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  5. Installation/operation & Technical Manual

Jackson AJ-100CE Installation/operation & Technical Manual - Stop!

Manual is about: RACK CONVEYOR DISHMACHINE SERIES

Summary of AJ-100CE

  • Page 1

    Installation/operation & technical manual for jackson models: and associated option packages including: side loader d226 external steam booster jackson msc llc. P.O. Box 1060 barbourville, ky. 40906 (606) 523-9795 fax: (606) 523-9196 www.Jacksonmsc.Com aj-64 rack conveyor dishmachine series septembe...

  • Page 2

    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. Ja...

  • Page 3: Stop!

    Ii stop! Pare! Arret! Call 1-888-800-5672 to register this product! Failure to do so will void the warranty! Llame al 1-888-800-5672 para registrar este producto! Al no hacerlo la garantia sera anulada! S.V.P. Appeler 1-888-800-5672 pour enregistrer ce produit, la garantie sera annulee pour tout pro...

  • Page 4

    Iii revision revision date made by applicable ecn details d 04-06-05 maw 6999, 7193 7217, 7064 7212, 7259 6685, 7096 6964, 7006 updated drawings for limit switch actuators. Changed aj-86 drain plumbing copper lengths. Added rack rail stabilizer kit. Replaced heater 04540-121-76-93 with 04540-002-29-...

  • Page 5

    Iv nomenclature for the models covered in this manual model: serial no.: installation date: service rep. Name: phone no.: aj-64cs aj = aj series of rack conveyors 64 = 64” wide machine 86 = 86” wide machine 100 = 100” wide machine ce = electrically heated, hot water sanitizing machine cs = steam hea...

  • Page 6

    Section description page i. Specification information operating characteristics 2 electrical requirements 3 d226 steam booster parameters 4 aj-64 electric - left to right 5 aj-64 electric - right to left 6 aj-64 gas - left to right 7 aj-64 gas - right to left 8 aj-64 steam - left to right 9 aj-64 st...

  • Page 7

    Vi. Parts section aj-64 control box assembly 54 aj-86/aj-100 control box assembly 56 motor overload chart 58 heater box assembly 59 heater assembly 60 frame weldments/front dress panels 62 prewash plumbing assembly 63 incoming plumbing assembly 64 rinse header plumbing assembly (cgp models) 66 exter...

  • Page 8

    Vii. Electrical schematics aj-64ce 208-230 volt, 60 hz, 1 phase primary side 114 208-230 volt, 60 hz, 1 phase secondary side 115 208-230 volt, 60 hz, 3 phase primary side 116 208-230 volt, 60 hz, 3 phase secondary side 117 460-575-600 volt, 60 hz, 3 phase primary side 118 460-575-600 volt, 60 hz, 3 ...

  • Page 9: Section 1:

    1 section 1: specification information.

  • Page 10

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information operating characteristics 2 racks per hour: aj-64-86-100ce/cs/cgp 287 dishes or glasses per hour: aj-64-86-100ce/cs/cgp 7200 prewash tank capacity (gallons): aj-86ce/cs/cgp 16 a...

  • Page 11

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information electrical requirements 3 aj-64ce models typical total electrical volts ph hz amps circuit 208 1 60 139 a 175 amp 230 1 60 128 a 175 amp 208 3 60 82 a 110 amp 230 3 60 76 a 100 ...

  • Page 12

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information electrical requirements (continued)/d226 steam booster parameters 4 aj-100ce models typical total electrical volts ph hz amps circuit 208 1 60 148 a 200 amp 230 1 60 136 a 175 a...

  • Page 13

    R ight side 34 [864mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] table to table over all dish clear ance b left to right dr iv e uni t left side 66 1 2 [1692mm] 1 2 [15mm] 84 [2134mm] w ith doors open rear of machine legend to dr awing a - m a chine water inlet 3/4" npt, 180° f hi- temp, 140° f lo...

  • Page 14

    R ight side 34 [864mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] table to table over all dish clear ance b right to left dr iv e uni t left side 66 1 2 [1692mm] 1 2 [15mm] 84 [2134mm] w ith doors open rear of machine legend to dr awing a - m a chine water inlet 3/4" npt, 180° f hi- temp, 140° f lo...

