- DL manuals
- Jackson
- Dishwasher
- AJ-44
- Installation/operation & Technical Manual
Jackson AJ-44 Installation/operation & Technical Manual - Section 1:
Summary of AJ-44
Page 1
Installation/operation & technical manual for jackson models: jackson msc llc. P.O. Box 1060 barbourville, ky. 40906 (606) 523-9795 fax: (606) 523-9196 www.Jacksonmsc.Com aj-44 rack conveyor dishmachine series september 29, 2007 p/n 07610-001-76-22 (revision h) aj-44ce aj-44cel aj-44cgp aj-44cs aj-4...
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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...
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Iii revision/ page revision date made by applicable ecn details d 05-14-2004 cbw n/a added exhaust fan hook-up schematic. E 03-08-2005 maw 7096 updated installation instructions. Added 3 instruction sheets for limit switches. Added instruction sheet for curtain installation. Changed layout. F 01-13-...
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Iv nomenclature for the models covered in this manual 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...
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Section description page i. Specification information operating characteristics 2 electrical requirements 3 d226 steam booster parameters 4 aj-44 electric - left to right 5 aj-44 electric - right to left 6 aj-44 gas - left to right 7 aj-44 gas - right to left 8 aj-44 steam - left to right 9 aj-44 st...
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V. 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 outle...
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Vi. Electrical schematics aj-44ce/cel 200-230 volt, 50/60 hz, 1 phase primary side 121 200-230 volt, 50/60 hz, 1 phase secondary side 122 200-230 volt, 50/60 hz, 3 phase primary side 123 200-230 volt, 50/60 hz, 3 phase secondary side 124 380-460-600 volt, 60 hz, 3 phase primary side 125 380-460-600 ...
Page 9: Section 1:
1 section 1: specification information.
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information operating characteristics 2 racks per hour: aj-44-66-80ce/cs/cgp 248 aj-44-66-80cel/csl 234 dishes or glasses per hour: aj-44-66-80ce/cs/cgp 6200 aj-44-66-80cel/csl 5850 prewash tank ca...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information electrical requirements 3 aj-44ce/cel models typical total electrical volts ph hz amps circuit 208 3 50 55 a 70 amp 220 3 50 49 a 70 amp 230 3 50 51 a 70 amp 380 3 50 29 a 40 amp 415 3 ...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information electrical requirements (continued)/d226 steam booster parameters 4 aj-80ce/cel models typical total electrical volts ph hz amps circuit 208 3 50 68 a 90 amp 220 3 50 62 a 80 amp 230 3 ...
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Left to right dr iv e uni t left si de dr iv e uni t front vi ew right si de 4" ( 102 mm) wide x 16" ( 406 mm) long cutout in vent cowl/ s plash shield. Shipped wit h cover plat e. F loor sink or dr ain with 3" ( 76 mm) minimum dr ain line 3/ 4" ( 19 mm) t able t u rndown f lange 3/ 4" max 21" ( 533...
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Ri ght to lef t dr iv e un it left side dri v e un it fr ont view right side 4" (102 mm) wi de x 1 6 " ( 406 m m ) long cut out i n vent c o w l/ sp la sh shi e ld . Shi pped wi th c o ve r pl a te . F loo r si nk o r drai n with 3 " ( 7 6 m m ) mi ni mu m drai n li n e 3/ 4" (19 mm) t a b le t u rn...
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Driv e un it fr ont view right side 75 1 2 [ 1919m m ] 62 1 2 [ 1590m m ] 34 [ 864m m ] 29 [ 737m m ] 6 [ 152m m ] 8 1 2 [ 218m m ] 21 [ 533m m ] 25 [ 635m m ] 12 [ 307m m ] 25 [ 635m m ] 10 [ 254m m ] 7 [ 178m m ] d e b 18 1 2 [ 467m m ] 4 [ 102m m ] 8 [ 206m m ] tabl e t o t abl e o v er al l d is...
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Rig ht to left dr iv e uni t left side driv e un it fr ont view right side 66 1 2 [ 1692m m ] 1 2 [1 5 mm] 84 [ 2134m m ] 75 1 2 [ 1919m m ] 62 1 2 [ 1590m m ] 34 [ 864m m ] 29 [ 737m m ] 7 [ 178m m ] 6 [ 152m m ] 7 1 2 [ 191m m ] 8 1 2 [ 218m m ] 21 [ 533m m ] 25 [ 635m m ] 12 [ 307m m ] 25 [ 635m ...
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L e ft to r ig h t dr iv e uni t le ft s ide dr iv e un it front v ie w right s ide 3/4" (19 mm) tabl e turndow n fl ange 3/4" max 21" (533 mm) r a c k ra il h e ig h t a bove d ishtabl e 1/4" (6mm) - 5/16" (8mm) r a c k ra il tub tabl e u s e s ilic one s eal er b e tw een tabl e and li p of machi ...
