CGP 208 230 VOLTS 60 HZ 3 PHASE PRIMARY SIDE gt lt IN 1 HOH Ox H 4 ge LK 1 D 180 NING R3 R LAC L D 14 2 E gt o RGENT RED DISPENSER NECTION M3 RS Lack 14 T ED LUE _ 85 LACK K E 161 a SECTION 6 ELECTRICAL SCHEMATICS AJ 66CGP amp AJ 80CGP 208 230 VOLTS 60 HZ 3 PHASE SECONDARY SIDE BLACK 1864 BLACK 1864 RED 1868 RED 186 1 BLK ORG BLK ORG 4 H Li al K B 15 oy WHT swe 87 BLK WHT 52 U WH ORG BLL ELK T RED 1 27 25 T BLK WHT Ko WHT YEL JHT i M i BLK WHT R2 GRY BLK wH H ofigo 8 BLK WH 51 GRY ME H GRN BLK WH GRY NHT 2115 2 89 BLK WH LK WH JUMI RE TLS 52 K WHT LU 8LK B BLK WHT NILUM GRY 1 14 EGEND GEN RI ORC 1 14 54 1 S RY 2 56 GRY NG PUMP ERLUAD R OVERLOAD GRY DRG YEL ORG YEL T ORG YEL e 58 XRS ATA T wH GRY LK CLIP TIONA ITCH OPTION R7 CRY 8 JID R11 GR BRN 9905 002 33 61c 162 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CGP amp AJ 80CGP
32. 5 RG BLK WHI WE SWE BLU WHT P ORG BLU 70 70 70 70 BLK WHT Bo ORG WHT _ 41 _ Ne BLU RED BLK ZWHT T lt ORG BLK 2 41 JMPER IRE BLK WHT 2225 5 7 R3 net 4l F 2 ORG OWER DISTRIBUTIO LCK UA 4 GREY 222 1 USE 9 ON ner 4 R4 R Zr BI IWER LIGH EATER HIG I LIGH AS LUAT S OR 4 ASH FLOAT S CH 2 EATER HIGH LII THERMOSTAT 15 IERMOS ABLE LIMI gt AS ILL SOLENOID IN RINSE LENLUIE 128 _ SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 440 VOLTS 50 HZ 3 PHASE PRIMARY SIDE BROWN 2 10GA RED 1466 Lo RED 14GA BROWN 14GA BROWN 1464 BLUE 14 BLUE 14G RED 1864 CYS RED 1408 AA S tes RED 1402 BRUWN 14GA BRUWN 146A 140 BLUE 1408 BLUE 140 Fo RED igGA DET DETERGENT DET BROWN 18 2 0 M DISPENSER CONNECTI RED 186A QC e BROWN 1860 BROWN 180 129 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 440 VOLTS 50 HZ 3 PHASE SECONDARY SIDE 8 K DRG 2 JHT 120 VAC BLK W 81 lt WH
33. 529 LdN JeJnjoejnueui Aq asoy euigoeulusip uo uonoeuuoo JORNO 1 45081 LdN v 5 1 e u 1 15004 seb 10 1 0 1 01 4 pJepuejs moo 3 0890 69 uonoeuuoo ueq O uono uuoo eoujoe g 4 Or L duue1 IH 50 401 LAN v 1 4 1 ss 5 D 81951 jo dr an ww 61 p e pue u w g uoollis esf 289 be 8 1 ve o1 dr 86 14 91951 e 12255 n 910 aes 4085314453 0 19 SPECIFICATION INFORMATION AJ 80 GAS RIGHT TO LEFT SECTION 1 epis 14 14014 144486 1 ez apis 6 921701 uuzsi e 1 1 1 1 1 1 1 R 141 41598 k LT i jo 1 91 199
34. SIDE LOADER TRACK ASSEMBLY LEG REPLACEMENTS STRAINER 2 Side loader track assembly left to right model shown 3 4 1 5 6 ITEM 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 Front Strainer Weldment 05700 021 85 10 112 w SECTION 5 PARTS SECTION SIDE LOADER PAWL BAR ASSEMBLIES PAWL BAR BRACKET MAGNET Replacement Kit Note The kits for the pawl bars come with the bar weldment 3 dogs and the hardware E lt Dog Wing Weldment 05700 021 86 79 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 k
35. gni eiqeiusiq 14 2 1 uonoeuuoo 2 2 uonoeuuoo 20149913 8 45598 09115 95 3 Or L duuei IH 269 301 4011 LAN v gil yz o dn 969 51 e yy 1deooy 9 81 SPECIFICATION INFORMATION SECTION 1 AJ 44 STEAM LEFT TO RIGHT epis 1 Lv 891 wwoor 26 14044 uug z 8 apis yo z uwgez L L I uug OL PIS yel t 8 25 19 2 89 10 1 62 1 zie 1 3 1 1 1 1 EL lt b K snm i 9 K uwy98 ve 1 2 24 ero 22 0 c 8 Jo 601 g 285 usejdsxyoeg Z 1951 416991 769 9844 0 uuuuz69 899 06811 z9 wwzo 21 17 44
36. luueeg iz 99 81 V 11 99 uuse9 62 96801 ty i 84000 ww pz 96 2 eur 19400 peddius PIOUS 92 aqe 91461 680 08 nono yun 9556 YSBMald 90 91 X apm 201 JO HUIS 1004 wwii vr 16 96 ubl deog r H 3 ___ 2 691 sz 28 wwiges 12 A unum 1 1 28 1 m 261 uugez 1 81 2 22118 E 9 1ejsouueu UOl28S ees 4 A 1 91 9 25 222 19 595 1 121 vg 389 ejqeisn pe enp 1 Suoisueuuip LIA LAN uonoeuuoo 3 0 1 4 011 LAN 19 UI USEMOJd sepoo 0 pejeisui eq 0 uonoeuuoo edid
37. peddius uwez ve 9 vz 20 use dS AoO Deis 4 o 90p X ZOL 1de2oy 990 97 oj enp 10 100 m wwe gs _ 9 ON 121 JO 10014 qni 91951 is deis 6 8 8144 1 9 9 41 Jeuondo 48165 dq Y 9 6 1 21 uonoeuuoo 9 pue 1 uonoeuuoo g 4995 9 03115 esf 12 ox 9 sz v 4 0 1 3 081 LAN v 1 v eiger 18 87 i pueBe v p uoneouqe 91481 14611 01 SPECIFICATION INFORMATION SECTION 1 AJ 44 ELECTRIC RIGHT TO LEFT epis 14 6 4 4 14044 210 epis 1 1
38. 01 266 90218 T 26911 299 4141556 lo 0 9 se 41 9 81 6 61 uedo 84000 ureq 09 v9 6 18400 JO 20014 m wwe 28 0 ul 1noino 19 ejqeisn pe o enp 91981 9 9 X p m 201 WOJ 2 1 SUOISUBLLIP 210 02 8 ug iL 4 9 uu 29 50 1 8 Y Sle ti 41659 sz CEN _ Y uuees 12 1 sepoo jevo 0 eq 1 ip Cr 1 Y 0 uonoeuuoo edid GO f 1986 211 uollo uuoO Seo 1 4e1njoejnueui A esou 6 00 2919 UO wget 4081 LAN 9 4 68 1915004 526 692198 4 091 4 011 LAN w e 4 3 gt Y wie 91 9 9 5 1 jeuondo 569 1 10
39. 126 oll BLACK REI E RE FI ACK 14GA RE of oos Coote BLUE X Loo ky TENA CYS RED INNECTIEN W1 INVEYER RUN Q E RED gyo nr ED 1 elle ex Yor 95 x 88 ago 015 22 85 RS qe lk RET RED 4 Ie RED 186 REI 141 wau SECTION 6 ELECTRICAL SCHEMATICS waw AJ 66CE CEL amp AJ 80CE CEL 200 208 220 230 VOLT 50 60 HZ 3 PHASE SECONDARY SIDE a BLK ORG URG BLU WH gt BLU VHT G BLU BLUE ol te W O GND GROUND R1 HEAT CONTACTOR REY Re DRIVE MOTOR CONTACTOR R3 WASH PUMP MOTOR CONTACTOR GREY FINAL RINSE RELAY R5 PRE WASH PUMP MOTOR C R WASH TANK FILI R8 PRE WASH TANK RELAY GREY RELAY E l E WASH PUMP MOL RIVE MOTOR OVERLOAD SH PUMP MOTOR OVERLOAD GREY 33 WASH PUMP MOTOR OVERLOAD TRANSFORMER ISPENSER CONNECTION VDLTAGE SIGNAL Sw 1 2 96 95 5 RMUSTA 58 IE CWTS BLK YE WHT CV TS i E vHT BLE A WHT 142 wawww SECTION 6 ELECTRICAL SCHEMATICS was AJ 66CE CEL amp AJ 80CE CEL 380 460 600 VOLTS 60 HZ 3 PHASE PRIMARY SIDE _ BLACK 106 Hd BLACK 10GA gt RE
40. Tube Copper 1 1 2 x 4 3 4 Long ES X 27 Adapter Male to Female 1 1 2 04730 401 25 01 1 Elbow 1 1 2 FNPT 90 Brass Tube Copper 1 1 2 x 4 1 4 Long 04730 011 73 77 All parts are common to both assemblies Right to Left Plumbing Connector No Hub 1 1 2 Assembly Tube Copper 1 1 2 x 8 1 4 Long 04720 604 06 00 ms _ Rte Tee Brass 1 1 2 x 1 1 2 x 1 1 2 Y 04730 011 69 93 1 y Nipple Rinse Weldment_ X 0 4 05700 021 84 61 5 AL wx N Mf Tube Copper 1 1 2 x 4 1 4 Long Elbow Brass Street 1 1 2 NPT 04730 206 32 00 N A Wy lt 2 EN b Valve Handle Assembly 2 S EN 06401 021 84 74 Valve Ball 1 1 2 Tube Copper 1 1 2 x 4 3 4 Long Service Note Copper tubing should be purchased locally and 04820 111 71 46 cut to length lengths provided in drawings 86 SECTION 5 PARTS SECTION RR AJ 80 DRAIN PLUMBING ASSEMBLIES Nipple Brass Close 1 1 2 NPT Tube Copper 1 1 2 x 15 3 16 Long 04730 207 40 00 2 ES 3 N A 5 ge ES h QE Xn S 1 1 Tube Copper 1 1 2 x 4 15 16 Long Y N Valve Ball 1 1 2 04820 111 71 46 Left to Right Plumbing Assembly G Tube Copper 4 4 2 x 11 3 16 Long Service Note Copper tubing should be pur
41. 1 Re 25 LACK 1 BLACK 1404 RED 1404 RED 1464 OH 4 1 Fa H 2 BLK 18 255 2 BLACK 1464 BLACK 146 RED 14GA RS REO 4 8119 BLK 18GA DE HT M3 Ro LACK 1 RED 14GA RED 14GA T 2116 BLACK 18GA BLACK 1864 _ n RED RED 1864 139 SECTION 6 ELECTRICAL SCHEMATICS waww AJ 66CE CEL amp AJ 80CE CEL 200 208 220 230 VOLT 50 60 2 1 PHASE SECONDARY SIDE BLK ORG AUN HT 120 E BLK WHT BLK WHT HT BLK wHT 5 1 ORG BLU HTS BLK NHT ORG BLU AF BLK WHT BLK WHT 41 HT YEL 1 ORG WHT _ 41 _ ORG WHT i HT He Fo cde BLU RED HT 7 BLK WHT BLU YEL 154 O o Fe gt ORG BLK TS 5 BLK WHT BLK WHT PWFSWI GRY WHT Eee HT t HIS BLK vHT PWFSW2 GRY RED m GRY WHT BLK RED ol 2 BLK WHT BLK WHT 54115 BLUE e E ID JUMPER IRE s2 s3 TLS 2 ERAN BH EBES R9 R3 BLK WHT GREY GREY ORG HT o 9 H p 8 13 14 e i ien R4 5 FG EN 1 ORG 1 Le POWER DISTRIBUTION BLOCK FM 22 GND GROUND o4 fg _ R1 HEAT
42. 99 uonoeuuoo O uonoeuuoo 3 9 duie MO7 4 07 35081 191 V 14011 01 uuussg p 27 y aiqeiysiq e oqy Wey 21 SPECIFICATION INFORMATION AJ 80 STEAM RIGHT TO LEFT SECTION 1 epis 14044 uusez 2 008 S DO oda e ww wuse 62 2 B ww z fg 2 9 0921 o 911 77 9 1 d 1 1 11 1 1 EM 4 j 5 291 U 9 5 it lt yun 441696 86 M N 44798 pe Le 4 1 zyi 1 Jo 2894 Tot wwz60L ev i 1 uus Wan 6281 09 799 9 H 11 wwzesi zo Gi 5 a 14 48 11 1 9 4 uuzoel zi q v 095 8 4 1 21 12 Lv 261 08 69 099 959 52 19 pz uue901 zr uedo si00g
43. 5 JO AUIS 40014 eseg jejsouueu L POD uonoes useweJg 9 uuggoz 28 p 4 age 91981 6 94 99 ww 699 22 2 eje d 19 02 peddius Ul 90 91 201 uus Lv 29 D eae 59 3 Y jue eJd 7 XEN p e eDue J qni geg 12 N umopuin del 011 61 pg 81981 99 998 2 Jejees 8 09 6 esf 269 eel 8 2 YZ 9 oDue J e 1deooy JON uBnoj 1 F JEDIA 1 8 9 9691 sz jeuondo LAN t g uonoeuuoo d Buiquunid 9 ped 3 071 3 011 luussg rL uuo v 4 piepuejs 3 jeuondo Jejoo uognoeuuoo O uonoeuuoo e91129 3 g 3 08 LAN 9U J9
44. 6 9 6 5 94 1 00 110 140 160 160 110 140 140 F 140 F 20 5 3 9 3 9 50 STEAM COIL TANK HEAT CS CSL MODELS ONLY STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG Ibs hr AJ 44 66 80CS CSL 60 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 WASH MOTOR HP 2 POWER RINSE MOTOR HP 2 PREWASH MOTOR HP AJ 66 MODELS 1 AJ 80 MODELS 2 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 protec tion than what is displayed here Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes These numbers are provided in this manual sim ply for reference and may change without notice at any given time SECTION 1 SPECIFICATION INFORMATION AJ 44CE CEL MODELS lt m gt JD rc 02 02 02 00 0 HZ 50 50 50 50 50 50 60 60 60 60 60 60 60 60 TOTAL AMPS 55A 49A 51A 29A 28A 28A 83A 76A 47 49 45 29 23 19 AJ 44CGP MODELS 60 60 60 60 60 TOTAL AMPS 12A 11A 8A 7A 5A AJ 44CS CSL MODELS gt 02 02 02 02 00 09 HZ 50 50 50 50 50 60 60 60
45. 9 292 uuuzsi 9 amp uussi g uuz67 11e 92 4 19 z a 1 m i T 3 529 17 8 1 1 4 Lum uuzoel I A V uuzoiv E 64 EN LL e uuzyoi 19 ww zet V 299 5 uuusg9 19 1 uedo 84000 WIM ww ypz 96 eur 92 2 JO 5 40014 uuotz t8 81981 uuugeoz 08 pun 9558 ung 16 wwz py 1 t 9 sz 12 151 ukucha 21 v 8 2 eje d paddiys use dS MO ul 909 9 201 26 05 46 6 v iA Y 399 ejqeisn pe oi enp 104 2 1 9 910 jeuondo 2 uoipeuuoo 01 45011 M Aq 59905 e20 9 515 eq edid GO HI Z ZZ 222
46. End Cap Replacement Kit B 06401 003 10 19 Lanyard 05340 011 72 46 Manifold Quick Release Key 05700 011 94 45 Lower Wash Arm Manifold Weldment 50 Hz Models 05700 002 24 87 Lower Wash Arm Manifold Weldment 60 Hz Models 05700 031 67 29 Complete Lower Wash Arm Assembly 50 Hz 05700 002 24 86 Complete Lower Wash Arm Assembly 60 Hz 05700 031 74 66 Service Note When replacing the 10 32 screws in the End Caps it is recom mended that a thread locking fluid be used to ensure that the screws do not back out during normal operation 93 SECTION 5 PARTS SECTION PREWASH ARM UPPER WASH ARM ASSEMBLY Replacement Kit Note The replacement kit for the end cap Prewash Tube Weldment 05700 001 16 89 includes the endcap lanyard mounting screw and the locknut End Cap Replacement Kit 06401 003 10 19 Complete Prewash Arm Assembly 05700 021 74 65 Upper Wash Manifold Support Bracket 05700 021 73 97 _ Lanyard 05340 011 72 46 End Cap Replacement Kit 06401 003 10 19 Replacement Kit Note The replacement kit for the end cap includes the endcap lanyard mounting h screw and the locknut Cap Wash Tube gt 2 05700 021 69 68 Upper Wash Arm Manifold Weldment 05700 031 67 34 Service Note When replacing the 10 32 screws in the End Caps it Complete Upper Arm Assembly is recommended that a thread locking fluid be used to 05700 031 74 99 ensure that the screws do not back
47. Lubrication Chart for Drive Gear Drive Motor Gear Reducer Preventative Maintenance TROUBLESHOOTING SECTION Common Problems D226 Common Problems 30 33 34 40 41 42 44 46 48 50 51 53 54 55 56 58 60 n TABLE OF CONTENTS PARTS PARTS SECTION AJ 44 Control Box Assembly 62 AJ 66 AJ 80 Control Box Assembly 64 Motor Overload Chart 66 Heater Assembly 67 Thermostats Dress Panels 69 Prewash Plumbing Assembly 70 Wash Section Plumbing 71 External Electric Booster Option Incoming Plumbing 72 External Electric Booster Option Outlet Plumbing 73 Water Hammer Arrestor OptionWPRK Plumbing Option 74 3 4 Solenoid Valve amp 3 4 NPT Vacuum Breaker Repair Parts Kits T5 Steam Unit Wash Tank Coil Assembly 76 Steam Plumbing Left to Right 77 Steam Plumbing Right to Left 78 Gas Coil Assembly CGP Models 79 Rinse Booster Tank Assembly CGP Models 80 Recirculating Pump Assembly CGP Models 81 Hose Connections CGP Models 82 Wash Fill Plumbing Assembly CGP Models 83 Rinse Header Plumbing Assembly CGP Models 84 AJ 44 Series Drain Plumbing Assemblies 85 AJ 66 Drain Plumbing Assemblies 86 AJ 80 Drain Plumbing Assemblies 87 AJ 66 Drain Plumbing Assembly Left to Right CGP Models 88 AJ 66 Drain Plumbing Assembly Right to Left CGP Models 89 Drain Quench Assembly 90 Motor Assemblies 91 Prewash amp Wash Pump Weldments 92 Lower Wash Arm Assembly 93 Prewash Arm Upper Wash Arm Assembly 94 Curtains Tub Magnets 95 Fina
48. 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 Weldment 05700 002 56 55 Scrap Basket Assembly 06401 011 87 78 109 SECTION 5 PARTS SECTION ERR VENT COWL ASSEMBLY VENT SCOOP OPTION Vent Cowl Cover Replacement Kit gt Gasket Top Vent Cowl 06401 003 10 16 05330 031 83 47 Gasket Side Vent Cowl 2 per assembly 05330 031 83 48 Vent Cowl 06401 003 11 62 Replacement Kit Note The kit for the vent cowl comes with the vent cowl weldment new gaskets and the lock nuts needed to mount it VENT SCOOP OPTION Vent Scoop Assembly 05700 002 04 08 110 Delay Timer 05945 011 65 44 Limit Switch 05930 002 62 81 SECTION 5 PARTS SECTION EXHAUST CONTROL TABLE LIMIT SWITCH 2 Din Rail 05700 002 36 09 FAN LOAD ON TIMER OUTPUT 5A 1 4HP 240 V Decal Fan Load 09905 003 32 20 111 Terminal Board 05940 011 84 41 Kit Exhaust Fan Electric amp Steam Models 05700 031 90 53 Kit Exhaust Fan Gas Models 05700 003 14 59 Striker Plate Limit Switch Assembly 05700 002 62 94 ws SECTION 5 PARTS SECTION
49. 05945 111 35 19 05305 171 02 00 5920 011 72 88 5920 002 75 95 5920 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 05305 173 12 00 05945 111 72 51 05325 011 46 73 05975 210 09 00 05975 011 47 81 05700 031 66 88 05700 021 68 57 05700 011 68 58 05311 174 01 00 05315 011 68 56 05930 301 22 18 09905 011 74 61 09905 011 47 35 05700 011 71 47 05306 011 83 52 05310 374 01 00 05700 031 67 03 05700 021 70 88 SECTION 5 PARTS SECTION AJ 66 amp AJ 80 CONTROL BOX ASSEMBLY 14 20 24 25 SG 9190 S 23 23 23 21 141 1 1 141 cnl 141 H 13 EET gt BEES es e ele 15 16 17 18 19 22 11 10 10 64 SECTION 5 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 11 1 Thermometer 48 Lead 12 1 Decal Ground 13 1 Terminal Board 14 3 Motor Contactor
50. 09 4 4069 229 gt x i 3 Nd 0 02 8 luuges 262 be 92 L ww L9 vz 96 J9jeM USeMeJd 9 sz px uuees LZ 3 91981 0 9861 602108 6 9988 9 i uuszr 9 7 669 12 1 XEN v c ebuel4 91981 Jo pue u w g 61 Jejeeg 269 91951 48 2 YZ 9 dn e 1deooy 91 9 qni eiqeyusiq 44 ley 9 81 wwzs 1 9 1 1 ju M JO eo EE 4 E ZL 6 99 sJooq Le 8 9 peddius ysejdg Imo9 3nojno 909 91 x epi ZOL
51. 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 lt 4 SAL x DESCRIPTION Reducer 3 4 to 1 2 Black Iron Union 3 4 NPT Black Iron Nipple Close 3 4 Black Valve Steam Solenoid 3 4 NPT 120V Elbow 90 3 4 FNPT Black Elbow Street 90 3 4 NPT Black Iron Y Strainer 3 4 NPT Black Iron Valve Gate Steam 3 4 NPT Plug 3 8 NPT Black Iron Nipple 3 4 NPT x 32 Long Reducer 3 4 NPT to 1 2 Black Iron Elbow 90 3 4 FNPT Black Iron Elbow Street 3 4 NPT Black Iron Union 3 4 NPT Black Iron Nipple Close 3 4 NPT Black Steam Trap 3 4 NPT Pipe 3 4 NPT x 10 Long Black 11 77 YC 3 8 Mfg No 04730 911 02 34 04730 912 01 00 04730 907 01 00 04820 011 87 39 04730 906 10 34 04730 011 87 37 04730 217 01 32 04820 100 19 00 04730 909 02 34 04730 002 21 27 04730 911 02 34 04730 906 10 34 04730 011 87 37 04730 912 01 00 04730 907 01 00 06680 500 02 77 04730 907 06 34 SECTION 5 PARTS SECTION STEAM PLUMBING RIGHT TO LEFT STEAM INLET PLUMBING 5 3 4 7 10 NC S AX Y 3 9 6 3 DESCRIPTION Reducer 3 4 to 1 2 NPT Black Iron Union 3 4 NPT Black Iron Nipple Close 3 4 NPT Black Valve Steam Solenoid 3 4 NPT 120V Elbow 90 3 4 FNPT Black
52. 230 1 60 06105 121 70 57 06401 003 10 42 200 3 60 06105 121 70 58 06401 003 10 43 220 3 60 06105 121 70 58 06401 003 10 43 230 3 60 06105 121 70 58 06401 003 10 43 380 3 60 06105 121 81 34 06401 003 10 39 Motor Mounting Gasket 460 3 60 06105 121 70 58 06401 003 10 43 06401 003 06 75 600 3 60 06105 002 48 31 06401 003 10 41 91 SECTION 5 PARTS SECTION PREWASH amp WASH PUMP WELDMENTS Prewash Intake Strainer Weldment 05700 021 74 96 Wash Pump Weldment Intake Suction Scoop Weldment 05700 041 68 88 05700 021 87 60 Prewash Strainer Bracket 05700 021 74 94 Prewash Pump Weldment Prewash Pump Weldment 66 80 Left to Right models J 66 AJ 80 Right to Left models 05700 002 10 62 05700 002 11 96 Gasket N Scoop Intake Suction Wash Discharge 0593000255 Weldment Weldment 05700 002 50 90 Wash Pump Weldment 05700 002 51 20 05700 002 50 92 Prewash Pump Weldment Prewash Pump Weldment AJ 66CGP Left to Right model AJ 66CGP Right to Left model 05700 002 42 69 05700 002 43 56 92 wa SECTION 5 PARTS SECTION LOWER WASH ARM ASSEMBLY Lower Wash Arm Support Bracket 05700 011 71 20 Secured with Locknut 1 4 20 with Nylon Insert 05310 374 01 00 Replacement Kit Note The replacement kit for the end cap includes the endcap lan M Saa
53. 73 Nipple 3 4 Close Bass gt gt 04730 207 34 00 SECTION 5 PARTS SECTION WATER HAMMER ARRESTOR OPTION WATER PRESSURE REGULATOR KIT OPTION WATER PRESSURE REGULATOR WITH ARRESTOR KIT OPTION Regulator Pressure 3 4 06685 011 58 22 WATER HAMMER ARRESTOR OPTION Water Arrestor 1 2 NPT 06685 100 05 00 Tee 3 4 x 3 4 x 1 2 lt 04730 211 06 00 Water Arrestor 1 2 NPT 06685 100 05 00 lt Bushing 3 4 x 1 2 04730 002 01 34 Tee Brass 3 4 x 3 4 x 3 4 04730 211 01 34 Nipple Close 3 4 04730 207 34 00 74 SECTION 5 PARTS SECTION RINSE SOLENOID VALVE amp VACUUM BREAKER REPAIR PARTS KITS amp Screw Data Plate gt Coil amp Housing Valve Bonnet Spring lt 06401 003 07 40 Spring position is moved for clarity Plunger Goes below the plunger 06401 003 07 40 lt O Ring 06401 003 07 42 Diaphragm Retainer lt Diaphragm 06401 003 07 42 Screen Retainer lt Mesh Screen Valve Body Complete 110 Volt Solenoid Valve Assembly 3 4 04810 100 53 00 Coil amp Housing only 3 4 06401 003 07 43 Possible Problems 1 Pilot port extension 1 clogged Clean hole 2 Hole 2 Clogged Pass heated straight pin through hole Cap Screw Data Plate gt Cap Retainer gt lt lt