  • Page 15

    Rig h t side 34 [864mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] table to table o v er all d is h c lear ance 20 3 4 [527mm] 8 3 4 [222mm] 11 3 4 [298mm] 14 3 4 [375mm] 6 [154mm] 30 [763mm] 14 [357mm] 7 1 4 [185mm] 1 1 4 [35mm] 6 [152mm] 31 1 4 [795mm] 6 1 2 [165mm] 26 1 2 [673mm] b left to r igh...

  • Page 16

    Right side 34 [ 8 6 4 m m ] 21 [ 5 3 3 m m ] 25 [ 6 3 5 m m ] 12 [ 3 0 7 m m ] 25 [ 6 3 5 m m ] t abl e t o t a b le o v er al l d is h c lear anc e b dr iv e uni t left side 66 1 2 [1 6 9 2 mm] 1 2 [1 5 mm] 8 4 [2 1 3 4 mm] w ith do o rs op e n re a r o f ma ch in e 1 [ 2 5m m ] 4 " (1 0 2 mm) wid ...

  • Page 17

    Ri ght side 34 [864mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] table to table over all d ish c learance b dr iv e un it left side 66 1 2 [1692mm] 1 2 [15mm] 84 [2134mm] with d oors open r ear of machine 1 [25mm] 3/4" ( 19 mm) table tur ndow n flange 3/4" max 21" ( 533 mm) ra ck ra il he ig h t a...

  • Page 18

    R ight side 34 [ 864mm] 21 [ 533mm] 25 [ 635mm] 12 [ 307mm] 25 [ 635mm] tabl e t o tabl e ov er al l di s h cl ear anc e b right to left dri ve un it left side 66 1 2 [ 1692mm] 1 2 [ 15mm] 84 [ 2134mm] wi th door s open rear of mac h in e 1 [ 25mm] 4" ( 102 mm) wi de x 16" ( 406 mm) long c u tout i ...

  • Page 19

    32 3 4 [833mm] 94 [2388mm] drive un it 75 1 2 [1918mm] 62 1 2 [1590mm] 34 [864mm] 29 [737mm] 8 1 2 [218mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] 10 [254mm] c b g 4 [102mm] 24 [609mm] 45 3 4 [1161mm] f a 102 [2591mm] 23 1 2 [598mm] 6 [152mm] 7 [178mm] d e b 33 1 2 [851mm] 8 [206mm] drive un it ...

  • Page 20

    Right s id e 34 [864mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] tabl e to tabl e o v eral l di sh cl earance b right to left drive unit l e ft si de 1 2 [ 15mm] 84 [2134mm] w ith doors open rear of ma c h in e legend a - m a chi ne water i n le t 3/4" npt, 180° f hi -temp, 140° f low-temp mi ni ...

  • Page 21

    5 1 2 [140mm] 41 [1040mm] 20 3 4 [527mm] 8 3 4 [222mm] 11 3 4 [298mm] 14 3 4 [375mm] 6 [154mm] 30 [763mm] 14 [357mm] 7 1 4 [185mm] 1 1 4 [35mm] 32 3 4 [833mm] 94 [2388mm] dr iv e uni t 75 1 2 [1918mm] 2 1 2 [61mm] 62 1 2 [1590mm] 34 [864mm] 29 [737mm] 8 1 2 [218mm] 21 [533mm] 25 [635mm] 12 [307mm] 1...

  • Page 22

    Dr iv e un it 60 1 4 [ 1530m m] 62 1 2 [ 1590m m] 29 [ 737mm] 6 [ 152m m] 10 [ 254mm] 4 [ 102m m] 7 [ 178m m] d e 8 [ 203m m] l 24 [ 610mm] m 23 1 2 [ 599mm] 10 1 4 [ 261mm] 47 [ 1194m m] a 53 3 4 [ 1365m m] b c 43 [ 1092m m] 75 1 2 [ 1919m m] 6 [ 155m m] 36 [ 914mm] 31 1 4 [ 797mm] 6 1 2 [ 165mm] 2...

  • Page 23

    32 3 4 [ 833 mm] 9 4 [2 38 8m m ] 10 1 2 [ 264 mm] dr iv e un it 75 1 2 [1 91 8m m ] 2 1 2 [ 61mm] 62 1 2 [1 59 0m m ] 3 4 [8 64 m m ] 2 9 [7 37 m m ] 8 1 2 [ 218 mm] 2 1 [5 33 m m ] 2 5 [6 35 m m ] 1 2 [3 07 m m ] 2 5 [6 35 m m ] 1 0 [2 54 m m ] c b o 4 [ 1 02 mm] g 2 4 [6 09 m m ] 45 3 4 [1 16 1m ...