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Right to left drive uni t le ft side driv e unit front vie w r ight side 3/ 4" ( 19 m m ) table tur ndown flange 3/ 4" m a x 21" ( 533 m m ) rac k rail height above disht able 1 /4 " (6 mm) - 5 /1 6 " (8 mm) rac k rail tub table use silicone sealer bet w een table and lip of m a chine t o pr event l...
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Dr ive un it l e ft side dr ive un it 66 1 2 [ 1692m m ] 3 [ 79m m ] 1 2 [1 5 mm] 84 [ 2134m m ] 75 1 2 [ 1919m m ] 60 1 4 [ 1530m m ] 29 [ 737m m ] 10 1 4 [ 260m m ] 6 [ 152m m ] 10 [ 254m m ] 7 [ 178m m ] d e a c c g b 4 [ 102m m ] 8 [ 206m m ] 24 [ 609m m ] 41 [ 1040m m ] f a 18 [ 457m m ] 27 [ 6...
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C ri ght si de 34 [864mm] 8 1 2 [217mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] b dish clearance drive unit le ft s ide 66 1 2 [1692mm] 3 [79mm] 1 2 [15mm] 84 [2134mm] a g f with doors open rear of machine 6 [152mm] right to left legend a - machine water inlet 3/4" npt, 180° f hi-temp,140°f low-...
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Dr iv e un it lef t si de dr iv e un it 4 1 4 [ 105mm] 3 [ 79mm] 1 2 [1 5 m m ] 84 [ 2134 mm] 75 1 2 [1 9 1 9 m m ] 60 1 4 [ 1530 mm] 2 1 2 [ 61mm] 29 [ 737 mm] 6 [ 152 mm] 10 [ 254 mm] 7 [ 1 78 mm] d e a c c m b 4 [ 102 mm] 8 [ 206 mm] 24 [ 609 mm] 41 [ 1 040 mm] l a 18 [ 4 57 mm] 27 [ 687 mm] m l ...
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C ri ght side 34 [864mm] 8 1 2 [217mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] b dis h clearanc e drive unit left si de 66 1 2 [1692mm] 3 [79mm] 1 2 [ 15mm] 84 [2134mm] a m l with doors open rear of m a ch in e 6 [152mm] 1 [25mm] drive unit front view 75 1 2 [1919mm] 62 1 2 [1590mm] 29 [737mm] 6...
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Driv e unit left side driv e unit 66 1 2 [1692mm] 3 [79mm] 1 2 [15mm] 84 [2134mm] 75 1 2 [1919mm] 60 1 4 [1530mm] 29 [737mm] 24 [610mm] 10 1 4 [260mm] 17 1 2 [445mm] 6 [152mm] 10 [254mm] 7 [178mm] d e a c c o b 4 [102mm] 8 [206mm] g 24 [609mm] 41 [1040mm] n a 18 [457mm] 27 [687mm] o n 23 1 2 [598mm]...
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C ri ght s ide 34 [864mm] 8 1 2 [217mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] b di sh clear ance driv e unit le ft s ide 66 1 2 [1692mm] 3 [79mm] 1 2 [15mm] 84 [2134mm] a g f wi th door s open rear of machi n e 6 [152mm] right to left legend a - machi ne water inl e t 3/4" npt , 180° f hi- tem...
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Dr iv e uni t l e ft si de 66 1 2 [1692mm] 3 [79mm] 1 2 [ 15mm] 84 [2134mm] a c g f r igh t si de 34 [864mm] 8 1 2 [217mm] 21 [533mm] 25 [635mm] 12 [307mm] 25 [635mm] b di sh cl earance w ith doors open rear of ma c h in e base uni t o v eral l prewash pl an vi ew secti o n w ith c o ld w a ter ther...
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C r igh t side 3 4 [8 64m m ] 8 1 2 [ 2 1 7 mm] 2 1 [5 33m m ] 2 5 [6 35m m ] 1 2 [3 07m m ] 2 5 [6 35m m ] b d ish clea rance driv e unit left si d e 66 1 2 [169 2mm] 3 [ 7 9mm] 1 2 [ 1 5 mm] 8 4 [21 34m m ] a g f w ith do ors open r ear of ma c h in e 6 [ 1 52 m m ] right to left legend a - m a c ...
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Dr ive unit left si de 66 1 2 [ 1692m m ] 3 [ 79m m ] 1 2 [ 1 5 mm] 84 [ 2134m m ] a c m l r ight si de 34 [ 864m m ] 8 1 2 [ 217m m ] 21 [ 533m m ] 25 [ 635m m ] 12 [ 307m m ] 25 [ 635m m ] b d ish cl earance w it h doors open r ear of ma c h in e ba s e u n it overal l p rew ash p lan v iew s e ct...