54. If there is damage to both the container and machine do not throw away the container The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new undam aged condition However rough handling by carriers or others may result in damage to the unit while in transit If such a situ ation occurs do not return the unit to Jackson instead contact the carrier and ask them to send a representative to the site to inspect the damage to the unit and to complete an inspection report You must contact the carrier within 48 hours of receiving the machine Also contact the dealer through which you purchased the unit UNPACKING THE DISHMACHINE The machine should be unboxed and removed from shipping pallet prior to being installed Open the front door and remove all of the packing materials Once unpacked ensure that there are no missing parts from the machine This may not be obvious at f rst If it is discovered that an item is missing contact J ackson 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 b
55. O Ring wu Components of Repair Kit 04820 001 60 57 lt Plunger lt Complete Vacuum Breaker Assembly 3 4 04820 002 53 77 DISASSEMBLY These valves may be taken apart by unscrewing the bonnet and the enclosing tube assembly from the valve body assembly After unscrewing carefully lift off the bonnet and enclosing tube assembly Don t drop the plunger The o ring seal and diaphragm cartridge can now be lifted out Be careful not to damage the machined faces while the valve is apart TO REASSEMBLE Place the diaphragm cartridge in the body with the pilot port extension UP Hold the plunger with the synthetic seat against the pilot port Make sure the o ring is in place then lower the bonnet and enclosing tube assem bly over the plunger Screw the bonnet assembly snugly down on the body assembly Stand D Weldment 05700 002 74 85 Stand B Weldment SECTION 5 PARTS SECTION STEAM UNIT WASH TANK COIL ASSEMBLY Coil Weldment 05700 002 84 03 05700 002 74 83 Coil Nut 05310 011 17 85 SERVICE NOTE Jackson HIGHLY recommends that the Coil Gaskets be replaced any time the Coil Weldment is replaced or removed for an extended period of time Flat Washer 05700 001 17 87 Stand C Weldment 05700 002 74 84 Coil Gasket 05700 001 17 86 76 SECTION 5 PARTS SECTION STEAM PLUMBING LEFT TO RIGHT STEAM INLET PLUMBING 10 STEAM OUTLET PLUMBING QTY
56. Terminal Board Thermostat Bracket Decal Thermostat Regulating Thermostat Wash Regulating Fitting 1 4 Imperial Brass 79 Mfg No 05930 011 49 43 05940 002 78 97 05700 011 81 64 09905 011 84 31 06401 140 00 32 05310 924 02 05 ws SECTION 5 PARTS SECTION TANK RINSE BOOSTER CGP MODELS ONLY 1 4 p E 7 N X lt EE 8 7 5 lt Y D BOTTOM ANGLED VIEW Y DN 5 gt 6 gt 2 177 TOP ANGLED VIEW ITEM QTY 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 80 ws SECTION 5 PARTS SECTION RECIRCULATING PUMP ASSEMBLY CGP MODELS ONLY Elbow 3 4 90 Brass 2 per 04730 206 13 00 Pump Recirculating with Adapters 05700 002 51 28 gt 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 Mounting Bracket Mounting Bracket 05700 002 25 74 05700 002 23 61 81 SECTION 5 PARTS SECTION HOSE CONNECTIONS CGP MODELS ONLY
57. ditions Long term storage or infrequent operation If speed reducer is to stand idle for an extended period of time either prior to installation or during use it is recommended that the unit be filled completely with oil to protect interior parts from rust and corrosion due to internal condensation Be sure to drain the oil to the proper level before placing the speed reducer in service Grease fittings Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash These fittings must be lubricated every 3 6 months depending on operating conditions bearing greases must be compatible with the type of gear lubricant being used i e mineral synthetic food grade etc For mineral oils use a high quality lithium base NLGOI 2 bearing grease For synthetic oils use a synthetic bearing grease such as Mobil Synthetic Universal gease Mobilith SHC 100 or a sutable equiva lent For food grade lubricants use Chevron FM grease NGLI 2 or equivalent Low input speeds under 1600 RPM When input speeds are less than 1600 RPM grease fittings will be required to lubricate any bearings not partially covered by the normal oil level Oil temperature Speed reducers in normal operation can generate temperatures up to 200 depending on the type of reducer and the severity of the application 9loading duration of service ambient temperatures Excessive oil temperatures may be the result of sev eral fa
58. uonoeuuoo O 451595 95 uonoeuuoo 55115513 g 4 4 07 duo M Dx 5 91981 4 08 LAN v 48 4 YZ 9 dn 9 91951 e Wey 1deooy qn L 20 uoneonqe J 1 1 ye o11uBr 10 SPECIFICATION INFORMATION SECTION 1 AJ 66 ELECTRIC LEFT TO RIGHT epis 14044 don 12 ez 3 9 wwogz Zor 119 1 1 1 11 1 1 __ S 4 A 180 9 9 6 04 uup9g 4248 1 uwose m JO 05 2 i AMI 95 8 29 usiq 4689 sz 3 09 99 5 K i 2 utuug L 1 06611 zo BEER 8 v 02 9 0 wwzo p ug 106121 902 8 quusz 1 wwees 2 9 g uu609 tZ V 0 869 5 uwse9 92 44070 Ly uedo 84000 97
59. 1 81 000 ui Le vg eje d 19409 peddius nono Buo 90 91 X 201 021 8 7 9 sz uses LZ eur 92 JO AUIS 10014 gt 669 026 109 j 09 n wwo ort 91981 51981 756 L1 21 S 04 e qejsn pe 100 3 5 gU ata LOA 93oN Cb 1 9EM 2 08 LAN y ETE 9 2 5 3 H 4 0 1 Butuoou LAN v 14 6 983 uwes 19 uonoeuuoo ejesuepuo x 21 996 W MESS t f 5 0839 03 5534129919 H BJESUBSPUOD 1 9 qn uonoeuuoo WSIS LdN 4 Y a 8 91 9 Wee 3 v c ebue 4 JO dr 1 0890 3u9A L pue 91481 ueewjeg yoey 61 i
60. 125 208 1 60 19A 25 AMP 230 1 60 19A 25 AMP 200 3 60 13A 20 AMP 208 3 60 13A 20 AMP 230 3 60 13A 20 AMP 380 3 60 13A 20 AMP 460 3 60 15 600 3 60 8 15 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 SPECIFICATION INFORMATION SECTION 1 AJ 44 ELECTRIC LEFT TO RIGHT epis 14044 5 91 uuipsz 1 ME 9 9 6 ez uei o uug1 1 1 1 2 Pun pe ae i wwgge 059 1 99 ysig 3 441068 229 9 SZ gt ysejdsyoeg 261 61611 oz 4 OL ww 2991 59 9 299 xe v c eDue J 81981 1884 0612 0 1 6 L 64 g 8 1 uuees yz 2 D 5 1 te Y 1 1 9 2 669 LZ uedo 8 00 2 229 19 02
61. 15 1 Circuit Breaker 200 208 230 360 Volt 60 Hz Models Only 15 1 Circuit Breaker CGP 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 1 Relay 22 1 Transformer 200 Volt Models Only Transformer 208 220 230 460 Models Only 208 220 230 460 Volt CGP Models Transformer 380 415 Volt Models Only Transformer 600 Volt Models Only 23 3 Control Relay 24 1 Fuse Holder 380 60 Hz 460 600 Volt Models Only 25 1 Fuse 380 60 Hz 460 Volt Models Only 1 Fuse 600 Volt Models Only 26 2 Control Relay CGP Models Not Shown MISCELLANEOUS PARTS NOT SHOWN Manual Delime Switch Manual Delime Switch Decal Decal High Limit Warning Light Transformer 150V 60 Cycle Control Box Cover Control Box Leg Conduit Bracket 65 Mfg No 05700 041 88 50 09905 101 12 66 05940 011 48 27 05940 021 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 06685 111 68 48 09905 011 86 86 05940 002 78 97 05945 111 68 38 5925 011 68 34 5925 111 64 18 See Chart 05930 301 46 00 See Chart See Chart 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 5920 011 72 89 5920 011 72 88 5920 002 75 95 05945 111 72 51 05930 301 22 18 09905 011 74 61 09905 002 49 48 05950 011 68 35 05700 031 66 88 05700 011 71 47 0570
62. 22118 uut 9 E wwege Fp 9 1 o 7 1 XEN abue 1972M UNA 669 12 uonoes ue d USEA 1d lt zn 61 269 8 4 ve o1 dr e 1deooy 910N Ysemald 90 91 X epi 201 1 659 2 deos 1 171 1 2 6 9 sz uwgoz 8 wwegs 12 2 457 7 Z uussg 91 6 yor 49598 euoois esf Y 9951 91451 EIA 910 jeuondo uonoeuuoo 0 1 3 01 19 M Aq sepoo pejeisur eq 0 uonoeuuoo edid GO uonoeuuot 520 LdN v H Jen ejnueu Aq papiaoid esou uo 0 45081 LdN 9 Jeyeeu 500 996 JO 19 1 0 1 3 0111 LdN v 4 M09 3 euondo 1ejoo 1u9A
63. 460 VOLTS 60 HZ 3 PHASE PRIMARY SIDE GND Re 1MOL MOL Re BLACK 14GA o 3 BLACK 1464 RED 1464 HE LL EH 146 Syro R2 BLK 1 RED 1 3 MOL 241 R3 BLACK 14GA BLACK 1464 RED 146A 2 4l RED 1464 HOR X B 2 5 BLUE 14GA Le BLUE 145A Lue R3 LK 186A DETERGENT RED 1804 DISPENSER CONNECTION AQ M3 5 SMDL R5 BLACK 14GA 4 BLACK 1404 RED 14GA MT 4 E RED 14 SUA ELT GE y RED 1488 M T ve BLUE 14 4l BLUE 1464 T 3 MOL 85 5 BLACK 1864 BLACK 18GA Ti RED 186A RED 1864 163 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CGP amp AJ 80CGP 460 VOLTS 60 HZ 3 PHASE SECONDARY SIDE 9905 Led 002 BLK URG BLK URG HT WH c BLK WHT FUSE BLK WHT WH 3 K WHT B T ORG BLU H n BLK T ORG BLU 4 7 BLK WHT BLK WHT HT YEI HT BLK a ORG WHT HT uus 123 No ke A Fe ONS 807215 151 O epee WHT BLU 5 4 10 BLK WHT BLK YEL RED WH WHT WHT BLK WHT gt T GRY BLK ORY BLK wH 551112 BLK WHT BLK GRY WHI WH BLK 22 GRY WHT elle 9 7 4 IT BLK WHT 1 BLUE 41 n WHT JUMPER WIRE 5 se 7653 BLU BLK M BLK WHT GRY RY ORG 9 7 D po OR
64. 60 60 60 60 TOTAL AMPS 13A 13A 13A 6A 7A 6A 11A 11A 7A 7A 7A 6A 4A 4A ELECTRICAL REQUIREMENTS TYPICAL ELECTRICAL CIRCUIT 70 AMP 70 AMP 70 AMP 40 AMP 35 AMP 35 AMP 110 100 AMP 60 AMP 70 AMP 60 AMP 40 AMP 30 AMP 25 AMP TYPICAL ELECTRICAL CIRCUIT 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP TYPICAL ELECTRICAL CIRCUIT 20 AMP 20 AMP 20 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP AJ 66CE CEL MODELS T 00 HZ 50 50 50 50 50 50 60 60 60 60 60 60 60 60 TOTAL AMPS 56 53 54 31 34 33 89 82 51 52 48 31 24 22 AJ 66CGP MODELS 02 gt gt D E 60 60 60 60 60 TOTAL AMPS 17A 17A 11A 11A 6A AJ 66CS CSL MODELS 200 208 380 460 600 T 09 02 02 HZ 50 50 50 50 50 60 60 60 60 60 60 60 TOTAL AMPS 17A 17A 17A 6A 7A 6A 18A 18A 12A 12A 12A 12A 7A 7A TYPICAL ELECTRICAL CIRCUIT 80 AMP 70 AMP 70 AMP 40 AMP 45 AMP 45 AMP 125 110 AMP 70 AMP 70 AMP 60 AMP 40 AMP 30 AMP 30 AMP TYPICAL ELECTRICAL CIRCUIT 15 AMP 15 AMP 15 AMP 15 AMP 15 AMP TYPICAL ELECTRICAL CIRCUIT 25 AMP 25 AMP 25 AMP 15 AMP 15 AMP 15 AMP 25 AMP 25 AMP 15 AMP 15 AMP 15 AMP 15 A
65. 80CGP 208 230 VOLTS 60 2 1 PHASE SECONDARY SIDE BLACK 186 BLACK 185 NN RED 1864 RED 18GA S BLK ORG 88 87 5 WHI wH BLK WH HT BLK W BLK WH ORG BLU HT BLK WH J WH URG BLU Ire BLK WH BLK WH 2 Ds HT BLK JRG WHT pm H gt BLU YEL 17 BLU BLK 2 H BLK WH IRY BLK jRY B K WHT BLK WHT GRY WHT WHT 88 RS PWFS BLK WH BLK W N BLUE vH NO ole 5 5 BLK WHT F BLU BLK WHT BLK WHT GRY GRY ORG ORG vH GEND B 1 POWER DISTRIBUTION BLOCK 27 GND GROUND 4 H 2 Re DRIVE MOTOR CON R3 WASH PUMP MOTOR 24 NAL RINSE RELAY y M RS VASH PUMP MOTOR CONTACTOR ainda oe R7 TANK FIL RELA RS VASH TANK FILL RELAY Be EXE 59 IR SAFETY SWITCH R10 WASH RECIRCULATING RELAY R11 MASTER SOLENOID RELAY GRY M1 DRIVE MOTOR Me H PUMP MOTOR M3 VASH PUMP MOTOR Ry p 4 RECIRCULATING PUMP CB 280011 BREAKER 1 1 URG YEL 1 DRG YE vH se Y SWITCH 1 53 DOOR SAFETY SWITCH 2 SA PUMP SWITCH 1 ORG YEL 55 e 5 5 em 59 CH IT RED HT RE vH SWIT CH 1 Ua 2 CTS BL lt kS WHT H GEN SWITCH 1 4 SWITCH 2 1 THERMOSTAT MOSTAT GRY ot se HT BLK GRY BRN BRN ins WHT GRY BRN
66. Ibs Heater Contactor 35 In Ibs Heater Nuts 16 In Ibs Terminal Block 50 In Ibs 59 SECTION 4 TROUBLESHOOTING N D226 COMMON PROBLEMS WARNING Inspection testing and repair of electrical equipment should be performed only by qualified service per sonnel Certain procedures in this section require electrical tests or measurements while power is applied to the machine Exercise extreme caution at all times If test points are not easily accessible disconnect power attach test equipment and reapply power to test When replacing electrical parts disconnect power at source circuit breaker Problem Power light does not illuminate 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light 2 Service breaker tripped or open Verify that the breaker is closed 3 Power switch connections could be loose Ensure that the connections are of sound quality 4 Power switch is faulty Replace the power switch 5 Power light is faulty Replace the light Problem Water pressure is too low 1 Water pressure regulator is out of adjustment Follow the instructions provided in the maintenance section and adjust so that the flow pressure is 20 5 PSI 2 Water pressure regulator internal strainer is clogged Clean in accordance with the instructions provided in the maintenance section 3 Water pressure regulator is faulty Replace t
67. Lower Rinse Arm Replacement Kit 06401 003 10 09 Replacement Kit Note The replacement kits for the rinse arms have the rinse arms end caps o rings and the retaining rings C Rinse Pan Strainer Weldment E 05700 041 85 09 lt Locknut 1 4 20 with Nylon Insert lt 05310 374 01 00 On Rinse Drain Control Plate Dx 28 5700 011 68 70 Rinse Tray Weldment mod All models except CGP iw 05700 031 66 75 acm Left Rinse Pan Locator Bracket 05700 021 92 38 Optional Parts for CGP e Models 2 Rinse Drain Control Plate E HM 05700 011 68 70 Rinse Tray Weldment CGP models only x 05700 031 66 75 7 2 Rinse Drain Overflow Plate 05700 002 53 62 96 SECTION 5 PARTS SECTION DRIVE ASSEMBLY 2 1 af lt 2 11 13 97 14 SECTION 5 PARTS SECTION DRIVE ASSEMBLY CONTINUED ITEM QTY DESCRIPTION Mfg No 1 1 Drive Plate and Rod Weldment 05700 021 67 44 Replacement Kit with Expansion Legs 06401 021 86 80 Replacement Kit with Expansion Legs Adjuster Crank 06401 011 94 54 2 1 Adjuster Crank Assembly 05700 021 69 95 3 1 Skotch Yoke Weldment Replacement Kit 06401 003 08 48 4 2 Coupling amp Expansion Leg Weldment 09515 003 58 12 5 1 Pawl Bar Drive Linkage Casting 09515 021 87 73 6 1 Spacer Plate 05700 011 67 58 7 2 Pillow Block Replacment Kit 06401 003 08 50 8 2 Shaft Collar 05700 011
68. NPT x 3 4 NPT Brass Nipple 3 4 NPT x 1 3 8 Long Bushing Hex 3 4 M x 1 2 F Brass Y Strainer 1 NPT Black Iron Pressure Gauge Steam Relief Valve Nipple 3 4 NPT x 4 Long Brass Tee 3 4 x 3 4 x 3 4 Brass Bushing 2 NPT 1 NPT Black Iron Elbow 90 1 Black Iron Nipple 1 NPT x 4 Long Black Iron Elbow 90 Street 3 4 Black Iron Nipple Pigtail 1 4 NPT Coupling 1 4 NPT x 1 4 NPT Steam Solenoid Valve 240VA Steam Solenoid Valve 200VA Steam Solenoid Valve ASCO Tee 3 4 x 3 4 x 1 4 Brass Valve Test Cock 1 4 Tee 1 NPT x 1 NPT x 1 NPT Black Iron Valve Safety Relief 1 NPT Tee 1 NPT x 1 NPT x 1 4 Black Iron Union 3 4 Black Iron Nipple 3 4 NPT x 2 Long Brass Nipple 3 4 NPT Close Black Iron 117 Mfg No 04820 100 01 06 05700 001 26 74 05306 458 01 04 05700 002 78 02 04420 100 01 05 06680 500 02 77 04730 902 06 34 04730 206 13 00 04730 907 08 34 04730 212 05 00 04730 202 18 00 04730 207 34 00 04730 002 56 27 04730 217 02 32 06685 111 88 34 04820 100 07 06 04730 207 05 00 04730 211 01 34 04730 002 94 51 04730 906 03 34 04730 907 09 34 04730 011 87 37 04730 907 14 34 04730 904 01 34 04820 100 29 34 04820 002 93 66 04820 002 90 26 04730 211 04 00 04810 011 72 67 04730 911 01 34 04820 100 01 35 04730 911 01 00 04730 912 01 00 04730 207 46 00 0473
69. QOF NDB 219 Updated manufacturer information 232 Updated temperature 13 14 19 and 20 03 23 2015 Updated pressure regulator info on pg 30 and 45 Updated gas drawings pg s 7 8 13 14 19 20 07 17 2015 EE QOF 386 Updated drawing amp p n for suction weldment strainer on pg 108 Pg 96 Updated Final Rinse Manifold Weldment P N to 05700 031 74 88 NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Jackson AJ 44CSL AJ AJ series of rack conveyors 44 44 wide machine 66 66 wide machine 80 80 wide machine CE Electrically heated hot water sanitizing machine CEL Electrically heated chemical sanitizing machine CS Steam heated hot water sanitizing machine CSL Steam heated chemical sanitzing machine CGP Gas heated hot water sanitizing machine Model Jackson WWS INC provides technical support for all of the dishmachines detailed in this manual We strongly recommend that you refer to this manual before making a call to our technical support staff Please have this manual with you when you call so that our staff can refer you if necessary to the prop er page Technical support is available from 8 00 a m to 5 00 p m EST Monday through Friday Technical support is not available on holidays Contact technical support toll free at 1 888 800 5672 Please remember that technical support is is available for service personnel only Serial No Installation Date Service R
70. Right Part Number 05700 031 72 22 05700 002 52 77 05700 031 71 85 05700 002 51 22 05700 031 74 06 69 Right to Left Part Number 05700 031 72 22 05700 002 52 77 05700 031 72 42 05700 002 57 84 05700 031 77 10 06401 003 18 20 06401 003 18 21 05930 011 49 43 05700 031 66 81 05700 031 66 82 05940 002 78 97 Nipple 3 4 Brass Close 04730 207 34 00 Y Strainer 3 4 NPT Brass 04730 717 02 06 SECTION 5 PARTS SECTION PREWASH PLUMBING ASSEMBLY Vacuum Breaker 3 4 04820 002 53 77 Valve Solenoid 3 4 04810 100 53 00 3 SAN Nipple 3 4 Brass Close 04730 207 34 00 Elbow 90 3 4 Brass 04730 206 04 34 70 Elbow 90 3 4 Brass 04730 206 04 34 2 2 5 Nipple 3 4 x 6 Long 05700 001 26 74 A new gasket can be 1 ordered using part num N ber 05330 111 42 81 Fill Line Injector Replacement Kit 06401 003 09 93 Replacement Kit Note The kit for the fill line injector comes with the injector weldment a new gasket and the mounting hardware SECTION 5 PARTS SECTION WASH SECTION INCOMING PLUMBING ASSEMBLY 13 14 15 Left to right direction shown 6 8 7 TJ Tube Length Chart Y Y Length Inches X 5 x 3 7 16 17 A N lt 7 x 2 5 8 4 x 3 x 2 13 16 lt 20 Replacment Kits Notes The rinse and fill injector replacement kit
71. chased locally and cut to length lengths provid ed in drawings Assemblies are mirrored and all parts are common to both assemblies Right to Left Plumbing SN Assembly 2 as Tee Brass 1 1 2 x 1 1 2 x 1 1 2 lt 04730 011 69 93 Nipple Rinse Weldment gt 05700 021 84 61 NN Connector No Hub 1 1 2 4 04720 604 06 00 CON Ae i Adapter Male to Female 1 1 2 2 04730 401 25 01 7 x Elbow Brass Street 1 1 2 NPT Ball Valve Handle Assembly Elbow 1 1 2 FNPT 90 Brass 04730 206 32 00 06401 021 84 74 04730 011 73 77 87 lt ITEM QTY 1 6 2 3 3 3 4 2 2 5 2 6 2 7 2 8 1 9 2 10 2 11 1 SECTION 5 PARTS SECTION AJ 66CGP LEFT TO RIGHT DRAIN PLUMBING ASSEMBLY 10 2 10 lt lt 2 13 I 5 gt 7 6 1 9 5 4 5 3 1 DESCRIPTION Adapter Male to Female 1 1 2 No Hub Connector Tee Brass 1 1 2 FNPT Ball Valve 1 1 2 FNPT Valve Handle Weldment Assembly Not Shown Nipple Brass Close 1 1 2 NPT Elbow Brass 90 1 1 2 FNPT Tube Copper 1 1 2 x 1 3 4 Long Rinse Nipple Weldment Tube Copper 1 1 2 x 3 1 2 Long Tube Copper 1 1 2 x 7 1 2 Long Nipple Brass 1 1 2 NPT x 3 Long 3 11 8 i 4 13 Mfg No 04730 401 25 01 04720 604 06 00 04730 011 69 93 04820 011 71 46 06401 021 84 74 04730 207 40 00 04730 011 73 77 See Service Note 05700 021 84 61 See Service Note See Service Not
72. of steam to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strain ers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rinse tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the inside of the unit and then reassemble with the components previously removed SHUTDOWN AND CLEANING GAS HEATED MODELS At the end of the work day shut down the gas booster in accor dance with manufacturer s instructions Place the power switch in the OFF position secure the flow to the machine and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap basket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstructions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rinse tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the in