  • Page 24

    Dri ve uni t 60 1 4 [ 1530m m ] 62 1 2 [ 1590m m ] 29 [ 737m m ] 6 [ 152m m ] 10 [ 254m m ] 4 [ 102m m ] 7 [ 178m m ] d e 8 [ 203m m ] n 24 [ 610m m ] o 23 1 2 [ 599m m ] 10 1 4 [ 261m m ] 47 [ 1194m m ] a 53 3 4 [ 1365m m ] b c 43 [ 1092m m ] 75 1 2 [ 1919m m ] front vie w 3/ 4" [ 19 m m ] table tu...

  • Page 25

    108 [ 2743mm] 34 [ 864mm] 8 1 2 [ 218mm] 21 [ 533mm] 25 [ 635mm] 12 [ 307mm] 25 [ 635mm] c b dr iv e uni t 1 2 [ 15mm] 84 [ 2134mm] a g f di sh cl earance w it h doors open rear of mac h in e tabl e t o tabl e o v eral l 6 [ 152mm] left side r ight s ide fl oor si nk or drai n w it h 3" (76 mm) mi n...

  • Page 26

    Dr ive unit 29 [ 737m m ] 6 [ 152m m ] 10 [ 254m m ] 4 [ 102m m ] 8 [ 203m m ] f g 23 1 2 [ 599m m ] 10 1 4 [ 261m m ] 47 [ 1194m m ] a b 10 1 2 [ 264m m ] c 43 [ 1092m m ] fr on t vi e w rig h t side 67 1 4 [ 1707m m ] tabl e t o tabl e o v er al l 108 [ 2743m m ] 36 [ 914m m ] 64 [ 1626m m ] ba s ...

  • Page 27

    108 [ 2743m m ] 34 [ 864m m ] 8 1 2 [ 218m m ] 21 [ 533m m ] 25 [ 635m m ] 12 [ 307m m ] 25 [ 635m m ] c b dri ve un it 1 2 [1 5 mm] 84 [ 2134m m ] a m l di sh cl e a ra n c e w it h d oors open r ear of ma ch in e t able t o t abl e ov er al l 6 [ 152m m ] left side right side f loor si nk or d rai...

  • Page 28

    8 [203mm] drive unit 60 1 4 [1530mm] 62 1 2 [1590mm] 29 [737mm] 6 [152mm] 8 1 2 [218mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] 10 [254mm] c b 4 [102mm] 8 [203mm] l m 23 1 2 [599mm] 10 1 4 [261mm] 47 [1194mm] a b c 43 [1092mm] 75 1 2 [1919mm] d is h c learanc e 31 1 4 [797mm] 6 1 2 [165mm] 6 [15...

  • Page 29

    108 [ 2 74 3 mm] 34 [ 864 mm] 8 1 2 [ 218mm] 21 [ 533 mm] 25 [ 635 mm] 12 [ 3 07 mm] 25 [ 635 mm] c b dr iv e un it 1 2 [1 5 m m ] 84 [ 2 134 mm] a o n d is h clea ra nc e with d o o rs op e n rear o f ma ch in e t abl e t o t a b le o v er all 6 [ 152 mm] left side right side f loo r si nk o r drai...

  • Page 30

    Dr iv e un it 29 [ 737m m ] 6 [ 152m m ] 10 [ 254m m ] 4 [ 102m m ] 8 [ 203m m ] n o 23 1 2 [ 599m m ] 10 1 4 [ 261m m ] 47 [ 1194m m ] a b 10 1 2 [ 264m m ] c g 43 [ 1092m m ] front v iew right s ide 10 1 4 [261m m ] 67 1 4 [1707m m ] tabl e t o tabl e o v er al l 1 08 [2 743m m ] 3 6 [914m m ] 6 4...

  • Page 31

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information side loader (left to right) dimensions 23 **23” conveyor dishw asher length *8” 4 1/2” minimum 25” dishwasher 5” 12 1/2” 14 1/2” 29” 1 1/2” t able roll 20 3/4” opening 1” a a 1/...

  • Page 32

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information side loader (right to left) dimensions 24 14 1/2” 29” *8” **23” conveyor dishmachine length 4 1/2” minimum 12 1/2” 25” dishwasher 5” 1 1/2” t able roll 20 3/4” opening 1” 1/2” m...