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Drive unit left sid e 66 1 2 [1692mm] 3 [79mm] 1 2 [ 15mm] 84 [2134mm] a m l w ith d oor s op e n r ear o f m a ch in e 6 [152mm] ri ght to left 1 [25mm] 66 1 4 [1684mm] fl oor si nk or d ra in w ith 3" ( 7 6 m m ) mi ni mum dr ai n l in e 25 [635mm] 4 1/2 [114mm] 8 1 4 [210m m ] 21 [533mm] b a l ta...
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Dri ve un it lef t side 66 1 2 [ 1692mm] 3 [ 79mm] 1 2 [ 15mm] 84 [ 2134mm] a c o n r ight s ide 34 [ 8 64mm] 8 1 2 [2 1 7 m m ] 2 1 [5 3 3 m m ] 25 [ 6 35mm] 12 [ 307mm] 2 5 [6 3 5 m m ] b di s h cl earanc e w it h doors o pen rear of machi n e base u n it o v eral l prewash pl an vi ew sect io n w...
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C 3 4 [8 64mm] 8 1 2 [21 7 mm] 2 1 [5 33mm] 2 5 [6 35mm] 1 2 [3 07mm] 2 5 [6 35mm] b di sh cle ar a n c e drive unit left s ide 66 1 2 [169 2mm] 3 [7 9mm] 1 2 [15 mm] 8 4 [21 34mm] a g f w ith d o ors o pen r ear of m a chi n e 6 [ 1 52 m m ] right to lef t 1 [2 5mm] 66 1 4 [168 4mm] f loo r s ink o...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information side loader (left to right) dimensions 23 note: all dimensions are typical. 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...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information side loader (right to left) dimensions 24 note: all dimensions are typical. 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...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information side loader (installed) dimensions 25 refer to chart above. 34” 23” or 30” 10” 4” 23” side loader dimensions 30” side loader dimensions model aj-44 aj-66 aj-80 model aj-44 aj-66 aj-80 d...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 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”.
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 1: specification information d226 steam booster plumbing line drawings 27 steam booster piping - double tank machine steam booster piping - single tank machine.
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 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 electical con...
Page 37: Section 2:
29 section 2: installation & operation instructions.
Page 38
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 so...
Page 39
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 desig...
Page 40
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-44...
Page 41
Deliming operations: in order to maintain the dishmachine at its optimum performance level, it will be required to remove lime and corrosion deposits on a frequent basis. A deliming solution should be available from your detergent supplier. Read and follow all instructions on the label of the delimi...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel 34 the aj-44 dishmachine has the ability to have its direction of travel changed from left to right, or from right to left. Directi...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel (continued) 35 4. Remove the upper wash arm assembly bracket. This step may require that you have help as the bolts for securing th...
Page 44
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel (continued) 36 9. Remove the lower rinse arm support bracket, which is mounted directly opposite of the lower wash arm support brac...
Page 45
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel (continued) 37 and the strainer within in. The assembly should lift right out. (see next page for photograph detailing this step) 1...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel (continued) 38 22. Separate the rinse plumbing from the rest of the incoming plumbing by loosening the union. Ensure that the gaske...
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Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions changing the aj-44ce/cs direction of travel (continued) 39 conveyor switch chart: the chart above lists the conveyor switches and their func- tions, depending on the direction...
Page 48
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions curtain installation diagrams 40 80 country b u f f e t 21" l l 21" 21" l ot he r s 12" l r ls s l l 21" 12" 12" 21" 21" 21" 21" 12" 12" 21" ll s s l r l hooded s ide loade r ...
Page 49
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 50
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 51
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 52
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 prov...
Page 53
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions gas conveyor hose installation (continued) 45 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 eater i...
Page 54
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 55
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 56
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: 05-03-2007 section 2: installation/operation instructions changing dual sanitization mode 48 figure 2 figure 1: drive mechanism model: aj-44ce serial # 60 hz 3 phase 3 wire 2.0 hp wash motor conveyor speed wash tank temperatur...
Page 57
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). The wash tank regulating thermostat will maintain the correct wash water temperature. N...
Page 58
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 59
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions striker plate limit switch installation instructions 51 table limit switch through rod holes table switch rods strike plate strike plate bolts mounting bolts table bottom 3.00...
Page 60: Section 3:
52 section 3: preventative maintenance.
Page 61
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 62
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 63
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 3: preventative maintenance lubrication chart for drive gear 55 note: the maintenance procedures detailed here are manufacturer’s instructions for the winsmith brand of gear reducer that is installed on the rack co...
Page 64
Aj-44c series technical manual 7610-001-76-22 issued: 03-21-2006 revised: n/a section 3: preventative maintenance drive motor gear reducer preventative maintenance 56 note: the maintenance procedures detailed here are manufacturer’s instructions for the winsmith brand of gear reducer that is install...
Page 65: Section 4:
57 section 4: troubleshooting section.
Page 66
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 ...
Page 67
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 ins...
Page 68
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 ...