73. supplied be installed in the incoming water line This prevents line hammer hydraulic shock induced by the solenoid valve as it operates from causing damage to the equipment 30 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED It is also recommended that a shock absorber not supplied be installed in the incoming water line This prevents line hammer hydraulic shock induced by the solenoid valve as it operates from causing damage to the equipment STEAM LINE CONNECTIONS Some machines covered in this manual are designed to use low pressure steam as a source of heat for wash tank water The machines come with lines by which outside source steam needs to be connected Connect all incoming steam lines in accordance with the steam booster manufacturer s instructions Ensure that all applicable codes and regulations are adhered to See machine data plate for information concerning steam flow pressure GAS CONNECTIONS Some machines covered in this manual are designed to use gas as an outside source of heat for wash tank water The machines come with connections by which an outside source needs to 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 Chec
74. wHT BLK 152 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CGP 208 230 VOLT 60 HZ 1 PHASE PRIMARY SIDE ND L ML R2 A R2 BLACK 1464 A BLACK 1464 RED 1464 o bo RED 1464 alls CONSTANT A GA CYS VOLTAGE RED 1854 WITH CONVEYOR RUNNING 23 4 BLACK 1404 4 BLACK 1464 RED 146 Er RED 1404 Tell gt BLK 18GA DET DETERGENT DET RED DISPENSER CONNECTION BLACK 1864 BLACK 180 _ RED 1864 RED 1864 153 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CGP 208 230 VOLT 60 HZ 1 PHASE SECONDARY SIDE a BLK ORG ps BLK ORG WHT WHT 120 BLK WHT BLK WHT yc WHT HT BLK WHT ORG BLU WHT Sw BLK wHT WFSW2 ORG BLU Bl KAN RED 1 BLU YEL 151 N BLK WHT RED WHT WHT WH e BLK WHT BLK WHT 2 Re _ WHT YEL n DRG WHT D ORG WHT dr WHT ede A ke ON ASSO BLK WHT GRY BLK GRY BLK WHT H Ho XRB JUMPER WIRE TLS s2 18122251 BLU BLK WHT BLK WHT GRY GRY DRG H 21 Fe 226 GRY n ORG e gt LEGEND 5 5 L1 L8 P R DISTRIBUTION BLOCK GND G D Re D MOTOR CONTACTOR e PY CENTS 1 m R3 PUMP MOTOR CONTACTOR gt R3
75. 0 021 70 88 44 5 66 5 AJ 80 S 380 440 208 230 200 208 230 380 460 600 200 208 220 230 380 415 440 208 230 200 208 230 380 460 600 200 208 220 230 380 415 440 208 230 200 208 230 380 460 600 60 60 60 60 60 50 50 50 50 50 60 60 60 60 60 60 60 50 50 50 50 50 50 60 60 60 60 60 60 SECTION 5 PARTS SECTION Phase 02 02 02 09 02 00 09 02 Q 09 00 09 02 02 00 09 wW 02 CO MOTOR OVERLOAD CHART Drive Motor 05945 011 84 59 05945 011 84 59 05945 011 84 59 05945 002 71 09 05945 111 69 12 05945 111 69 12 N A N A 05945 002 66 00 05945 111 68 39 05945 111 68 39 05945 111 69 12 05945 111 68 39 05945 111 69 12 05945 011 84 59 05945 011 84 59 05945 011 84 59 05945 011 84 59 05945 002 71 09 05945 111 69 12 05945 111 69 12 N A N A 05945 002 66 00 05945 111 68 39 05945 111 68 39 05945 111 69 12 05945 111 68 39 05945 111 69 12 05945 011 84 59 05945 011 84 59 05945 011 84 59 05945 011 84 59 05945 002 71 09 05945 111 69 12 05945 111 69 12 N A N A 05945 002 66 00 05945 111 68 39 05945 111 68 39 05945 111 69 12 05945 111 68 39 05945 111 69 12 66 Prewash Motor N A N A N A N A N A N A N A N A N A N A N A N A N A N A 05
76. 0 907 01 00 SECTION 5 PARTS SECTION GO BOX COMPONENTS A GO BOX is a kit of the most needed parts for a particular model or model familly to successfully effect a repair in the first call 90 or more of the time The following components may be ordered together using part number 06401 002 14 99 QTY N _ DESCRIPTION Drive Motor Contactor Contactor Wash Heater 3 ph 3 pole Contactor Wash Heater 1 ph 4 pole Final Rinse Arm End Cap Float Switch Dual Wash amp Prewash Gasket Pawl Bar Gutter Gauge Pressure Glide Door Edge Magnet Door Reed Switch O Ring Prewash Manifold O Ring Wash Manifold Overload Drive Motor Overload Wash Motor Relay 120v 3 PDT Relay 120v 50 60Hz Control Repair Kit 3 4 Vacuum Breaker Roller Pawl Bar Seal Kit for Wash and Prewash pump Solenoid Valve Fill amp Rinse Switch Power Switch Reed Actuator NC Switch Reed Door NO Thermometer 48 Capillary Thermometer 96 Capillary Thermostat Wash High Limit Thermostat Wash Regulating Transformer 150VA Valve Ball 1 1 2 NPT 118 Mfg No 05945 111 68 38 05945 002 24 70 05945 111 68 37 05700 011 35 92 06680 121 70 71 05330 011 68 55 06685 111 88 34 05700 111 70 92 05930 111 51 68 05330 400 12 08 05330 011 74 56 05945 111 68 39 05945 111 68 40 05945 111 72 51 05945 111 35 19 04820 001 60 57 05700 011 68 16 05330 011 71 98 04810 100 53 00 05930 011 49 55 05930 111 68 44 0
77. 08 220 230 VOLTS 50 60HZ 1 PHASE SECONDARY SIDE i is Jl Jh I T ORC H 4 5 7 20 EP FGEND GREY Ak Oh Ro IVE MOTOR CHI SA j ASH PUMP MUT FINAL RINSE REL BEN PA ud HEATI E 17 5 SPE oh 5 gt ETY AH 2 1 MAT DEILI RINSE SWITCH 1 m kr 1 MIT 1101 BS SH FLO 110004 2 ASH FLUA TCH 5 NM I EN n A MI ONAL 1 41 OLI 122 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 200 208 220 230 VOLTS 50 60HZ 3 PHASE PRIMARY SIDE 11 2 R HH 3 Ww Fo 123 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 200 208 220 230 VOLTS 50 60HZ 3 PHASE SECONDARY SIDE e Als entes D hs i ONS T REY 1 OL MOTO 3 ASH PUMP MOTO 124 _ SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 380 460 600 VOLTS 60 HZ 3 PHASE PRIMARY SIDE
78. 208 1 15 06401 003 10 21 heater gasket lockwashers 230 1 15 06401 003 10 22 and locknuts 200 3 15 06401 003 10 21 208 3 15 06401 003 10 21 220 3 15 06401 003 10 22 230 3 15 06401 003 10 22 380 3 15 06401 003 10 28 415 3 15 06401 003 10 28 440 3 15 06401 003 10 29 460 3 15 06401 003 10 31 600 3 15 06401 003 10 33 AJ 44CGP AJ 44CS AJ 44CSL AJ 66CGP AJ 66CS AJ 66CSL AJ 80CS AJ 80CSL models do not use electric heaters in the wash tank SERVICE NOTE SERVICE NOTE When replacing the tub heaters it is HIGHLY recom The nuts used to secure the heater to the tub should be mended that you also change out the gasket as well torqued to 154 in lbs After tightening the unit should be Once installed gaskets become compressed and allowed to heat up and operate normally for approximately 30 are subjected to extreme temperature changes minutes Secure power to the machine and check the nuts Replacing the gasket with a new one when replacing once more to ensure that they are torqued to 154 in Ibs the heater may prevent future leaks 67 w SECTION 5 PARTS SECTION HEATER 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 cont
79. 5 Re DRIVE MOTOR R3 ASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY Oo 24 R5 PRE WASH PUMP MOTOR CONTACTOR 55 7 ASH TANK FILL RELAY 4 R8 PRE ASH TANK FILL RELAY R9 DO SAFETY SWITCH RELAY Hi 11 DR 12 GREY ES PRE WASH PUMP MOTOR S CB CONTROL CIRCU BREAKER 1 CONTROL TRANSFORMER corey l geen DET DETERGENT DISPENSER CONNECTION QO CVS CONSTAN SIGNAL 51 POWER S CH Se DOOR SAFETY 53 DOOR S 5 ITCH GREY CUR 54 ASH PUMP SWITCH H AK 4 5 ASH PUMP SWITCH 2 ARYO S6 AUTO MAN DELIME SWITCH S FINAL RINSE S CH 58 PRE WASH PUMP S CH REY 1 POWER LIGHT HT RED E HEATER HIGH L LIGH 7 FSW ASH FLOAT 5 CH FSWe ASH FLOAT 5 Cre PWFSWI PRE WASH FLHAT S CH 1 PWFSWe PRE WASH FLOAT SWITCH 2 BLK YEL HT 151 HEATER HIGH L THERMOSTAT E P t TES ASH REGULATING THERMOSTAT CWTS COLD WATER THERMOSTAT 2 COLD WATER VAL COP TIONAL gt TES TABLE LIMIT S CH OPTIONAL FS ASH F PWFS PRE WA DID GREY 411 HT BLK RS FINAL RIN 4 r 9905 002 57 20a 140 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CE CEL 8 AJ 80CE CEL 200 208 220 230 VOLT 50 60 HZ 3 PHASE PRIMARY SIDE GND E H a 1064 Ak f 1 be 21 10GA 100 i l 3 13 14 BLUE 100 T3 II 3
80. 5330 111 42 81 Prewash Fill Tube Weldment AJ 66 amp AJ 80 Models Only 05700 021 74 76 Shoulder Bolt Wingnut Weldment Wash Strainer Separator Weldment 05700 002 46 02 05700 031 84 38 107 SECTION 5 PARTS SECTION STRAINERS lt 1 e Poe OG oP mn On On bD 6 0 0 0 OLO OLOLLO 035 ou 5 Ore Poo o9 o9 99 2599989969 Front Strainer Weldment Back Strainer Weldment 05700 021 85 10 05700 021 85 11 Q M SANS eS 9 Overf ow Strainer Support 05700 001 96 48 Drain Guard Strainer Weldment 05700 002 09 15 05700 001 22 23 QS QS Suction Weldment Strainer SS Tub Strainer Weldment CGP Models 05700 002 03 21 Screen Strainer with Handle Weldment 05700 002 09 04 108 SECTION 5 PARTS SECTION _ FLOAT SWITCH COMPONENTS SCRAP BASKETS Wash Tank Float Switch Replacment Kit 06401 003 11 75 Prewash Tank Float Switch Replacment Kit Float Switch Support Bracket 06401 003 11 76 Replacement Kit 06401 003 11 77 Replacment Kit Note The float switch support bracket replace ment kit contains the bracket and asso ciated hardware for mounting
81. 5930 111 68 86 06685 111 68 48 06685 111 68 49 05930 121 71 36 05930 121 67 72 05950 011 68 35 04820 111 71 46 wawas SECTION 5 PARTS SECTION BC FERRIES OPTIONS Screw 10 32 x 3 8 Truss Head Complete Lower Wash Arm Assembly 05305 173 12 00 05700 003 03 70 6 End 05700 011 67 11 Lower Wash Support Bracket Weldment 05700 003 03 59 Secured with Locknut 1 4 20 with Nylon Insert 05310 374 01 00 Lanyard 05340 011 72 46 Key Lock Weldment 05700 003 03 58 Locknut 10 24 with Nylon Insert e 05310 373 01 00 3 lt Lower Wash Arm Manifold Weldment 05700 031 67 29 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 Rinse Drain Control Plate 1 68 70 Wash Arm Lock Down Assembly 05700 003 03 64 Rinse Tray Weldment 05700 003 03 67 Wash Fill Tube Weldment 05700 003 03 69 Back Strainer Weldment Front Strainer Weldment Gasket 05700 003 03 55 05700 003 03 56 05330 111 42 81 119 SECTION 6 ELECTRICAL SCHEMATICS waww SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 200 208 220 230 VOLTS 50 60HZ 1 PHASE PRIMARY SIDE l 1 4i 4E 121 wama SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 200 2
82. 6 7 4 11 a qn e qeiusiq ees 12 9 yey 61 pue u w g Jejeeg esf o y 229 8 4 01 oDue J e 1deooy JoN 9 81 10 seay t H 1 pee 34 luusz L M uuuz69 299 sJooq Y Je 02 uy 5 0 3nojno 907 91 ZOL ejqejsn pe enp 400 211 IV 4 Jeuondo LAN uonoeuuoo 3 0 3 01 LAN v 9 d piepue s 3 jeuondo Jus 2 L uonoeuuoo O uonoeuuoo g 4 081 dwe IH 3 08 LAN V ye1 12 SPECIFICATION INFORMATION AJ 66 GAS LEFT TO RIGHT SECTION 1
83. 89 18 9 1 Drive Socket 05700 021 67 39 10 1 Drive Plate 05700 021 67 42 11 2 Pillow Block 03120 021 71 87 12 1 Drive Spring 05315 011 83 51 13 2 Shaft Collar 05700 011 89 18 14 1 Drive Motor Mounting Bracket 05700 031 73 56 15 1 Adjuster Spring 05315 011 71 90 16 1 Adjusting Handle Weldment 05700 021 72 28 17 1 Drive Motor Replacement Kits Drive Motor 50 Hz Models 06401 003 08 41 1 Drive Motor 208 230 Volt 60 Hz Single Phase Models 06401 003 08 42 Drive Motor 208 230 Volt 60 Hz Three Phase Models 06401 003 08 40 Drive Motor 600 Volt 60 Hz Three Phase Models 06401 003 08 43 18 1 Gear Drive 06105 011 71 88 19 1 Roller Bearing 03120 011 71 81 20 1 Drive Hub 05700 011 67 97 Front Drive Motor Cover Replacement Kit 06401 003 11 64 Rear Drive Motor Cover Replacment Kit 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 98 SECTION 5 PARTS SECTION RR DOOR ASSEMBLIES Left Door Guide Weldment 05700 002 32 51 Door Switch Magnet Replacement Kit 06401 003 10 34 Right Door Guide Weldment 05700 031 76 44 Y SS Door Catch Weldment Ps 41 05700 031 84 80 1 TR Door Glide 2 C 05700 111 70 92 ES Door Stop 08700 002 05 46 Wash Door Handle Weldment Wash Door Hood Support 05700 031 84 13 05700 011 82 63 Prewash Door Hood Support 05700 031 84 14 Prewash
84. 9 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE 23 waw SECTION 1 SPECIFICATION INFORMATION SIDE LOADER RIGHT TO LEFT DIMENSIONS DISHTABLE 1 2 MINIMUM USE SILICONE NOTE ALL DIMENSIONS ARE TYPICAL BETWEEN TABLE LOADER AND LIP OF SIDE LOADER TO PRE VENT LEAKAGE 1 2 7 25 Suec lt lt DISHWASHER gt SECTION A A I 12 1 2 gt DISHMACHINE VENT CONNECTION OPENING CONVEYOR DISHMACHINE SPLASH SHIELD TIO 1 SNIN3dO 0 gt lt 1M 1 27 gt 1 1 2 DRAIN CONNECTED DISHMACHINE DRAIN LINE 29 4 1 2 MINIMUM HI9N3I ANIHOVWHSIG gt lt lt 3 ABRE NUNC GEE CUE 15 30 model 30 on 30 model 24 wawww SECTION 1 SPECIFICATION INFORMATION SIDE LOADER INSTALLED DIMENSIONS 23 SIDE LOADER DIMENSIONS MODEL AJ 44 AJ 66 AJ 80 I Left to Right installation shown for reference 30 SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ 44 82 AJ 66 104 AJ 80 118 NOTE ALL DIMENSIONS ARE TYPICAL 23 or 30 lt Refer to chart above 25 SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER DIMENSIONS 43
85. 945 002 65 98 05945 002 24 70 05945 002 24 70 05945 002 24 70 05945 002 24 70 05945 002 24 70 05945 002 24 70 N A N A 05945 002 66 02 05945 111 68 41 05945 111 68 41 05945 002 24 70 05945 111 68 41 05945 111 81 33 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 81 33 N A N A 05945 002 65 99 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 81 33 Wash Motor 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 81 33 N A N A 05945 002 65 99 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 81 33 N A N A 05945 002 65 99 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 81 33 N A N A 05945 002 65 99 05945 111 68 40 05945 111 68 40 05945 111 81 33 05945 111 68 40 05945 111 81 33 SECTION 5 PARTS SECTION S M HEATER ASSEMBLY See Heater Chart Below 5 16 18 Hex Nut Y Y lt Heater Gasket 05330 200 02 70 lt 5 16 Lockwasher Heater Replacement Kit Chart Model Volts Phase KW Part Number Replacement Kit Note All heater kits come with the
86. AJ 44 RACK CONVEYOR DISHMACHINE SERIES INSTALLATION OPERATION amp TECHNICAL MANUAL FOR JACKSON MODELS AJ 44CE AJ 66CE AJ 80CE AJ 44CEL AJ 66CEL AJ 80CEL AJ 44CGP AJ 66CGP AJ 80CS AJ 44CS AJ 66CS AJ 80CSL AJ 44CSL AJ 66CSL ackson Warewashing Systems Jackson MSC LLC P O Box 1060 Barbourville KY 40906 888 800 5672 August 7 2015 7 Fax 606 523 1799 P N 07610 001 76 22 Revision M www jacksonmsc com MANUFACTURERS WARRANTY ONE YEAR LIMITED PARTS amp LABOR WARRANTY ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP UNDER NORMAL USE AND OPERATION FOR A PERIOD OF 1 ONE YEAR FROM THE DATE OF PURCHASE BUT IN NO EVENT TO EXCEED 18 EIGHTEEN MONTHS FROM THE DATE OF SHIPMENT FROM THE FACTORY Jackson MSC agrees under this warranty to repair or replace at its discretion any original part which fails under normal use due to faulty material or workmanship during the warranty period providing the equipment has been unaltered and has been properly installed main tained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to the authorized service agency within the warranty period This includes the use of factory specified genuine replacement parts purchased directly from a Jackson authorized parts distributor or service agency Use of generic replaceme
87. AL 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 41 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION amp OPERATION INSTRUCTIONS CONCEALED DAMAGE OR MISSING PARTS A IMPORTANT FOR YOUR PROTECTION PLEASE READ AND OBSERVE THE FOLLOWING This steam booster has been thoroughly inspected and carefully packed before leaving our warehouse Concealed loss or damage means loss or damage which does not become apparent until the booster has been unpacked The contents may be damaged in transit due to rough handling even though the carton may not show external damage If it is found that the shipment has concealed damage PLEASE DO NOT RETURN IT TO JACKSON but notify the carrier within 48 hours asking them to send their agent to fill out an inspection report Save the cartons so he may inspect them and be sure to note in the report any black marks creases tears crushed corners or any other marks indicating ro
88. C z 4 SE RELAY AL az R6 q RELAY R7 Y SWITCH RELAY R8 CIRCULATING RELAY R11 D RELAY 1 Me M3 RINSE RECIRCULATING PUMP CB C CIRCUIT BREAKER 1 CONTROL TRANSFORMER DE PENSER CONNECTION 58 56 CVS AGE SIGNAL m ORG YEL ORG YEL WHT 1 ih H S3 1 S4 e ORG YEL WHT 55 SWITCH S6 2 R4 9 5 T 4 GRY WHT BLK O HERMDSTAT COP TIONAL OID MS NOID 4 GRY BRN BRN WH 7 R11 GRY BRN 99052 002 58542 154 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CGP 208 230 VOLT 60 HZ 3 PHASE PRIMARY SIDE 155 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CGP 208 230 VOLT 60 HZ 3 PHASE SECONDARY SIDE BLACK 186A BLACK 18GA H RED 18GA RED 18GA CB a BLK ORG Js BLK ORG WHT WHT BLK WHT BLK WHT WHT BLK WHT BLK W ORG BLU WHT BLK T DRG BLU E WHT BLU BLK WHT Rs x BLK YEL RED WHT WHT WHT 7 4 3l KA RG W RG W MES BLK WHT BLK WHT 9119 WHT YEL A k HT gt WHT lt HT 18 12 GRY BLK GRY BLK vH ibt ga JUMPER WIRE TLS se 209 a BLU BLK WHT BLK WHT 8 GRY _ R ORG AAT O WHT s 18 151114 e 96 595 57 ORG EGENI 11213 POWER DISTRIBUTION BLU
89. CK GND GROUND RIVE in 07 gRY YEL YEL d HT 24 96 95 RG ati GRY YEL R7 58 R11 1 gt Me GRY YEL 43 PUMP 9 MOL RLOAD eMUL R OVERLOAD CB 3REAKER GRY 56 RMER 6 1 ORG YEL WHT DE SER CONNECTION 5 AGE SIGNAL S 22 ORG YEL S3 Gen 1 S4 CH 8 SS ME SWITCH 82 5 WHT B e WHT 4 511 HT BLK lt SWI CH 2 51 THERMOSTAT T MS s GRY N w 115 CH lt ode BRN WFS NDID RS LENDID MS fs 9905 002 33 156 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CGP 460 VOLT 60 HZ 3 PHASE PRIMARY SIDE Ox X00 K vs NY lt xo fo SPENS B 2 157 _ SECTION 6 ELECTRICAL SCHEMATICS a AJ 44CGP 460 VOLT 60 HZ 3 PHASE SECONDARY SIDE 6 K OR x FSW GZ BLI A 3LK lt AJ AJ AJ AJ AJ CAT 158 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CGP 8 AJ 80CGP 208 230 VOLTS 60 2 1 PHASE PRIMARY SIDE E BLACK 14GA 9 BLACK 14 ED 14 Re gt BLACK 14 CK 1 4 15 gt BLACK 14GA oth ACK 14GA RED 1408 BLACK 186 159 a SECTION 6 ELECTRICAL SCHEMATICS was AJ 66CGP amp AJ
90. Close Brass 04730 406 42 01 04730 207 34 00 Incoming Plumbing Support Bracket 05700 002 50 70 Inlet Plumbing Mounting Bracket _ 2 per A 7 05700 002 51 41 2 3 4 x 56 Long Clamp Pipe 2 per 05700 000 35 06 a S Elbow 3 4 NPT 90 Brass 04730 206 13 00 Adapter 3 4 8 04730 401 10 01 Nipple 3 4 Close Brass 7 04730 207 34 00 3 4 3 4 gt 1 F 04730 411 46 01 84 ww SECTION 5 PARTS SECTION AJ 44 SERIES DRAIN PLUMBING ASSEMBLIES Fitting Barbed 1 1 2 NPT x 1 1 2 Nipple Rinse Weldment AJ 44 Series Ball Valve Handle A bl 04730 011 69 92 eries Ball Valve Handle Assembly 05700 021 84 61 06401 021 83 53 AJ 44CGP Ball Valve Handle Assembly 06401 021 84 74 de Ball Valve 1 1 2 NPT N 04820 111 71 46 Y 2 S E NY Y N N N N Tee 1 1 2 Brass Nipple 4 1 2 Brass Close Elbow 1 1 2 Brass 90 Street 04730 011 69 93 04730 207 40 00 04730 206 32 00 85 SECTION 5 PARTS SECTION 66 DRAIN PLUMBING ASSEMBLIES Left to Right Plumbing Nipple Brass Close 3 NPT Nipple Brass Close 1 1 2 NPT Assembly 04730 011 87 04 04730 207 40 00 5 NN 5 Tube Copper 1 1 2 x 8 1 4 Long N TPL 2 N gt A gt N 58