  • Page 33

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information side loader installation dimensions 25 refer to chart above. 34” 23” or 30” 10” 4” 23” side loader dimensions 30” side loader dimensions model aj-64 aj-86 aj-100 model aj-64 aj-...

  • Page 34

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information d226 steam booster dimensions 26 16 6 16 16 13 11 note: all dimensions are in inches and are for reference only. 43 11 24 14 4 43” 11” 14” 4” 24” 11” 16” 16” 13” 6” 16”.

  • Page 35

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information d226 steam booster plumbing line drawings 27 steam booster piping - double tank machine.

  • Page 36

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 1: specification information typical electric and gas booster dimensions 28 3 4 / " npt coupling for temperature/pressure relief valve 30 / 1 2 " (775 mm) 24" (610 mm) inlet rear view outlet side view elect...

  • Page 37: Section 2:

    29 section 2: installation/operation instructions.

  • Page 38

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions installation instructions 30 note: the instructions provided herein, unless otherwise specified are for the dishma- chines only. There are separate directions for the ...

  • Page 39

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions installation instructions (continued) 31 steam line connections: some machines covered in this manual are designed to use low pressure steam as a source of heat for wa...

  • Page 40

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions installation instructions (continued) 32 electric heat: the thermostats for the machines covered in this manual are factory set. They should not be adjusted except by ...

  • Page 41

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions deliming operations 33 deliming operations: in order to maintain the dishmachine at its optimum performance level, it will be required to remove lime and corrosion dep...

  • Page 42

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions curtain installation diagrams 34 21" 12" 12" 21" ls s l r l 64 s 12" 12" ss 12" 12" s l r ss l 12" 12" 21" s 12" l r ls s l 21" 12" 12" 21" 12" s 86- 100 s 12" 21" 12"...

  • Page 43

    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...

  • Page 44

    Concealed damage or missing parts: important: for your protection, please read and observe the following: this steam booster has been thoroughly inspected and carefully packed before leaving our warehouse. Concealed loss or damage means loss or damage which does not become apparent until the booster...

  • Page 45

    Electrical: warning: electrical and grounding connections must comply with applicable portions of the national electrical code ansi / nfpa 70 (latest edition) and/or other electrical codes.Disconnect electrical power supply and place a tag or lock at the disconnect switch to indicate that you are wo...

  • Page 46

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions gas conveyor hose installation 38 due to the fact that each customer may have different requirements for the orientation of the gas booster heater relative to the main...

  • Page 47

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions gas conveyor hose installation (continued) 39 t y p ical recircul at ing w a t e r hook- u p f o r al l g a s heat e d co nveyo rs h o o k u p w h en g as bo o s ter h...

  • Page 48

    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 ...

  • Page 49

    Shutdown and cleaning (steam-heated models): at the end of the workday, place the power switch in the off position, secure the flow of steam to the machine and open the door(s). Open the drain valves and allow the machine to drain completely. Remove the pawl bar assembly (clean as required). Remove ...

  • Page 50

    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 eff...

  • Page 51

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 2: installation/operation instructions striker plate limit switch installation instructions 43 table limit switch through rod holes table switch rods strike plate strike plate bolts mounting bolts table bot...

  • Page 52: Section 3:

    44 section 3: preventative maintenance.

  • Page 53

    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 perfo...

  • Page 54

    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 ...

  • Page 55

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 3: preventative maintenance 47 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...

  • Page 56

    Note: the maintenance procedures detailed here are manufacturer’s instructions for the winsmith brand of gear reducer that is installed on the rack conveyors covered in this manual. Lubrication & maintenance: factory filling - winsmith speed reducers are oil filled at the factory to the proper level...

  • Page 57: Section 4:

    49 section 4: troubleshooting section.

  • Page 58

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 4: troubleshooting common problems 50 warning: inspection, testing and repair of electrical equipment should be performed only by qualified service per- sonnel. Certain procedures in this section require el...

  • Page 59

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 4: troubleshooting common problems 51 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 w...

  • Page 60

    Aj-64 conveyor series technical manual 7610-003-30-93 issued: 05-02-2006 revised: n/a section 4: troubleshooting d226 troubleshooting section 52 warning: inspection, testing and repair of electrical equipment should be performed only by qualified service per- sonnel. Certain procedures in this secti...