91. D 10GA elle RED 106GA 4 5 SLACK 1003 1 be BLACK 10GA BLUE 10GA i n BLUE me A BLACK 1464 vs OOOO 143 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CE CEL amp AJ 80CE CEL 380 460 600 VOLTS 60 HZ 3 PHASE SECONDARY SIDE BLK ORG WHT WHT BLK WHT BLK WHT WHT e KELO BLK WHT BLK WHT DRG BLU WHT 5 ET WHT GRN BLK WHT WFSW BLU WHT 22 DRG BLU RED K BLK WHT BLK WHT 2 WHT YEL 6 n _ URGAWHT _ WHT BLU RED WHT BLK WHT o bo BLU YEL TS WHT BLU 4 BLK WHT BLK WHT WHT HT BLK WHT GRY WHT BLK VHT BLK WHT BLUE 0 21 JUMPER WIRE N BLU B I BLK WHT LU BLK WHT e R9 92 1MDL BLK WHT GREY GREY I x DRG BRN O WHT ala R4 GREY ORG EGEND Abs 1 Le L3 POWER DISTRIBUTION BLOCK GREY RS DRG GND GROUND RI HEAT CONTACTOR Re RIVE MOTOR CONTACTOR 525 R3 WASH PUMP MOTOR CONTACTOR TS GRY YEL c odo R4 FINAL RINSE RELAY 96 795 RS PRE WASH PUMP MOTOR CONTACTOR GREY
92. D L La 5 2 M 2 2 R 1MOL Eb N BLACK 140 o4 TM s 1 or 3 ME L RED TH NING A 12 R N MOL BLACK 1464 CK 14 RED 1464 RED 14 N 22 BLUE 14GA E BLUE 14GA 2 R RED M3 RS 3MOL 340 R5 BLACK 14GA 5 5 BLACK 14GA ED RED 1464 BLUE BLU A RS cB BLACK 1 BLACK i RED 4 151 SECTION 6 ELECTRICAL SCHEMATICS AJ 66CS CSL 8 AJ 80CS CSL 380 415 440 460 600 VOLTS 50 60 HZ 3 PHASE SECONDARY SIDE 3LK DRG 20 RARI BLK WHT HT BLK WHT B ORG BLU 7 1 XR7 C BLK BLUZ WH ORG BLU BLK WHT BLX WHT HT YEL HT WHT BLU WHT 6 4 8 SRY WHT As H O RB O R8 RED T GR T BLK WHT BLK WHT I BLUE ay 10 vat 3 6 E 52 53 BLK WHT 203 BLU BLK BLU BLK BLK WHT x GREY 086 mS BRN HK 5118 GREY ORG 5 DISTRIBUTION BLOCK GREY ORG MOTOR CONTACTOR R3 UMP MOTOR CONTACTOR RA GREY B RS GRY YEL YEL WHT 55 GREY ch GRY YEL PUMP MOTOR R LDAD 56 R 21 5 ERLOAD GRY YEL GREY HT RED ER CONNECTION GREY ORG YEL RDO GREY 39 WHT RED WHT 25 2 BLK YEL Y WHT GRE AL 49 4 2 T HT B RS HT GREY
93. DARY SIDE e ES e 9 Gh R X S JMP KS ISE K RE AS R7 GRE 5 ae 4 JE MOTO HEO 5 TOR 5 IMD OTOR O S TUR R CB ONTRO lt x K S 5 Sf R S S 5 S 56 5 ARE 5 3 1 5 5 P IF A SI NOID 4 fo X NSE SO 1111 136 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 380 415 440 460 600 VOLTS 60 HZ 3 PHASE PRIMARY SIDE 51159 137 SECTION 6 ELECTRICAL SCHEMATICS AJ 44CS CSL 380 415 440 460 600 VOLTS 60 HZ 3 PHASE SECONDARY SIDE IND 4 VI SH UMP LN REI TANK ILE T LII SSH 1 IRI IH TER O ASH PUMP MOTO 1151 CONTROL FUSE CONTI DI JETERGENT DI CONSTANT 1 SA PUM SSH PUM 5 MAN DEI IN RIN R LIGH 138 ac SECTION 6 ELECTRICAL SCHEMATICS AJ 66CE CEL 8 AJ 80CE CEL 200 208 220 230 VOLT 50 60 2 1 PHASE PRIMARY SIDE H1 81 r 81 BLACK 864 BLACK 86 RED 864 RED 864 4 118 de RI RI BLACK 8GA BLACK 8GA RED 864 RED 8 A H Ho 3
94. Door Handle Weldment 05700 011 80 45 ITEM DESCRIPTION Mfg No 1 1 Wash Door Assembly 05700 002 43 29 2 1 Prewash Door Weldment Left to Right Model 05700 002 52 50 2 1 Prewash Door Weldment Right to Left Model 05700 002 49 60 Door Stiffener Not Shown 05700 031 83 43 99 ws SECTION 5 PARTS SECTION PAWL BAR MISCELLANEOUS COMPONENTS Pawl Bar Roller Replacement Kit 06401 003 11 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 Replacment Kit et 06401 003 10 15 Top Guide Block Bottom 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 100 SECTION 5 PARTS SECTION AJ 44 amp AJ 66 PAWL BAR ASSEMBLIES Pawl Bar Dog Casting 12 per 05700 021 69 00 Lf Pawl Bar Spacer 24 per 05700 011 71 45 Pawl Bar Spacer 36 per 05700 011 71 45 Pawl bar Weldment AJ 44 Complete Assembly with Hardware 06401 131 81 00 AJ 44 Pr
95. FF DRAIN 17 2 Motor Contactor 18 1 Heater Contactor 19 1 Overload 20 1 Overload 21 3 Control Relay 22 12 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 CGP 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 3 Screw 10 32 x 3 8 Long Phillips Trusshead 30 2 Control Relay CGP Models Only Not Shown MISCELLANEOUS PARTS NOT SHOWN Grommet 1 2 OD x 3 8 ID Bushing Heyco SB100 Plug Heyco 2700 G 875 Control Box Cover Control Box Cover Hinge Weldment Control Hinge Rod Washer Flat S S 1 4 ID 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 Control Box Leg Bolt 1 4 20 x 2 1 2 Long Hex Head Locknut 1 4 20 with Nylon Insert Component Mounting Plate located inside the control box Conduit Bracket 63 Mfg No 05700 04 1 88 43 05940 011 48 27 06685 111 68 49 05311 273 02 00 05305 011 62 17 09905 021 72 29 06685 111 68 48 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 5925 011 68 34 5925 111 64 18 05930 301 46 00 05945 111 68 38 05700 011 71 44 See Chart See Chart
96. G Omala RL 220 Pinnacle 220 16 50 F up to 2000 FPM 460 7 Compounded 600W Super Cylinder 7 Gear Oil Tribol 1105 7C Cylinder Oil W460 Inca Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 51 95 F up to 450 680 6 Compounded Extra Hecla Super 8 Gear Oil Tribol 1105 8C Cylinder Oil W680 Inca Oil 680 Spartan EP 680 SPO 288 Valvata J 680 Vanguard 680 51 95 F above 450 FPM 460 7 Compounded 600W Super Cylinder 7 Gear Oil Tribol 1105 7C Cylinder Oil W460 Inca Oil 460 Spartan EP 460 SPO 277 Valvata J 460 Vanguard 460 96 131 up to 450 680 85 5 636 Tribol 800 680 Tegra 680 N A Teresstic SHP 680 N A Omala RL 680 Pinnacle 680 96 131 F above 450 FPM 460 7S SHC 634 N A Tribol 800 460 Tegra 460 SynconR 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 55 SECTION 3 PREVENTATIVE MAINTENANCE DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE Note The maintenance procedures detailed here are manufacturer s instructions for the WINSMITH bra
97. G POWER DISTRIBUTION BLOCK 5 GROUND 9 DRIVE MOTOR CONTACTOR WASH PUMP MOTOR CONTACTOR FINAL RINSE RELAY p PRE WASH PUMP MOTOR CONTACTOR e 1 WASH TANK FILL RELAY m ane PRE WASH TANK FILL RELAY o DOOR SAFETY SWITCH RELAY 22 WASH RECIRCULATING RELAY WASTER SOLENOID RELAY DRIVE MOTOR RY YE WASH PUMP MOTOR PRE WASH PUMP MOTOR GRY RINSE RECIRCULATING PUMP DRIVE MOTOR OVERLOAD WASH PUMP MOTOR OVERLOAD 87 RE WASH PUMP MOTOR OVERLOAD DRGZYEL CONTROL FUSE CONTROL 7 SFORMER POWER SWITC ORG YEL WHT DOOR SAFETY DOOR SAFETY u 3 w ME 2 HT REI I GRN WHT o ON RINSE Sw ASH PUMP 2 aon ER LIGHT mn I 5 H PRE FLOAT S R4 PT RS WASH REGULATING THERMOSTAT 9119 LD WATER THERMOSTAT gt VATER VALVE gt LIME ITCH OPTIONAL R WASH FILL SOLENOID 4 odo 5 BRN _ RE WASH FILL SOLENOID gom FIN RINSE SOLENOID MASTER SOLENOID GRY TN 25 BRI 5115 53 25 164 _ SECTION 6 ELECTRICAL SCHEMATICS CONVEYOR SIDE LOADER D226 STEAM BOOSTER 44 INCI CRY GND L1 7 Q 51 D226 STEAM BOOSTER ON Q OFF E 151 THERM
98. HP 11 06 WASH HEATER LOAD 15KW 417A 377A 18 8A TOTAL AMP LOAD HOT WATER CHEMICAL SANITIZING 6 9 FPM CONVEYOR SPEED 6 5 FPM 160 F MIN WASH TANK TEMPERATURE 140 F MIN 180 F MIN FINAL RINSE TEMPERATURE 140 MIN 20 5 PSI FLOW PRESSURE 20 5 PSI NOTE SEE INSTRUCTION IN MANUAL FOR MODIFYING MODE OF SANITIZING SANITIZATION US Patent Number s LISTED 6 012 567 Commercial Canadian Patent Number s Dishwasher 2 205 331 597G Made in the USA Jackson MSC Inc Box 1060 Barbourville KY 40906 606 523 9795 09905 021 70 81 E Please note the parameters for both modes of sanitization If your data plate has this information it is convertible from one mode to another Retighten the Bottom Jam Nut against the Top Jam Nut _ Adjustment Nut Top Jam Nut Bottom Jam Nut Figure 2 Figure 1 Drive Mechanism 48 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING DUAL SANITIZATION MODE CONTINUED THERMOSTAT ADJUSTMENT Remove the front dress panel from the machine to expose the heater thermostat box Remove the cover from the heater thermostat box Locate the wash tank regulating thermostat see diagram Wash Thermostat The wash tank regulating thermostat will maintain the correct wash water temperature NSF requirements specify that the wash water during operation be 140 F minimum in the chem ical sanitizing
99. J amp M V 148611 01 y9eY 9 81 11 SPECIFICATION INFORMATION SECTION 1 AJ 66 ELECTRIC RIGHT TO LEFT epis 4 14014 epis Je uupsz OL 7 _ uuze eT 921701 uuzgi 9 1 1 11 1 1 1 5 Wun 98 pe 019 Suq 110 799 93 8 5 9 03 usiq 9 52 3 06 16569 94 09 6 229 6 8 u L 669 lt 9 2 1 019 vz 97 v wwzoll v wwgoz g I Ly 901 22 9 9802 28 0 951 9 99 7 JO 40014 yun 9958 2 699 22 I 012 i7 398 YSEMAd 9 sz 12 uuuges 12 MT EE oid dL 142121 291 22 227 23 52 i y 9
100. MP 15 AMP 15 AMP SECTION 1 SPECIFICATION INFORMATION n ELECTRICAL REQUIREMENTS CONTINUED D226 STEAM BOOSTER PARAMETERS AJ 80CE CEL MODELS D226 STEAM BOOSTER TYPICAL TOTAL ELECTRICAL ELECTRICAL REQUIREMENTS VOLTS PH HZ AMPS CIRCUIT VOLTAGE V 200 230 ap FREQUENCY HZ 50 60 220 3 50 62A 80 AMP PHASE SINGLE 230 3 50 63A 80 AMP 380 3 50 34A 45 AMP 415 3 50 25A 35 AMP WATER REQUIREMENTS 440 3 50 22 30 INCOMING WATER TEMPERATURE MINIMUM 110 F FLOW PRESSURE PSI 20 5 208 1 60 125 230 1 60 84 110 STEAM REQUIREMENTS 200 3 60 53A 70 AMP INCOMING STEAM PRESSURE PSIG 15 25 208 3 60 54A 70 AMP 330 3 zn 22 512 HEAT EXCHANGER SPECIFICATIONS 380 3 60 34 45 TUBESIDE WORKING PRESSURE PSI 125 460 3 60 25A 35 AMP SHELLSIDE WORKING PRESSURE PSI 125 600 3 60 22A 30 AMP TUBESIDE HYDROSTATIC TEST PRESSURE PSI 250 SHELLSIDE HYDROSTATIC TEST PRESSURE PSI 188 AJ 80CS CSL MODELS MAXIMUM OPERATING TEMPERATURE 295 TYPICAL MAXIMUM SHELLSIDE STEAM PRESSURE PSI 125 TOTAL ELECTRICAL VOLTS HZ AMPS CIRCUIT Indicates typical design criteria but is subject to change 2 2 AME without notice For more information contact you authorized 230 3 50 19A 25 AMP Jackson service representative 380 3 50 15 72 BA IE AME STEAM RELIEF VALVE SET PRESSURE PSI 50 440 3 50 8A 15 AMP WATER OUTLET SAFETY VALVE SET PRESSURE PSI
101. OSTAT 851 SOLENOID COIL 51 POWER SWITCH POWER LIGHT E2 SOLENOID LIGHT 165 SECTION 6 ELECTRICAL SCHEMATICS EXHAUST FAN HOOK UP SCHEMATICS L2 CUSTOMER SUPPLIED RED YEL 250 B TERMINAI CUSTOMER PROVIDED AN CONTACTOR RED BLK 9905 002 55 86 RED YE A 250V RED BLK BLU BLK 9905 003 14 58 166
102. S AJ 66CS CSL 8 AJ 80CS CSL 200 208 220 230 VOLT 50 60 HZ 3 PHASE SECONDAY SIDE 23 20 BLK ORG Hr BLK HT BL HT 4 BLK HT BLK ORG BLU BLK ORG BLU BLI IT BLK Re OF H lt HK BLK TSI 2 wHT BLU BLK HT BLK GRY HT BLK RY NHT BLK WHT BLK WHT E 2 TLS se BLK WH 228 BLU BLK BLK WHT 2 HK Ake 1 ORG LEGEND Ak L1 Le L3 POWER DISTRIBUTION BLOCK ot BRE GND GROUND gle Re DRIVE MOTOR CONTACTOR ASH PUMP MOTOR CONTACTOR R4 FINAL RINSE RELAY 5 PRE WASH PUMP MOTOR CONTACTOR GRY YEL e ASH TANK FILL RELAY PRE WASH TANK FILL RELAY DOOR SAFETY SWITCH RELAY DRIVE MOTOR ASH PUMP MOTOR PRE WASH PUMP MOTOR DRIVE MOTOR Dv WASH PUMP MOT PRE WASH PUMP MOTOR D CONTROL CIRCUIT BREAKER JHT RED CONTROL RANS T DIS OLTAGE SIGNAL ITCH 2 TCH 1 OOR SAFETY lt 2 84 ASH PUMP SWITCH 1 5 ASH PUMP SWITCH 2 AUTO MAN DELIME SWITCH FINAL RINSE SWITCH WASH PUMP SWITCH ER LIGHT t d SH FLOA TS BLK Y ASH FILL SOLENOID HEAT SOLENGID E WASH FILL SOLENOID IAL RINSE SOLENOID H Fo HT BLK M SECTION 6 ELECTRICAL SCHEMATICS AJ 66CS CSL amp AJ 80CS CSL 380 415 440 460 600 VOLTS 50 60 HZ 3 PHASE PRIMARY SIDE GN
103. S LOCATED TO THE RIGHT OF THE DISHMACHINE THE RINSE TANK INLET PIPE IS ROTATED 180 TO ACCOMMODATE THE HOSE COMING FROM THE OPPOSITE DIRECTION NOTE HOWTHE 90 ELBOW SWITCHES TO THE OPPOSITE SIDE OF THE PIPING TEE TOACCOMMODATE THE HOSE COMING FROMTHE OPPOSITE DIRECTIONS CONNECTION HOSES ARE CUT TO LENGTH DURING INSTALLATION ENOUGH HOSE IS PROVIDED TO LOCATE THE GAS BOOTER HEATER APPROXIMATELY 9 FEET AWAY FROM THE DISHMACHINE ADDITIONAL HOSE MUST BE ORDERED IF A GREATER DISTANCE IS REQUIRED DISTANCES GREATER THAN 20 FEET AWAY CAN AFFECT THE HEATING PERFORMANCE OF THE UNIT HOSES MARKED A IN THE ABOVE ILLUSTRATIONS CONNECT TO THE INLET wATER CONNECTION OF THE GAS BOOSTER HEATER HOSES MARKED B IN THE ABOVE ILLUSTRATIONS CONNECT TO THE OUTLET WATER CONNECTION OF THE GAS BOOSTER HEATER ITEMS MARKED C ARE THE INCOMING PLUMBING CONNECTIONS TO MACHINE THAT SHOULD 110 140 DEGREES 45 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATING INSTRUCTIONS PREPARATION Before proceeding with the start up of the unit verify the following 1 Close door s on dishmachine 2 Close the drain valve s POWER UP ELECTRICALLY HEATED MODELS To energize the unit turn on the power at the service breaker The volt age should have been previously verified as being correct If n
104. T a BLK WHT BL DRG BLU WHT e BLK FS sj E RS 8 WESW2 T ORG BLU 4 BLK WHT lt Re IT YEL R7 DRG WET 23810 ORG WHT 3 K W 2 ORG oN RED di HT BLU RED 4 BLK WH 151 C uRG BLK 152 5 HT BLL HT 3 e BLK W GRE Y Y CXR X L Li Le L3 GREY R3 GND A ae R1 31 n GREY ORI R3 2115 DA 24 96 GRE 2M0L uS Li 22 1 96 95 4 5 GREY 114111 FUS RANSFORMER FUSE 1 ER a AARNES GRE DE R CONNECTION 5 SIGNAL Se S3 1 ny 6 S 2 GRE on RG YE S5 SWITCH 4 ORG YEL fes S6 B LIGHI 23 WoT or E R4 FSWe ITCH 2 8 151 THERMDSTAT VES SAN CH SOLENO ERMOSTA DPTIDNAL ID 130 wama SECTION 6 ELECTRICAL SCHEMATICS AJ 44CE CEL 440 VOLTS 50 HERTZ THREE PHASE FIVE WIRE PRIMARY SIDE 131 Fre ete of bo F waw SECTION 6 ELECTRICAL SCHEMATICS www AJ 44CE CEL 440 VOLTS 50 2 PHASE FIVE WIRE SECONDARY SIDE 1 K 9 K WF SWE M 2 54 v
105. act a qualified service agency to examine the problem Do not run the dishmachine if the voltage is too high or too low Shut off the service breaker and mark it as being for the dishmachine Advise all proper per sonnel of any problems and of the location of the service break er Replace the control box cover and tighten down the screws Incoming Power Connection VENTILATION OF DISHMACHINE The dishmachine should be located with provisions for venting into an adequate exhaust hood or ventilation system This is essential to permit efficient removal of the condensation exhaust Ensure that the exhaust System is acceptable in accordance with all applicable codes and standards NOTE Any damage that is caused by steam or moisture due to improper ventilation is NOT covered under the war This units covered in this manual have the following exhaust requirements Load End 200 CFM Unload End 400 CFM 31 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CONTINUED The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to ELECTRIC HEAT The thermostats for the machines covered in this manual are factory set They should not be adjusted except by an authorized service agent CHEMICAL FEEDER EQUIPMENT The AJ 44CEL CSL AJ 66CEL CSL and AJ 80CEL CSL are designed to operate with a third party chemical injection system Jackson does not endorse any p
106. articular chemical injection system The system select ed must be able to provide detergent and sanitizer in the required concentrations The minimum chlorine concentration for prop er sanitization is 50 PPM Furthermore the selected feeder needs to be able to operate against a head of 25 PSI and deliver 7 38 ml of a 10 chlorine sanitizer per minute Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting Remove the bulkhead plug in the side of the tub to install the detergent concentration probe For more information concerning detergent concerns please refer to Brass Plug the page entitled Detergent Control Detergent Connection Point Machine rear view sanitizer and rinse aid injection fittings ___ Brass Plugs Back of Control Box wires for the chemical injectors should be routed through one of the extra openings in the back of the control box Terminals the control box marked CVS provide a constant voltage signal whenever the drive motor is operating Terminals in the control box marked DET provide a voltage signal whenever the wash motor 115 operating Aid Connection Points 32 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DELIMING OPERATIONS DELIMING OPERATIONS In order to maintain the dishmachine at its optimum performance level it will
107. ation for 16 hours per day or 10 days of operation for 24 hours per day Subsequent oil changes Under normal conditions after the initial oil change the oil should be changed after every 2500 hours of operation or every 6 months whichever occurs first Under severe conditions rapid temperature changes moist dirty or corrosive envi ronment it may be necessary to mchange oil at intervals of one to three months Periodic examination of oil samples taken from the unit will help establish the appropriate interval Synthetic oils Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable 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 dam age to seals or other components It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation to remove metal particles that accumulate during break in Subsequent oil changes should be made after 5000 hours operation if units are operating in a clean environment This can be extended to 10 000 hours if using new reformulated Mobil SHC lubricants orange in color and the lubri cant remains free of contamination over this period See comments under Subsequent oil changes for discussion of severe ambient con
108. be required to remove lime and corrosion deposits on a frequent basis A deliming solution should be available from your detergent supplier Read and follow all instructions on the label of the deliming solution To proceed with the deliming operation fill the dishmachine and add the correct amount of deliming solution as recommended by the deliming solution manufacturer The water capacity of the various tanks of the dishmachine can be verified on the spec ification sheet s of this manual Perform the following operations to delime the dishmachine 1 Turn the AUTOMATIC DELIME switch on the back of the control box to the DELIME position P 3 2 2 Disconnect or turn off all chemical feeder pumps MANUAL DELIME 3 Close all doors after adding the deliming solution 4 Run the machine for the recommended period of time 5 Turn the unit off and open the doors Delime Switch 6 Wait five minutes then inspect the inside of the machine If the machine is not delimed run another time cycle as per the deliming solution s instructions 7 When clean drain and re fill the machine 8 Run in MANUAL for 10 minutes to remove residual deliming solution 9 Drain and re fill the machine This equipment is not recommend for use with deionized water or other aggressive fluids Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components Use of deionized water or other aggressive
109. ce on the dishmachine could lead to larg er problems or even cause harm to the operator If a problem is discovered secure the dishmachine using proper shut down procedures as listed in this manual and contact Jackson Some problems however may having nothing to do with the machine itself and no amount of preventative maintanence is going to help A common problem has to do with temperatures being too low Verify that the water temperatures coming to your dishmachine match the requirements listed on the machine data plate There can be a variety of reasons why your water tem perature could be too low and you should discuss it with Jackson to determine what can be done By following the operating and cleaning instructions in this manual you should get the most efficient results from your machine As a reminder here are some steps to take to ensure that you 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 bei
110. contact Jackson There are many things that operators can do to prevent catastrophic damage to the dishmachine One of the major causes of component failure has to do with prescrapping procedures A dishmachine is not a garbage disposal any large pieces of mate rial that are put into the machine shall remain in the machine until they are either broken up after spreading out on your ware or physically removed Strainers are installed to help catch debris but they do no good if they are clogged Have operators reg ularly inspect the pan strainers to ensure 1 that they are free of soil and debris and 2 they are laying flat in the tub When cleaning out strainers do NOT beat them on waste cans The strainers are made of metal and can be forgiving but once severe damage is done it is next to impossible for the strainer to work in the way it was designed to Wipe out strainers with a rag and rinse under a faucet if necessary For stubborn debris a toothpick should be able to dislodge any obstructions from the perforations Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub You may wish to also refer to the page entitled Detergent Control in order to learn more about how your water hardness will effect the 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 maintenan
111. ctors including overloading overfilling underfilling or inadequate cooling Nominal Ratio Size 5 7 5 10 15 20 25 30 40 50 60 80 100 920 0347 0 268 0 225 0 216 0202 0 191 0 215 0200 0 188 0 182 0 164 0 161 Lubricant selections are provided by the lubricant manufacturer based on AGMA recommeded viscosity grades Viscosity grades are based on Lubrication Standard ANSI AGMA 9005 D94 56 SECTION 4 TROUBLESHOOTING SECTION SECTION 4 TROUBLESHOOTING N COMMON PROBLEMS WARNING Inspection testing and repair of electrical equipment should be performed only by qualified service per sonnel Certain procedures in this section require electrical tests or measurements while power is applied to the machine Exercise extreme caution at all times If test points are not easily accessible disconnect power attach test equipment and reapply power to test When replacing electrical parts disconnect power at source circuit breaker Problem Nothing on dishmachine operates The power switch is ON and the power indicator light is OFF 1 Machine is not wired correctly to incoming power source Have an electrician verify wiring 2 Machine circuit breaker is tripped Reset the circuit breaker If it trips again contact an electrician to verify the machine amp draw 3 Service breaker is tripped Reset the service breaker If it trips again contact an electrician to verify the machine amp draw Problem Machine will not fill The power switch
112. dance with applicable codes The D226 Booster is designed to operate at a water flow rate of 20 5 PSI The assembly comes with water pressure reg ulator which is preset at the factory However adjustment may be required so ensure that you verify the the flow pressure before beginning operations See the instructions regarding adjustment and maintenance of the water pressure regulator for more information WARNING The D226 Booster is designed to heat water to a minimum of 180 F and is extremely hot during operations Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur This equipment is not recommend for use with deionized water or other aggressive fluids Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components Use of deion ized water or other aggressive fluids will void the manufacturer s warranty 42 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION amp OPERATION INSTRUCTIONS CONTINUED ELECTRICAL WARNING Electrical and grounding connections must comply with applicable portions of the National Electrical Code ANSI NFPA 70 latest edition and or other electrical codes Disconnect electrical power supply and a tag or lock at the disconnect switch to indicate that you are working on the circuit Terminal Block To connect the incoming power run the conduit for powe
113. e 04730 011 87 04 Service Note Copper tubing should be purchased locally and cut to length lengths provided in parts list above 88 SECTION 5 PARTS SECTION AJ 66CGP RIGHT TO LEFT DRAIN PLUMBING ASSEMBLY 3 4 10 4 3 5 6 5 3 4 lt _________6 lt b lt 12 4 lt 2 lt 14 1 3 10 13 35 DESCRIPTION Elbow 1 1 2 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 9 Tube Length Chart Item 4 7 8 Length Inches 1 1 2 x 1 7 8 1 1 2 x 5 3 16 1 1 2 x 8 1 8 Mfg No 04730 206 32 00 04820 011 71 46 04730 401 25 01 See Chart 04730 011 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 89 ws SECTION 5 PARTS SECTION DRAIN QUENCH SYSTEM Schematic lt 2 lt 1 lt 9 3 To Dishmachine Drain 10 T Cold Water Supply i 8 gt 2277 27 7 25 x To Drain 6 From the existing drain attach the two additional Tees Item 7 using the 1 1 2
114. e able to adjust the over all height of the unit by turning the bullet feet from between 75 1 2 to 76 1 2 Frame with Adjustable Foot PLUMBING THE DISHMACHINE plumbing connections must comply with all applicable local state and national plumb ing codes The plumber is responsible for ensuring that the incoming water line is thoroughly f ushed 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 f Iter 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 must be a minimum 1 1 2 and should not be reduced There must also be Locking nut x an air gap between the machine drain line and the f oor sink or drain If a grease trap is required by code it should have af ow capacity of 30 gallons per minute Adjusting
115. e against a head of 25 PSI and deliver 7 38 ml of a 1096 chlorine sanitizer per minute FINAL CHECK Verify that the incoming water matches the flow pressure and temperature requirements listed on the machine data plate Verify that minimum wash and rinse tem peratures are maintained during operation 49 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DETERGENT CONTROL Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate Using detergent in the proper amount can become in time a source of substantial savings A qualified water treatment spe cialist can tell you what is needed for maximum efficiency from your detergent but you should still know some basics so you ll understand what they are talking about First you must understand that hard water greatly effects the performance of the dishmachine Water hardness is the amount of dissolved calcium and magnesium in the water supply The more dissolved solids in the water the greater the water hard ness Hard water works against detergent thereby causing the amount of detergent required for washing to increase As you use more detergent your costs for operating the dishmachine will increase and the results will decrease The solids in hard water also may build up as a scale on wash and rinse heaters decreasing their ability to heat water Water temperature is important in removing soil and sanitizing dishes If th
116. e water cannot get hot enough your results may not be satisfactory This is why Jackson recommends that if you have installed the machine in an area with hard water that you also install some type of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine Second hard water may have you adding drying agents to your operating cycle to prevent spotting when the real problem is deposited solids on your ware As the water evaporates off of the ware the solids will be left behind to form the spotting and no amount of drying agent will prevent this Again using treated water will undoubtedly reduce the occurrences of this prob lem Third treated water may not be suitable for use in other areas of your operation For instance coffee made with soft water may have an acid or bitter flavor It may only be feasible to install a small treatment unit for the water going into the dishmachine itself Discuss this option with your qualified water treatment specialist Even after the water hardness problems have been solved there still must be proper training of dishmachine operators in how much detergent is to be used per cycle Talk with your water treatment specialist and detergent vendor and come up with a complete training program for operators Using too much detergent has as detrimental effects as using too little The proper amount of detergent must be used for job It is important to remember that cer
117. ect the threads while putting the plumbing back together Ensure that the wash drain barb is in the exact same position it was prior to this step 18 On the underside of the tub remove the rinse drain weld ment and the rinse drain plug Switch their locations so that the rinse drain weldment is in the spot that the rinse drain plug was in Removing the rinse drain plug 19 Reconnect the rinse drain hose and the wash drain hose to the drain plumbing 20 On the opposite end from where they were removed install the front and rear rinse pan assembly locating brackets Note the brackets are mounted to the bolts that secure the tub weldment to the frame Install the brackets one at a time and ensure that they are firmly tightened down once installed 21 Remove the hole cover weldment from the top of the hood The cover is located on the end of the hood opposite of the rinse injector weldment Once removed set to the side along with its gasket 37 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED Removing the hole cover weldment 22 Separate the rinse plumbing from the rest of the incoming plumbing by loosening the union Ensure that the gasket on the bottom of the rinse injector stays with the assembly as you remove it 7 WAY Loosening the union on the incoming plumbing 23 Remove the remaining half of the union from the incoming plumbi
118. eft to Right 05700 031 81 53 Opposite Rail 05700 041 74 13 Actuator Switch Replacement Kit 06401 003 10 85 Actuator Switch Replacment Kit 06401 003 10 14 105 SECTION 5 PARTS SECTION MISCELLANEOUS PARTS AND WELDMENTS Plate Left Water Plate Right Water Directional Directional 05700 021 79 27 05700 021 79 23 Run Off Sheet Weldment Splash Shield Weldment 05700 021 71 39 05700 031 85 16 Replacment Kit Note The kit for the hole direction plate comes with the plate a new gasket and the mounting hardware Hole Direction Plate Replacment Kit Pipe Clamp 06401 003 10 00 05700 000 35 05 Rinse Drain Plate Replacment Kit Rinse Drain Plug Replacement Kit CGP Models Only 06401 003 10 06 1 003 10 07 Rinse Drain Weldment Replacement Kit 06401 003 10 05 Replacement Kits Notes The kits for the drain weldments and drain plugs come with the weldments parts a new gasket and the mounting hardware Rinse Drain Plate Gasket 05330 011 72 27 106 SECTION 5 PARTS SECTION MANIFOLDS STRAINER SUPPORT WELDMENTS Prewash Manifold Weldment AJ 66 Models Only 05700 031 69 70 Wash Manifold Weldment gt Prewash Manifold Weldment 05700 031 71 13 AJ 80 Models Only 05700 002 24 94 Wash Manifold Weldment CGP Models Only 05700 002 51 14 Prewash Manifold Weldment CGP Models Only 05700 002 59 51 Wash Fill Tube Weldment Vellumoid Gasket 05700 021 71 21 0
119. ejqejsn pe 100 4 240 Jeuondo LdN uonoeuuoo Buiquunid 0 9 3071 35011 3914 d pJepuejs 3 Jeuondo 9 2 L uonoeuuo 9 uonoeuuoo 2 3 8 dui9j MO7 4 07 4 08 LAN 1 lu V 0 14614 18 SPECIFICATION INFORMATION AJ 80 GAS LEFT TO RIGHT SECTION 1 epis 14 14014 epis 427 uz or 1 5162 uwzsilo 1 1 11 1 1 1 1 N 4 gt Sud H 3 9 98 6901 Lp deos lt 19 p n Even usiq 91 292 UBIH OL 11989 92 6 116 5 66 H 09 799 x 3 4 wwe tet 71 10 z m M 1 7 1 9021 8 9 ve
120. ep Name Phone No SECTION TABLE OF CONTENTS DESCRIPTION SPECIFICATION INFORMATION Operating Characteristics Electrical Requirements D226 Steam Booster Parameters AJ 44 Electric Left to Right AJ 44 Electric Right to Left AJ 44 Gas Left to Right AJ 44 Gas Right to Left AJ 44 Steam Left to Right AJ 44 Steam Right to Left AJ 66 Electric Left to Right AJ 66 Electric Right to Left AJ 66 Gas Left to Right AJ 66 Gas Right to Left AJ 66 Steam Left to Right AJ 66 Steam Right to Left AJ 80 Electric Left to Right AJ 80 Electric Right to Left AJ 80 Gas Left to Right AJ 80 Gas Right to Left AJ 80 Steam Left to Right AJ 80 Steam Right to Left Side Loader Left to Right Dimensions Side Loader Right to Left Dimensions Side Loader Installed Dimensions D226 Steam Booster Dimensions D226 Steam Booster Plumbing Line Drawings Typical Electric and Gas Booster Dimensions INSTALLATION amp OPERATION INSTRUCTIONS Installation Instructions Deliming Operations Changing the AJ 44CE CS Direction of Travel Curtain Installation Diagrams Side Loader Installation amp Operation Instructions D226 Steam Booster Installation amp Operation Instructions Gas Conveyor Hose Installation Dishmachine Operating Instructions Changing Dual Sanitizatio Mode Detergent Control Striker Plate Limit Switch Installation Instructions PREVENTATIVE MAINTENANCE General Maintenance D226 Maintenance
121. es with the switch two spac ers and the mounting hardware 103 SECTION 5 PARTS SECTION AJ 66 RACK RAIL ASSEMBLIES Left to Right Assembly Rack Rail Weldment 05700 031 76 27 Opposite Rack Rail 222 05700 041 71 37 5 lt 2 e y 4 Actuator Switch Replacement Rack Guide Spacer i 06401 003 10 99 8 05700 011 71 44 p d 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 14 104 Actuator Switch Replacment Kit 06401 003 10 83 SECTION 5 PARTS SECTION AJ 80 RACK RAIL ASSEMBLIES Left to Right Assembly Rack Guide Spacer 05700 011 71 44 Actuator Switch Replacement Kit 06401 003 10 14 Right to Left Assembly Rack Guide Spacer 05700 011 71 44 Rack Guide Weldment Right to Left 05700 031 81 54 Opposite Rail 05700 041 74 14 Replacement Kit Notes The replacement kits for the actu ator switches come with the switch mounting hardware two spacers and the Rack Guide Weldment L
122. fluids will void the manufacturer s warranty 33 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL The AJ 44 dishmachine has the ability to have its direction of travel changed from left to right or from right to left Direction of travel is determined by which end the rack of ware is put into the machine and which end the rack comes out There may come times when it is necessary to change the direction of travel after the unit is installed The instructions provided here are for maintenance personnel only Unauthorized persons should not attempt any of the steps contained in these instructions Warning many of the instructions and steps within this document require the use of tools and may also require that personnel change the wiring of the machine Only authorized personnel should ever perform any maintenance evolution on the dishmachine PREPARATION 1 Power must be secured to the unit at the service breaker Tag or lock out the service breaker to prevent acci dental or unauthorized energizing of the machine 2 Disconnect incoming water at the water pressure regulator or Y strainer 3 Disconnect the service drain line from the drain plumbing of the dishmachine itself Ensure that the unit is completely drained before doing this 4 Remove the locking screw from the control box 5 Remove the front dress panel TOOLS REQUIRED The following tools will be needed to perfo
123. fy that the plumbing has been reassembled correctly and that the hole cover weldment has been replaced and none of the gaskets are torn or pinched as this could lead to leaking when the machine operates 35 Re install the heater box cover SPECIAL PARTS Gasket Rinse Injector Mfg No 05330 111 42 81 Incoming plumbing assembly for a Left to Right machine note hole cover weldment in lower right corner Incoming plumbing assembly for a Right to Left machine note hole cover weldment in upper left corner AFTER MAINTENANCE ACTIONS 1 Reconnect the incoming water and drain lines and then restore power to the unit Run the unit for at least 1 2 hour to ensure there are no leaks Test the unit with an empty rack to ensure that it pulls the rack all of the way through the unit If any problems arise you can contact your Jackson rep resentative 2 Replace the front dress panel once the unit is ready for service again SPECIAL NOTES 1 There is a possibility that you may be required to shorten or lengthen the conduit and wire lengths for the inlet solenoid on the rinse plumbing once it is moved This work should be performed by qualified technicians who will do the work according to applicable local state and national codes Questions concerning this should be directed to your Jackson representative CURTAIN INSTALLATION DIAGRAMS SECTION 2 INSTALLATION OPERATION INSTRUCTIONS Please refer to the chart for place
124. he 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 TABLE LIMIT SWITCH THROUGH ROD HOLES TABLE SWITCH RODS STRIKE PLATE MOUNTING BOLTS TABLE BOTTOM 90 75 Unless noted all dimensions are in inches STRIKE PLATE BOLTS INSTALL AT FAR END OF TABLE 1 3 RACK WIDTH 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 51 3 00 2 00 1 875 0 25 4 50 TABLE BOTTOM 41 SECTION 3 PREVENTATIVE MAINTENANCE waww 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
125. he 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 68 The thermostat range is from 140 to 240 with a maximum bulb exposure temperature of 300 Calibration Wash Thermostat Set Point 165 F Adjustable range Hi Llmit Thermostat Fixed set point 210 F Non adjustable SECTION 5 PARTS SECTION THERMOSTATS HEATER ASSEMBLY CONTINUED THERMOSTATS DRESS PANELS 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 for 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 To order the thermostats and corresponding decals Kit Thermostat Wash Regulating CE CEL Models Kit Thermostat Wash Regulating CS CSL Models Thermostat High Limit Control Heater Box Weldment Heater Box Cover Terminal Board AJ 44 s AJ 44CGP AJ 66 s AJ 66CGP AJ 80 s HEATER BOX COMPONENTS FRONT DRESS PANELS Left to
126. he regulator 4 Water pressure gauge is faulty or the cut off from the system Verify that the test cock valve under the gauge is open to allow for the sensing of line pressure Replace gauge if necessary 5 Heat exchanger is clogged Replace the heat exchanger Problem Solenoid valve is not opening shutting 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light 2 Service breaker tripped or open Verify that the breaker is closed 3 Power switch connections could be loose Ensure that the connections are of sound quality 4 Power switch is faulty Replace the power switch 5 Thermostat is faulty Replace the thermostat 6 Solenoid wires are loose or broken Verify that the electrical connections are of sound quality 7 Faulty solenoid coil Replace the solenoid Problem Outlet water temperature too low 1 Power not connected to the unit through the control box Open the control box cover and verify that incoming power lines are connected and light Service breaker tripped or open Verify that the breaker is closed Power switch connections could be loose Ensure that the connections are of sound quality Power switch is faulty Replace the power switch Thermostat is faulty Replace the thermostat Solenoid wires are loose or broken Verify that the electrical connections are of sound quality Faulty solenoid coil Re
127. heck 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 thermometer 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 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 DN 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 t
128. in the unit and turn the spin nut so that it is all the way down This needs to be done because in a further step if the spin nut is out it will get in the way Do not over tighten the spin nut as it only needs to be out of the way not secured SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED 4 Remove the upper wash arm assembly bracket This step may require that you have help as the bolts for securing the bracket to the top of the inner hood are the same bolts that hold the control box to the hood top Do not remove the bolts once the nuts are taken off Once the bracket is removed place the nuts immediately back on the bolts To hold the bolts to keep them from spinning a 7 16 combination wrench or 7 16 nutdriver will be required in order to hold the bolt head inside the control box Removing bracket bottom view Removing bracket control box view Remove the locknuts from the opposite bolts used to hold down the control box do not remove the bolts and secure the bracket to underside of the hood The folded part of the brack et should be facing the rear of the machine Immediately tight en down the locknuts 5 Remove the splash shield which is bolted to the underside of the hood next to the wash manifold and turn it 180 35 Removing and turning splash shield 6 Remove the pawl bar and set to the side Remove the pawl bar by grasping fi
129. irements 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 50 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions 1 Wiring The switch is wired common and nor mally open because of the hinge design By interrupting the line in series with the door switches the dishmachine ceases to operate Refer to the machine schematic for details on how to wire the switch 2 Parts of the table switch are mounted in the dishtable at the end of the table and under the table See the drawing s for the relationship of the switch to the table 3 Move the limit switch as far down on the two slots as possible and see that the limit switch is straight on t
130. is ON and the power indicator light is ON 1 No water supply to machine Verify that water lines have been connected to the machine 2 Dishmachine doors are not closed Close doors completely 3 Incoming water solenoid valve damaged faulty Verify that the valve is operating If not replace 4 Tank floats faulty Verify the wiring of the floats Verify that no debris is jamming the floats Replace if necessary Problem Machine fills but fill is weak 1 Low incoming water pressure Verify that incoming water pressure during fill 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 noz
131. ison Assembly with Hardware 06401 231 81 00 Pawl Bar Weldment 05700 031 72 77 AJ 66 Complete Assembly with Hardware 06401 141 74 64 AJ 66 Prison Assembly with Hardware 06401 241 74 64 Pawl Bar Dog Casting 18 per 05700 021 69 00 7 05700 031 72 78 101 SECTION 5 PARTS SECTION AJ 80 PAWL BAR ASSEMBLIES Bolt 3 8 16 x 1 3 4 Long 05306 011 36 94 Pawl Bar Dog Casting 05700 021 69 00 Pawl Bar Weldment 05700 031 74 19 AJ 80 Complete L R Assembly Pawl Bar Spacer 06401 141 81 06 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 05700 011 71 45 AJ 80 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 assembly 102 waw SECTION 5 PARTS SECTION _ AJ 44 RACK RAIL ASSEMBLY X Rack Rail Weldment LON 05700 031 67 59 4 2 Opposite Rack Rail Vx 05700 031 69 48 Spacer 6 per 05700 011 71 44 Actuator Switch Replacement Kit 06401 003 10 14 Replacement Kit Note The replacement kit for the actuator switch com
132. its for the drive linkages come also with the hardware for mounting them to the pawl bars Drive Linkage Replacement R L 06401 003 11 60 Replacement Kit Note The conveyor switch replacement kit comes with the switch a termi nal and a wire nut See page entitled Pawl Bar Miscellaneous Components for other parts used on the Side Loader Service Note The cord for the conveyor switch needs to be cut to length in the field and have the Pawl Bar Roller Bracket pink terminal applied there 05700 031 77 94 113 SECTION 5 PARTS SECTION _ to be cut to length in order to fit prop erly on the unit when replaced Replacement Kit Note The replacement kit s for the vent cowls come with the cowls the gaskets and mounting hardware 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 Vent Cowl Gasket Top 05330 031 83 47 Vent Cowl Gasket Sides 05330 031 83 48 VENT SCOOP OPTION STANDARD ASSEMBLY Vent Scoop Assembly Vent Cowl Cover Replacement Kit 05700 002 04 08 06401 003 10 16 Vent Cowl Assembly for Hooded Side Loader Option 05700 003 15 66 Replacement Kit Note The cover kit contains the cover and the hardware for mounting it 114 SECTION 5 PARTS SECTION D226 STEAM BOOSTER CONTROL BOX ASSEMBLY Decal Schematic D226 Booster on the inside of the control box c
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134. k for any leaks and repair as required All leaks must be repaired prior to placing the machine in operation ELECTRICAL POWER CONNECTION Electrical and grounding connections must comply with the applicable portions of the National Electrical Code ANSI NFPA 70 latest edition and or other electrical codes Disconnect electrical power supply and place a tag at the disconnect switch to indicate that you are working on the circuit The dishmachine data plate is located on the right side and to the front of the machine Refer to the data plate for machine operating requirements machine voltage total amperage load and serial number Decal showing L1 L2 amp L3 3 phase models only To install the incoming power lines open the control box Install conduit into the pre punched holes in the back of the control box Route power wires and connect to power block and grounding lug Install the service wires L1 L2 and L3 3 phase only to the appropriate terminals as they are marked on the terminal block Install the grounding wire into the lug provided Tighten the connections It is recommended that DE OX or another 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 cont
135. l Rinse Assembly 96 Drive Assembly 97 Door Assemblies 99 Pawl Bar Miscellaneous Components 100 AJ 44 amp AJ 66 Pawl Bar Assemblies 101 AJ 80 Pawl Bar Assemblies 102 AJ 44 Rack Rail Assembly 103 AJ 66 Rack Rail Assemblies 104 AJ 80 Rack Rail Assemblies 105 Miscellaneous Parts amp Weldments 106 Manifolds Strainer Support Weldments 107 Strainers 108 Float Switch Components Scrap Baskets 109 Vent Cowl Assembly Vent Scoop Option 110 Exhaust Fan Control Table Limit Switch 111 SIDE LOADER SECTION Side Loader Track Assembly Leg Replacements Strainer 112 Side LoaderPawl Bar Assemblies Pawl Bar Bracket Magnet 113 Side Loader Vent Cowl Option 114 D226 STEAM BOOSTER SECTION Control Box Assembly 115 Plumbing Assembly 116 Components 118 BC Ferries Options 119 VI TABLE OF CONTENTS ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS AJ 44CE CEL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 460 600 Volt 60 Hz 3 Phase Primary Side 380 460 600 Volt 60 Hz 3 Phase Secondary Side 380 415 Volt 50 Hz 3 Phase Primary Side 380 415 Volt 50 Hz 3 Phase Secondary Side 440 Volt 50 Hz 3 Phase Primary Side 440 Volt 50 Hz 3 Phase Secondary Side 440 Volt 50 Hz 3 Phase 5 Wire Primary Side 440 Volt 50 Hz 3 Phase 5 Wire Secondary Side AJ 44CS CSL 200 230 Volt 50 60 Hz 1 Phase Pri
136. lts and less re washes If not done properly ware may not come out clean and the efficiency of the dishmachine will be reduced It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are good ideas especially for silverware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to sanitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine DAILY MACHINE PREPARATION Refer to the section entitled PREPARATION at the top of this page and follow the instruc tions there Afterwards check that all of the chemical levels are correct and or that there is plenty of detergent available for the expected workload WASHING A RACK OF WARE To wash a rack simply slide a rack of soiled ware into the load end of the machine Once the the machine is started it should pull the rack through the machine and push it out the unload end Once a rack has started through you may put another rack in OPERATIONAL INSPECTION Based upon usage the pan strainers may become clogged with soil and debris as the work day progres
137. ly over the lower wash arm assembly 33 Remove the heater box cover by unscrewing the four screws holding it on Removing the heater box cover 11 Front of rack conveyor showing the conveyor switches 38 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED Conveyor Switch Chart Unit Direction Left to Right pur Rinse Switch Right to Left Rinse Switch n as Q lt The chart above lists the conveyor switches and their func tions depending on the direction of travel for the machine As you can see when you change the direction of the conveyor you must also alter the way the conveyor switches operate There is no need to remove the switches only to change the wiring inside the heater box Terminal board inside the heater box 34 Note Before beginning any part of this maintenance evo lution that deals with the wiring of the machine ensure that it is performed by qualified technicians only Always refer to the machine schematic located inside the control box for any questions Wash Switch 1 and the Rinse Switch need to have their wire positions changed on the terminal board pictured above Locate the gray yellow wire for Wash Switch 1 do not con fuse it with the gray yellow wire for Wash Switch 2 and the orange yellow wire for the Rinse Switch Exchange their posi tions on the terminal board 35 Veri
138. mary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Primary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Secondary Side AJ 66CE CEL amp AJ 80CE CEL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 460 600 Volt 60 Hz 3 Phase Primary Side 380 460 600 Volt 60 Hz 3 Phase Secondary Side 380 415 440 Volt 50 Hz 3 Phase Primary Side 380 415 440 Volt 50 Hz 3 Phase Secondary Side AJ 66CS CSL amp AJ 80CS CSL 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Primary Side 380 415 440 460 600 Volt 60 Hz 3 Phase Secondary Side AJ 44CGP 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 Hz 3 Phase Primary Side 200 230 Volt 50 Hz 3 Phase Secondary Side 460 Volt 60 Hz 3 Phase Primary Side 460 Volt 60 Hz 3 Phase Primary Side AJ 66CGP AJ 80CGP 200 230 Volt 50 60 Hz 1 Phase Primary Side 200 230 Volt 50 60 Hz 1 Phase Secondary Side 200 230 Volt 50 60 Hz 3 Phase Primary Side 200 230 Volt 50 60 Hz 3 Phase Secondary Side 460 Volt 50 60 H
139. ment of the curtains 9 1 133308 08 ZL Sve 42 S 1 SANIHOVW SVO S S adis E 4 1 1 z ale ze 42 zL 2 S 9 s 1 S S S adis H 1 1 Ze S 0 3019 ED S E 7 N 65 S S WVALS 9 OIH IO3 T3 E 40 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS SIDE LOADER INSTALLATION amp OPERATION INSTRUCTIONS This accessory assists in the delivery of a full dish rack from the break down scrapping table to the dishmachine It will con vert the direction of travel 90 Since the Side Loader is shipped mounted on the conveyor dishwasher there is no additional installation required for this option As it is operated mechanically by the dishwasher it does not require any plumbing or elec trical connections This Side Loader does not require or add any additional electrical or mechanical devices to the unit which could create opera tional or maintenance problems As designed the drive mechanism is powered by the conveyor drive motor
140. mes with the required 3 brass plugs ITEM DESCRIPTION 1 1 Rinse Injector Weldment Replacement Kit 1 Gasket 2 3 Plug 1 8 NPT Brass 3 2 Vacuum Breaker 3 4 NPT 4 2 Valve Solenoid 3 4 NPT 110 Volt 5 3 Elbow 3 4 Street Brass 6 4 Nipple Close Brass 3 4 NPT 7 4 Union 3 4 Copper to Copper 8 2 Adapter 3 4 Fitting x Male 9 1 Elbow 90 3 4 Copper to MSPS 10 1 Tee 3 4 CU x CU x CU 11 2 Tee 3 4 x 3 4 x 1 2 12 2 Fitting Adapter 1 2 to 1 4 13 1 Plug 1 4 NPT Brass 14 1 Test Cock Valve Ball 1 4 NPT 15 1 Gauge Pressure 0 100 PSI 16 1 Nipple Brass 6 Long 17 1 Fill Injector Replacement Kit 1 Gasket 18 1 Tube Copper 19 1 Tube Copper 20 1 Tube Copper 21 1 Tube Copper 22 1 Elbow 3 4 NPT 90 Brass 83 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 411 03 01 04730 401 41 01 04730 209 01 00 04810 011 72 67 06685 111 88 34 05700 001 26 74 06401 003 09 93 05330 111 42 81 See Chart See Chart See Chart See Chart 04730 206 13 00 ws SECTION 5 PARTS SECTION RINSE HEADER PLUMBING ASSEMBLY CGP MODELS ___ Valve 3 4 Pressure Reducing 04820 002 51 53 Y Strainer 3 4 Brass 04730 717 02 06 Solenoid Valve 3 4 110V 04810 100 53 00 2 Elbow 3 4 Slip 3 4 NPT Nipple 3 4
141. mode and 1609 minimum in the hot water san itizing mode Adjust the thermostat to achieve the required minimum temperatures during operation Turn the adjustment screw clockwise to increase the temperature set point coun terclockwise to decrease the temperature set point Replace heater thermostat box cover and front dress panel Control Box Gauge Location IDENTIFICATION OF SANITIZING MODE Apply the correct temperature gauge label to the face of the temperature gauges In the chemical sanitizing mode the temperature gauge labels must specify 140 F minimum wash temperature and 1409 minimum rinse temperature In the hot water san itizing mode the temperature gauge labels must specify 160 F minimum wash temperature and 180 F minimum rinse temperature Apply the correct sanitizing mode label in a visible location on the side of the control box NOTICE THIS MACHINE IS CURRENTLY IN CHEMICAL SANITIZING MODE Yellow background Orange background INSTALL SANITIZER DISPENSER For machines in the chemical sanitizing mode a NSF Standard 29 approved chemical dispenser must be installed to dispense sanitizer into the final rinse line Follow instructions included with the chemical dispenser The system selected must be able to pro vide detergent and sanitizer in the required concentrations The minimum chlorine concentration for proper sanitization is 50 PPM Furthermore the selected feeder needs to be able to operat
142. nd of gear reducer that is installed on the rack conveyors covered in this manual Lubrication amp Maintenance Factory filling WINSMITH speed reducers are oil filled at the factory to the proper level for the standard mounting position that you will find it in on the unit The oil level should be checked and adjusted if necessary prior to operation using the oil level plug provided and while the unit is oriented in its operating position Ambient temperature If the operating ambient temperature is other than 51 95 F then refer to the lubrication chart and refill the unit with the correct grade based on actual ambient temperature and operating speed See Oil changing below for additional information Oil changing When changing the oil for any reason it should be remembered that oils of various types may not be compatible Therefore when changing to a different oil it is recommended that the housing be completely drained and thoroughly flushed with a light flushing oil prior to refilling with the appropriate lubricant The oil level should be rechecked after a short period of operation and adjusted if necessary When changing double reduction models each housing should be drained and filled independently even though there may be a common level Initial oil change The new oil in a speed reducer should be changed at the end of 250 hours of operation This is equivalent to 30 days of peration for 8 hours per day 15 days of oper
143. nd plugs or caps Verify and replace as required Low tank heat Inadequate rinse Incorrect voltage coming to the machine Verify that the voltage matches that on the machine data plate Wash pump cavitation due to low water level Verify that the drains are shut and that the water level is correct Problem Spotting of silverware glasses and dishes 1 Incorrect final rinse temperature Verify that the rinse water temperature matches that which is listed on the machine data plate 2 Clogged wash and or rinse nozzles and arms Remove the arms and verify that they and their nozzles are from debris 3 Excessively hard water Install a water softener to reduce hardness 4 Loss of water pressure due to clogged obstructed wash pump Turn the power off to the machine at the source Drain the wash tank of water and verify that the pump intake is free from debris 5 Improper scrapping procedures Review the paragraph entitled Ware Preparation in Operating Instructions 6 incorrect detergent chemcial concentrations Verify that the detergent chemical concentrations are correct for the associat ed water volume TORQUE SETTINGS When replacing components either in the control box or the heater box area the manufacturer has suggestions on how much to torque the screws and nuts used in securing items to the machine Refer to the table below for the torque specific tions ITEMS TORQUE SPEC Relays 16 In
144. ng 24 Remove the incoming water pressure regulator from the incoming plumbing and replace with the union half that was removed in step 23 Place the water pressure regulator on the end that the union half was removed from 25 Place the removed rinse plumbing assembly with the gas ket in the hole left open from when you removed the hole cover weldment in step 21 Tighten the two halves of the union together 26 Place the hole cover weldment with its gasket over the hole from where the rinse plumbing assembly was originally installed Tighten down with the locknuts 27 Re install the rinse manifold with its gasket by connect ing it to the rinse injector weldment at its new location Remove the locknut from the stud for the bracket down near the rack rails and then secure the bracket to the machine using the same lock nut 28 Re install the lower wash arm support bracket to the pawl bar support on the end of the tub opposite from where it was removed 29 Re install the upper and lower rinse arms Reinstall the lower rinse arm support bracket 30 Re install the lower wash arm assembly turning it 180 and locking it in place with the locking screw 31 Re install the pawl bar Ensure that the pawl bar is placed so that when racks are placed in the unit the pawl bar dogs fold down 32 Re install the upper wash arm assembly If you performed all of the actions outlined in step 2 when you install it it will be direct
145. ng 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 53 SECTION 3 PREVENTATIVE MAINTENANCE D226 MAINTENANCE WARNING Maintenance should only be performed by authorized service personnel in order to ensure safe and effective workmanship while minimizing danger to operating personnel The D226 Steam Booster is designed to operate at temperatures capable of causing burns to personnel Always allow the unit to cool down to an acceptable temperature prior to performing any maintenance Very little maintenance is required to be performed on the D226 Booster So long as the steam and water used with the unit have the proper filtration and are operated at the correct temperature and pressures then you should expect many years of reliable service out of your system MAINTENANCE OF THE WATER PRESSURE REGULATOR Incoming water pressure can be regulated by adjusting the water pressure regulator on the system In order to adjust pressure loosen the top nut on the regulator This will allow you to turn the adjusting screw Turn the adjusting screw clockwise to increase pressure and counter clockwise to decrease Pressure can be read on the pressu
146. nt parts may create a hazard and void war ranty certification The labor to repair or replace such failed part will be paid by Jackson MSC within the continental United States Hawaii and Canada during the warranty period provided a Jackson MSC authorized service agency or those having prior authorization from the factory performs the service Any repair work by persons other than a Jackson MSC authorized service agency is the sole responsibility of the customer Labor coverage is limited to regular hourly rates overtime premiums and emergency service charges will not be paid by Jackson MSC Accessory components not installed by the factory carry a 1 one year parts warranty only Accessory components such as table limit switch es pressure regulators pre rinse units etc that are shipped with the unit and installed at the site are included Labor to repair or replace these components is not covered by Jackson MSC This warranty is void if failure is a direct result from shipping handling fire water accident misuse acts of god attempted repair by unau thorized persons improper installation if serial number has been removed or altered or if unit is used for purpose other than it was origi nally intended TRAVEL LIMITATIONS Jackson MSC limits warranty travel time to 2 two hours and mileage to 100 one hundred miles Jackson MSC will not pay for travel time and mileage that exceeds this or any fees such as those for air or boat t
147. on the dishma chine An extension on the pawl bar provides the drive to push the racks into the unit PREPARATION Before proceeding with the start up of the unit verify that the Side Loader pan strainer is installed WARE PREPARATION Proper preparation of ware will help ensure good results and less re washes If not done properly ware may not come out clean and the efficiency of the dishmachine will be reduced It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are good ideas especially for silverware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to sanitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine WASHING A RACK OF WARE Once a rack is fully loaded it should be positioned against the front of the dish table The rack should then be moved into the Side Loader until it activates the actuator switch Once the the machine is started it should pull the rack through the machine and push it out the unload end Once a rack has started through you may put another rack in OPERATION
148. ose Connection Due to the fact that each customer may have different requirements for the orientation of the gas booster heater relative to the main dishmachine the hose lengths that connect the two units must be customized during each installation The appropriate 3 4 hosing fittings and gaskets have been provided To prevent incorrect measurements of the hose it is recommended to place one barbed hose fitting into the end of the uncut length of hose coil and attach that fitting to an appropriate connection Run the hose to the corresponding connection on the other unit before cutting the hose Use a barbed hose fitting that is screwed into the second connection on the other unit before cutting the hose Use a barbed hose fitting that is screwed onto the second connection to gauge the correct distance Ensure a smooth flow of hose without any sharp turns or kinks To aid in pushing the barbed hose fitting into the hose place the fitting on a hard surface i e the floor with the barbed end of the fitting pointing upward and push the hose down onto the fitting A small amount of lubricant i e petroleum jelly may aid in this process 44 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS GAS CONVEYOR HOSE INSTALLATION CONTINUED 4TYPICAL RECIRCULATING WATER HOOK UP FOR ALL GAS HEATED CONVEYORS HOOKUP WHEN GAS BOOSTER HEATER IS LOCATED TO THE LEFT OF THE DISHMACHINE HOOKUP WHEN GAS BOOSTER HEATER I
149. ot the voltage will have to be verified POWER UP STEAM HEATED MODELS To energize the unit turn on the power at the service breaker The voltage should have been previously verified as being correct If not the voltage will have to be verified Ensure that the steam service is con nected and that steam is flowing to the machine Without steam the water will not reach the required minimum temperatures that the machine is designed to operate at POWER UP GAS HEATED MODELS To energize the unit turn on the power at the service breaker The voltage should have been previously verified as being correct If not the voltage will have to be verified Ensure that the gas service is connected and that gas is flowing to the machine Without gas the water will not reach the required minimum temperatures that the machine is designed to operate at FILLING THE WASH TUB Ensure that the delime switch is in the NORMAL position and place the power switch into the ON position The machine should fill automatically and shut off when the appropriate level is reached just below the pan strainer The wash tub must be completely filled before operating the wash pump to prevent damage to the component Once the wash tub is filled the unit is ready for operation Machines equipped with prewash sections should not be run without water in those sections This can cause damage to components WARE PREPARATION Proper preparation of ware will help ensure good resu
150. out during normal operation 94 SECTION 5 PARTS SECTION IR 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 Curtain 24 1 2 Long x 20 1 2 Wide Short Curtain Decal CGP MODELS ONLY 5 09905 011 73 82 08415 002 47 37 Long Curtain Decal 09905 011 73 84 Extra Long Curtain Decal Curtain Hook CGP MODELS ONLY 05700 011 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 Replacement Kit Note The conveyor switch replacement kit comes with the switch a terminal and a wire nut 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 95 Rinse Arm Support Bracket 05700 011 71 19 O Ring 05330 011 74 55 Retaining Ring Not Shown 05340 112 01 11 Right Rinse Pan Locator Bracket 05700 021 92 37 SECTION 5 PARTS SECTION FINAL RINSE ASSEMBLY Gasket 05330 111 42 81 End plugs can be ordered using N part number 04730 209 07 37 N Upper Rinse Arm Replacement Kit 06401 003 10 08 Final Rinse Manifold Weldment 05700 031 74 88
151. over 09905 002 78 56 Replacement Kit Note The kit for the terminal block replacement includes the block the spacer and the locknut Terminal Block Replacement Kit 06401 003 11 78 b Decal 11 42 B 09905 002 78 67 Ground Lug 05940 200 76 00 Spacer Terminal Block Light Red 05945 111 21 57 Power Switch 05930 011 49 55 Decal Warning Disconnect Power 09905 100 75 93 Control Box Cover p Replacement Kit 06401 003 11 63 The kit for the control box cover comes with the decals and the screws for securing the cover Decal Ground 09905 011 86 86 lt Thermostat 777 06680 500 01 77 Conduit Fitting 231 x 394 05975 011 49 03 Control Box with Decal 06401 002 78 87 115 2 326 1 Y ac 18 17 gt EA 16 19 n IL 13 1 SECTION 5 PARTS SECTION D226 STEAM BOOSTER PLUMBING ASSEMBLY 116 SECTION 5 PARTS SECTION D226 STEAM BOOSTER PLUMBING ASSEMBLY CONTINUED DESCRIPTION Water Pressure Regulator 3 4 Nipple Brass 3 4 NPT x 6 Long U Bolt 6 5 8 11 Thread Platform Weldment Heat Exchanger Steam Trap 3 4 Bushing 2 NPT x 3 4 NPT Black Iron Elbow 3 4 NPT Brass Nipple 1 Close Black Iron Union 3 4 Brass Bushing 2
152. place the solenoid Steam flow pressure is too low for the unit Verify that the steam flow is 15 25 PSIG Water flow pressure is too high Follow the instructions provided in the maintenance section and adjust so that the flow pres sure is 20 5 PSI 10 Heat exchanger is clogged Replace the heat exchanger 11 Insufficient volume of steam to unit Check the line size and flow pressure 60 SECTION 5 PARTS SECTION SECTION 5 PARTS SECTION RR AJ 44 CONTROL BOX ASSEMBLY 11 12 lt 4 8 9 10 4 4 4 14 77 aL X 13 10 17 Y Y 15 19 20 17 4 18 29 22 23 24 21 22 lt 25 26 21 22 21 22 22 28 lt 22 27 62 SECTION 5 PARTS SECTION AJ 44 CONTROL BOX ASSEMBLY CONTINUED ITEM DESCRIPTION 1 1 Electrical Box Weldment 2 1 Terminal Block 3 Pole 3 1 Thermometer 96 Lead 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 Thermometer 48 Lead 8 1 Wire Lug 2 AWG to 14 AWG 9 1 Decal Ground 10 1 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 CGP Models Only 16 1 Switch ON FILL O
153. r wires through the open N hole in the back of the control box Connect the power wires to the terminal block as EM it is labeled L1 and L2 Run the ground wire to the grounding lug marked GND Tight connections and conduit nuts and close the control box by putting the cover on and securing with the 10 32 screws OPERATION WARNING The heat exchanger used in the D226 Booster system is a pres sure vessel with very precise operating parameters Safety equipment such as relief valves should never be tampered with or disabled These devices are meant to protect the equipment and the operator from harm damage and death D226 Conrtol Box 1 Ensure that water steam and any condensate drains are connected to the booster 2 Start the water flow first open the condensate drains and then begin steam flow 3 On the control box press the power switch and put it in the ON position The power light should illuminate The unit should run normally now A WARNING Do not shock the system by applying the steam before the water This can cause damage to the booster The following explanation describes the operation of the D226 Booster NOTE This explanation assumes that water and steam have been connected to the machine 1 When the power switch S1 is placed in the ON position power is provided to both the power light E1 and the thermostat TS1 2 The thermostat TS1 will close when the water falls below the minimum se
154. ravel without prior authorization WARRANTY REGISTRATION To register your product go to www jacksonwws com or call 1 888 800 5672 Failure to register your product will void the warranty REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the factory which ever occurs first PRODUCT CHANGES AND UPDATES Jackson MSC reserves the right to make changes in design and specification of any equipment as engineering or necessity requires THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON MSC JACKSON S LIABILITY ON ANY CLAIM OF ANY KIND INCLUDING NEGLIGENCE WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER SHALL IN NO CASE EXCEED THE PRICE OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING FOR FITNESS OR MERCHANTABILITY THAT ARE NOT SET FORTH HEREIN OR THAT EXTEND BEYOND THE DURATION HEREOF UNDER NO CIRCUMSTANCES WILL JACKSON MSC BE LIABLE FOR ANY LOSS OR DAMAGE DIRECT OR CONSEQUENTIAL OR FOR THE DAMAGES IN THE NATURE OF PENALTIES ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS ITEMS NOT COVERED This warranty does not cover cleaning or deliming of the unit or any component such as but not limited to wash arms rinse arms or strain ers at anytime Nor does it cover adjustments such as but not limited to timer cams thermostats or door
155. re gauge located on the water out let side of the heat exchanger Once the desired pressure is achieved tighten the top nut to ensure that the adjustment can not be accidently changed The water pressure regulator has an internal strainer that can be removed through the bottom hexagonal plug This may need to be periodically checked depending on the water quality It is important that the water supply to the water pressure regulator be secured prior to trying to clean the strainer MAINTENANCE OF THE RELIEF VALVES SAFETY VALVES AND THERMOSTAT These components are shipped from the factory preset and should not be tampered with None of these components are con sidered adjustable and no attempt should be made to do so If a component does not appear to be working properly then it should be replaced immediately by an authorized service representative 54 SECTION 3 PREVENTATIVE MAINTENANCE LUBRICATION CHART FOR DRIVE GEAR Note The maintenance procedures detailed here are manufacturer s instructions for the WINSMITH brand of gear reducer that is installed on the rack conveyors covered in this manual Ambient Temperature Final Stage Worm Speed ISO Viscosity Grade AGMA Lubricant No Mobil American Lubricants Castrol Chevron Conoco Exxon Esso Fiske Brothers Shell Texaco 30 15 F up to 2000 FPM 220 55 5 630 SHC 90W Tribol 800 220 Tegra 220 SynconR amp O 220 Teresstic SHP220 SPO M
156. rm this maintenance evolution 5 16 nutdriver 7 16 nutdriver 7 16 combination wrench 7 16 socket with drive ratchet and 4 extension 12 pipe wrench 10 adjustable wrench Wire cutters Phillipshead screwdriver TIME REQUIRED It is estimated that it will take 1 person three hours to perform this task not including all of the items indicated in the section entitled PREPARATION GQ 3 IMPORTANT NOTES 1 Do not lose hardware Place hardware in a safe spot away from the machine ensuring that it does not fall loose into the machine tub Hardware that is drawing into the suction of the wash pump will damage the equipment If you do need more hardware contact your JACKSON representa tive to purchase new items 2 Read these instructions thoroughly before attempt ing this maintenance evolution Become familiar with the parts and what actions need to be taken This will save time in the long run STEPS 1 Remove the upper wash arm assembly by loosening the spin nut The spin nut has a stop so it will not come off Once it is loosened the wash arm assembly should slide off Spin nut 2 Remove the end cap from the wash arm assembly and place in the opposite end securing it snugly End cap 3 With the end cap securely in the opposite end of the wash arm assembly set the assembly gently to the side Go back inside the unit to where the upper wash arm assembly secured
157. rmly and lifting up 7 Remove the lower wash arm assembly by turning the lock ing screw to unlatch it The entire assembly should then lift out Locking screw 8 Remove the lower wash arm support bracket Place it to the side with its locknuts SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED b Removing the locknuts for the lower wash arm support bracket 9 Remove the lower rinse arm support bracket which is mounted directly opposite of the lower wash arm support bracket Removing the lower rinse arm support bracket 10 Remove the lower and upper rinse arms by unscrewing them and then gently pulling them out Unscrewing and removing the lower rinse arm 11 Behind the rinse manifold remove the nut on the bracket Removing the bracket nut 12 Remove the nuts from the rinse manifold mounting brack et located on the underside of the hood These nuts are mounted directly to the rinse injector weldment on the hood top Removing the locknuts from the rinse mani fold mounting bracket 13 The rinse manifold must be removed This may prove dif ficult while the rinse injector is still mounted With great care it is possible to gently lift the rinse injector off of the hood to allow the rinse manifold to be removed from the unit Ensure that the gasket in the underside of the hood stays with the rinse manifold as it must be replaced
158. rol 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 temperature is too high adjust thermostat using instructions on the page 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 while the power switch is turned and OFF If relay contacts move in and out the heater relay is operating correctly if not proceed to B If heater relay R1 closes 1 Check power supply at incoming terminal board L1 L2 amp L3 3 phase only 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 C
159. s beyond 30 days from the date of installation In addition the warranty will only cover the replacement of wear items such as curtains drain balls door guides or gaskets during the first 30 days after installation Also not covered are conditions caused by the use of incorrect non Commercial grade detergents incorrect water temperature or pressure or hard water conditions REVISION REVISION MADE APPLICABLE DETAILS PAGE DATE BY ECN mM 05 14 2004 Added exhaust fan hook up schematic Updated installation instructions Added 3 instruction sheets for E 03 08 2005 MAW 7096 limit switches Added instruction sheet for curtain installation Changed layout 01 13 2006 7470 Added service kits and maintenance instructions 01 26 2006 7600 Added Gas Exhaust Fan Schematic amp component kits 7571 7558 Added themostat replacement kits Added vent cowl assembly for H 03 21 2006 MAW 4 hooded side loader Replaced rinse drain weldment Added scrap 7634 basket strainer kit 04 19 2007 MAW 7898 Added 09905 003 32 20 fan load decal to the exhaust fan control kit Added warranty pages and service centers listings 35 amp 36 05 03 2007 MAW 7913 Added instructions and all necessary information for change of sanitization mode 5 thru 22 111 08 29 2007 2277 dimension pages Removed alternate table limit switch Changed the part from a weldment 05700 021 67 50 to a ws 19725 804 casting 09515 003 58 12 01 16 2014
160. s come with the injectors gasket and ho 7 19 mounting hardware The gt rinse injector kit item 1 21 12 16 18 5 16 11 18 9 22 22 ITEM DESCRIPTION Mfg No 1 1 Rinse Injector Replacement Kit 06401 003 11 88 1 Gasket 05330 111 42 81 2 3 Plug Brass 1 8 NPT 04730 209 07 37 3 2 Vacuum Breaker 3 4 NPT 04820 002 53 77 4 3 Elbow Street 3 4 NPT 04730 206 04 34 5 1 Plug 04730 209 01 00 6 2 Union Brass 3 4 04730 212 05 00 7 2 Solenoid Valve 3 4 04810 100 53 00 8 4 Nipple Close Brass 3 4 NPT 04730 207 34 00 9 2 Fitting 3 4 Male to Slip Copper 04730 401 11 01 10 1 Tube Copper See Chart 11 1 Fill Injector Replacement Kit 06401 003 09 93 1 Gasket 05330 111 42 81 12 1 Tube Copper See Chart 13 1 Gauge Pressure 0 100 PSI 06685 111 88 34 14 1 Valve Ball Test Cock 1 4 NPT 04810 011 72 67 15 1 Tube Copper See Chart 16 2 Tee 3 4 x 3 4 x 1 2 04730 411 03 01 17 1 Elbow Brass 90 3 4 Copper 04730 406 42 01 18 2 Tube Copper See Chart 19 1 Regulator Pressure 3 4 NPT Brass 06685 011 58 22 20 1 Nipple Brass 6 Long 05700 001 26 74 21 1 Tee 3 4 CU x CU x CU 04730 411 46 01 22 2 Fitting Adapter 1 2 to 1 4 04730 401 41 01 71 wr SECTION 5 PARTS SECTION EXTERNAL ELECTRIC BOOSTER INCOMING PLUMBING ASSEMBLIES Plumbing with Water Hammer Arrestor je N 5 10 7 4 un 2 ae i lt T Tube Length Char
161. screw gt WATER SUPPLY CONNECTION Ensure that you have read the section enti LS zm tled PLUMBING THE DISHMACHINE above before proceeding It is also recommended that a pressure regulator not supplied be installed in the in coming water line The supply water temperature must meet the minimum requirements listed on the machine data plate Install the water supply line 3 4 pipe size minimum to the dishmachine line strainer It is recommended that a water shut of valve be installed in the water line between the main supply and Incoming Plumbing Assembly the machine to allow accessfor service The water supply line is to be capable Optional of 25 PSI f ow pressure at the recommended temperature indicated on the data plate If the water level is too low ortoo 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 wil 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 f ow pressure Static pressure is the line pressure in a no f ow condition all valves and services are closed Flow pressure is the pressure in the f line when the f ll valve is opened during the cycle It is also recommended that a shock absorber not
162. ses Operators should regularly inspect the pan strainers to ensure they have not become clogged If the strainers do they will reduce the washing capability of the machine Instruct operators to clean out the pan strainers at regular intervals or as required by work load NOTE On units equipped with prewash sections AJ 66 and AJ 80 operators should also take the time to inspect the prewash section strainers and clean them as required by workload SHUTDOWN AND CLEANING ELECTRICALLY HEATED MODELS At the end of the workday place the power switch in the OFF position and open the door s Open the drain valves and allow the machine to drain completely Remove the pawl bar assembly clean as required Remove the pan strainers and if equipped the prewash strainers run off sheets and scrap bas ket strainer Remove the wash and if equipped the prewash arms and verify that the nozzles and arms are free from obstruc tions Flush the arms with fresh water Remove the pump suction strainers and clean out as required Remove the rinse tray assembly and clean Remove the curtains and scrub with a mild detergent and warm water Wipe out the inside of the unit and then reassemble with the components previously removed 46 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS DISHMACHINE OPERATION INSTRUCTIONS CONTINUED SHUTDOWN AND CLEANING STEAM HEATED MODELS At the end of the workday place the power switch in the OFF position secure the flow
163. side of the unit and then reassemble with the components previously removed 47 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING DUAL SANITIZATION MODE If the machine has a dataplate like the one shown which indi cates both Hot Water Sanitizing and Chemical Sanitizing operation parameters the area within dashed box it is pos sible to change the sanitizing mode after the machine has left the original manufacturer s facility This change can only be performed by an authorized Jackson service technician If the machine does not have a dataplate like the one shown the sanitization mode CAN NOT be changed Follow the instructions below to change the mode of sanitiza tion Failure to follow these instructions can result in a viola tion of applicable regulatory codes DRIVE MECHANISM MAXIMUM SPEED ADJUSTMENT Note This adjustment is only required when changing from hot water sanitizing to chemical sanitizing mode Locate the maximum speed adjustment mechanism at the top of the conveyor drive mechanism Figure 1 Figure 2 shows an enlarged view of the maximum speed adjustment mecha nism Loosen the Bottom Jam Nut approximately one turn counterclockwise Move the Top Jam Nut down on the threaded shaft by turning it approximately 1 2 turn counter clockwise Tighten the Adjustment Nut by turning it clockwise SERIAL XXXX X 60 HZ 3 PHASE 3 WIRE 208V 230V 460V WASH MOTOR 2 0 HP 56 56A 28 DRIVE MOTOR 1 4
164. t SS tem Length Inches 9 3 4 x 3 7 16 A 4 5 6 Plumbing without Water Hammer Arrestor 6 gt d 3 2 4 SQ d Uy 2 2 1 gt p pr UN E 22 p lt 7 ne 6 5 gt ITEM QTY DESCRIPTION Mfg No 1 Y Strainer 3 4 Brass 04730 717 02 06 2 Arrestor Water Hammer 1 2 06685 100 05 00 3 Regulator Pressure 3 4 NPT Brass 06685 011 58 22 4 Nipple 3 4 NPT x 2 Long Brass 04730 207 46 00 5 Elbow Brass 90 3 4 04730 206 13 00 6 Nipple 3 4 NPT Close Brass 04730 207 34 00 7 Coupling 3 4 FNPT x 3 4 FNPT Brass 04730 011 87 95 8 Adapter 3 4 Male 04730 401 11 01 9 Tube Copper See Chart 10 Adapter 1 2 NPT x Male 04730 401 07 01 11 Tee Copper 3 4 x 3 4 x 1 2 04730 411 03 01 72 SECTION 5 PARTS SECTION EXTERNAL ELECTRIC BOOSTER OPTION OUTLET PLUMBING Elbow 3 4 Copper to Copper Female Q x 04730 406 16 01 Eo m Tube Copper 3 4 x 5 7 8 Long Elbow 3 4 90 Street Copper to Copper 04730 406 40 01 Tube Copper 3 4 x 49 1 2 Long Adapter 3 4 Brass 04730 401 11 01 Nipple 3 4 NPT x 2 Long Brass Elbow 3 4 Copper to Copper Female 04730 207 46 00 04730 406 16 01 MC Tube Copper 3 4 x 24 Long Union 3 4 Brass 04730 212 05 00 Elbow Brass 90 3 4 04730 206 13 00
165. tain menu items may require extra detergent by their nature and personnel need to be made aware of this Experience in using the dishmachine under a variety of conditions along with good training in the operation of the machine can go a long way in ensuring your dishmachine operates as effi ciently as possible Certain dishmachine models require that chemicals be provided for proper operation and sanitization Some models even require the installation of third party chemical feeders to introduce those chemicals to the machine Jackson does not recom mend or endorse any brand name of chemicals or chemical dispensing equipment Contact your local chemical distributor for questions concerning these subjects Some dishmachines come equipped with integral solid detergent dispensers These dispensers are designed to accommodate detergents in a certain sized container If you have such a unit remember to explain this to your chemical distributor upon first contacting them As explained before water temperature is an important factor in ensuring that your dishmachine functions properly The data plate located on each unit details what the minimum temperatures must be for either the incoming water supply the wash tank and the rinse tank depending on what model of dishmachine you have installed These temperatures may also be followed by temperatures that Jackson recommends to ensure the highest performance from you dishmachine However if the minimum requ
166. tpoint energizing the steam solenoid light E2 and the steam solenoid FS1 3 The steam solenoid FS1 will remain open allowing steam into the booster until the water temperature reaches the desired temperature At that point the thermostat TS1 will open de energizing the steam solenoid FS1 and the steam solenoid light E2 IMPORTANT Please remember that all of the components in the control box are under line voltage 208 240 volts Under no circumstance is the control box cover to be removed or opened during normal operations SHUTDOWN FOR SERVICE ONLY WARNING The D226 Booster is designed to heat water to a minimum of 180 F and is extremely hot during operations Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur 1 Turn the power switch to the OFF position The power light should extinguish 2 Secure steam flow to the unit 3 Secure water flow 4 Close the condensate drains as required by procedure and or code 5 Do not attempt to clean wipe down or perform any maintenance on the booster until it has been given a generous amount of time to cool down 43 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS GAS CONVEYOR HOSE INSTALLATION Barbed Hose Fitting 1445 Attach the hose fitting to this Cut the hose at the location connection before making the where the hose is even cut at the other end of the with the yellow plastic stop hose H
167. ugh handling Also notify your JACKSON dealer immediately If itis discovered that there are missing parts please notify your JACKSON dealer immediately EQUIPMENT MOUNTING Your booster should come pre assembled and will require that it be permanently mounted in place The platform has pre punched holes to allow for mounting to the installation floor NOTE The D226 Booster must be properly mounted and level before being used Once the platform is secure to the floor attach the water and steam lines in accordance with local and national codes PLUMBING NOTE ALL CONNECTIONS MUST COMPLY WITH ALL APPLICABLE LOCAL STATE AND NATIONAL PLUMBING CODES The plumber is responsible for ensuring that the water lineis THOROUGHLY FLUSHED BEFORE connecting it to any manu al or solenoid valve It is necessary to remove all foreign matter such as chips resulting from cutting or threading pipes pipe joint compound or if soldered fittings are used bits of solder or cuttings from the lines This debris if not removed may lodge in the valves and render them inoperative The D226 Booster is designed to take incoming water from a minimum temperature of 110 F to approximately 180 for use in the final rinse of your Jackson dishmachine In order to do this water is supplied to the booster and is heated by tubes carry ing 15 25 PSIG flow steam Heat is transferred from the steam into the water raising the temperature Install condensate drains in accor
168. when re installing the manifold If the gasket becomes lost or torn order a new one immediately Lifting the rinse injector to make room 14 Remove the entire rinse tray assembly including the pan 36 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS CHANGING THE AJ 44CE CS DIRECTION OF TRAVEL CONTINUED and the strainer within in The assembly should lift right out See next page for photograph detailing this step 15 Remove the front and rear rinse pan locator brackets Note the brackets are mounted to the bolts that secure the tub weldment to the frame Once the locknuts are removed pull the locator brackets off and immediately replace the locknuts back onto the bolts Failure to do so at a minimum may cause excessive leaking of the tub once the unit is placed back in operation Removing a rinse tray guide bracket 16 On the drain plumbing the rinse drain tube needs to be removed from the plumbing as well as the wash drain tube Both of these tubes are secured with hose clamps Loosen the hose clamps and pull the tubes off Loosening the rinse drain hose from the rinse drain nipple 17 The tee that the rinse drain nipple is in must be turned 180 so that it is facing the opposite direction This may require dis mantling the plumbing by removing the tee with the wash drain barb in it Put the plumbing back together after ensuring that the rinse drain tee has been rotated Use thread tape to pro t
169. x 2 I 05305 011 74 98 gt Replacment Kit Notes The impeller replacement WASH MOTOR CHART kits come with Volts Phase Hz Motor Part Number Kit Part Number bolt The motor kits come 208 230 1 60 06105 021 70 57 06401 003 09 97 with everything detailed 200 230 3 60 06105 121 70 58 06401 003 09 98 Shave as wall new 380 3 60 06105 121 81 34 06401 003 09 96 mounting gaskets 460 3 60 06105 121 70 58 06401 003 09 98 600 3 60 06105 002 48 31 06401 003 09 99 Kit Motor Brkt Replace 06401 021 73 42 PREWASH MOTOR CHART Model s Volts Phase Hz Part Number Kit Part Number AJ 66 s 208 3 50 06105 121 70 56 06401 003 10 38 220 3 50 06105 121 70 56 06401 003 10 38 230 3 50 06105 121 70 56 06401 003 10 38 380 3 50 06105 121 81 34 06401 003 10 39 415 3 50 06105 121 81 34 06401 003 10 39 440 3 50 06105 121 70 56 06401 003 10 38 208 1 60 06105 121 70 55 06401 003 10 40 230 1 60 06105 121 70 55 06401 003 10 40 200 3 60 06105 121 70 56 06401 003 10 38 220 3 60 06105 121 70 56 06401 003 10 38 230 3 60 06105 121 70 56 06401 003 10 38 380 3 60 06105 121 70 56 06401 003 10 38 460 3 60 06105 121 70 56 06401 003 10 38 600 3 60 06105 002 48 31 06401 003 10 41 AJ 80 s 208 3 50 06105 121 81 34 06401 003 10 39 220 3 50 06105 121 81 34 06401 003 10 39 230 3 50 06105 121 81 34 06401 003 10 39 380 3 50 06105 121 81 34 06401 003 10 39 415 3 50 06105 121 81 34 06401 003 10 39 440 3 50 06105 121 81 34 06401 003 10 39 208 1 60 06105 121 70 57 06401 003 10 42
170. z 3 Phase Primary Side 460 Volt 50 60 Hz 3 Phase Secondary Side Conveyor Side Loader D226 Steam Booster Exhaust Fan Hook Up Schematics MAINTENANCE amp REPAIR CENTERS 121 122 123 124 126 127 128 130 131 132 133 134 135 137 138 139 140 141 142 144 145 146 147 SECTION 1 SPECIFICATION INFORMATION SECTION 1 SPECIFICATION INFORMATION _ OPERATING CHARACTERISTICS RACKS PER HOUR AJ 44 66 80CE CS CGP AJ 44 66 80CEL CSL DISHES OR GLASSES PER HOUR AJ 44 66 80CE CS CGP AJ 44 66 80CEL CSL PREWASH TANK CAPACITY GALLONS AJ 66CE CEL CS CSL CGP AJ 80CE CEL CS CSL CGP WASH TANK CAPACITY GALLONS AJ 44 66 80CE CS CGP PREWASH PUMP CAPACITY GPM AJ 66CE CEL CS CSL CGP AJ 80CE CEL CS CSL CGP WASH PUMP CAPACITY GALLONS PER MINUTE ALL MODELS VENTING REQUIREMENTS 100 CAP INPUT END OUTPUT END TOTAL CONVEYOR SPEED FPM AJ 44 66 80CE CS CGP MACHINES AJ 44 66 80CEL CSL MACHINES GALLONS PER RACK AJ 44 66 80CE CS CGP MACHINES AJ 44 66 80CEL CSL MACHINES WATER TEMPERATURES AJ 44 66 80CE CS CGP MODELS PREWASH RECOMMENDED WASH MINIMUM RINSE MINIMUM AJ 44 66 80CEL CSL MODELS PREWASH RECOMMENDED WASH MINIMUM RINSE MINIMUM FLOW PRESSURE PSI FLOWRATE GPM AJ 44 66 80CE CS CGP AJ 44 66 80CEL CSL MINIMUM CHLORINE PPM AJ 44 66 80CEL CSL MODELS ONLY 248 234 6200 5850 16 16 15 4 120 270 270 200 400 600
171. zles are not clogged with debris If so remove debris 2 Clogged prewash tank or prewash pump strainers Clean out strainers if necessary 3 Worn prewash pump impeller Verify status of impeller replace if necessary Problem Inadequate rinse 1 Low incoming water pressure Verify that incoming water pressure during fill is 20 5 PSI 2 Incoming water solenoid is clogged Verify that debris is not entrapped in valve If so remove debris Problem Pawl bar moves with no load but does not move when loaded 1 Clutch on drive assembly is out of adjustment Adjust as required 58 SECTION 4 TROUBLESHOOTING COMMON PROBLEMS Problem Pawl bar does not move 1 Failed or broken overload spring Replace spring if necessary 2 No power to the drive motor failed drive motor Verify power and wiring connections to the motor If necessary replace the motor 3 Pawl bar not properly installed Verify that the pawl bar is installed correctly Problem Racks go through the machine but results are poor 1 Verify that detergent is being dispensed into the machine at the appropriate quantities for the water volume If not get deter gent to appropriate level and review results of washing ware Clogged strainers scrap basket Clean out strainers and scrap basket and replace Ware not being properly prescrapped Review paragraph entitled Ware Preparation in Operating Instructions Wash or rinse arms missing e

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