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Jackson AJ-44TE Installation/operation & Technical Manual - Section 1:

Manual is about: AJ-44T/AJ-66T/AJ-80T SERIES RACK CONVEYOR DISHMACHINE

Summary of AJ-44TE

  • Page 1

    Installation/operation & technical manual jackson msc llc. P.O. Box 1060 barbourville, ky. 40906 (606) 523-9795 fax: (606) 523-9196 www.Jacksonmsc.Com aj-44t series rack conveyor dishmachine september 29, 2007 p/n 7610-003-07-21 (revision c) aj-44t series aj-44te aj-44tg aj-44ts aj-66t series aj-66t...

  • 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!

    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 produi...

  • Page 4

    I revision revision date made by applicable ecn details a 08-03-2005 maw 7442 initial release of manual. B 02-13-2006 maw 7600, 7558 7462, 7367 7463 added gas exhaust fan schematic, updated electric exhaust fan schematic. Replaced rinse drain weldment 05700-021-68-28 with 05700-002-51-12. Added wash...

  • Page 5

    Nomenclature for the models covered in this manual aj-44ts aj = aj series of rack conveyors 44 = 44” wide machine 66 = 66” wide machine 80 = 80” wide machine te = electrically heated, hot water sanitizing machine tg = gas heated, hot water sanitizing machine ts = steam heated, hot water sanitizing m...

  • Page 6

    Section description page i. Specification information operating characteristics 2 electrical requirements 3 aj-44t electric - left to right 4 aj-44t electric - right to left 5 aj-44t gas - left to right 6 aj-44t gas - right to left 7 aj-44t steam - left to right 8 aj-44t steam - right to left 9 aj-6...

  • Page 7

    Section description page v. Parts section (continued) rinse booster tank assembly (tg models) 63 recirculating pump assembly (tg models) 64 hose connections (tg models) 65 aj-44t series drain plumbing assemblies 66 aj-66t series drain plumbing assemblies 67 aj-80t series drain plumbing assemblies 68...

  • Page 8

    Section description page vii. Electrical schematics aj-66tg & aj-80tg 208-230 volt, 60 hz, 1 phase 110 208-230 volt, 60 hz, 3 phase 111 460 volt, 60 hz, 3 phase 112 aj-66ts & aj-80ts 208-230 volt, 60 hz, 1 phase 113 208-230 volt, 60 hz, 3 phase 114 460 volt, 60 hz, 3 phase 115 conveyor side loader/d...

  • Page 9: Section 1:

    1 section 1: specification information.

  • Page 10

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 1: specification information operating characteristics 2 racks per hour: aj-44-66-80te/tg/ts 204 dishes or glasses per hour: aj-44-66-80te/tg/ts 5100 prewash tank capacity (gallons): aj-66te/tg/ts 17.25 aj-80te/tg/...

  • Page 11

    Note: typical electrical circuit is based upon (1) 125% of the full amperage load of the machine and (2) typical fixed- trip circuit breaker sizes as listed in the nec 2002 edition. Local codes may require more stringent protection than what is displayed here. Always verify with your electrical serv...

  • Page 12

    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...

  • Page 13

    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...

  • Page 14

    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...

  • Page 15

    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 ...

  • Page 16

    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 ...

  • Page 17

    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...

  • Page 18

    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...

  • Page 19

    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-...

  • Page 20

    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 ...

  • Page 21

    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...

  • Page 22

    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]...

  • Page 23

    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...

  • Page 24

    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...

  • Page 25

    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 ...

  • Page 26

    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...

  • Page 27

    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...

  • Page 28

    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...

  • Page 29

    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...

  • Page 30

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 1: specification information side loader (left to right) dimensions 22 note: all dimensions are typical. 23” or 30” depending on the wid th of the side loader . Conveyor dishw asher length 8” or 15” depending on th...

  • Page 31

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 1: specification information side loader (right to left) dimensions 23 note: all dimensions are typical. 14 1/2” 29” 8” or 15” depending on the wid th of the side loader . 23” or 30” depending on the wid th of the ...

  • Page 32

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 1: specification information side loader (installed) dimensions 24 refer to chart above. 34” 23” or 30” depending on the width of the side loader. 10” 4” 23” side loader dimensions 30” side loader dimensions model ...

  • Page 33: Section 2:

    25 section 2: installation & operation instructions.

  • Page 34

    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 35

    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 manufac...

  • Page 36

    Electric heat: the thermostats for the machines covered in this manual are factory set. They should not be adjusted except by an authorized service agent. Chemical feeder equipment: detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacin...

  • Page 37

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions curtain installation diagrams 29 44 l r ls s l l 21" 12" 12" 21" 21" 21" 21" 12" 12" ll s s r l 21" 21" 12" 12" 21" ll s s l r l 66 12" s 80 s 12" l r ss l l 12" 12" 21" 21" s...

  • Page 38

    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...

  • Page 39

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions side loader installation & operation instructions 31 this accessory assists in the delivery of a full dish rack from the break down (scrapping) table to the dishmachine. It wi...

  • Page 40

    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 41

    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...

  • Page 42

    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 43

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 2: installation/operation instructions striker plate limit switch installation instructions 35 table limit switch through rod holes table switch rods strike plate strike plate bolts mounting bolts table bottom 3.00...

  • Page 44: Section 3:

    36 section 3: preventative maintenance.

  • Page 45

    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 46

    Aj-44t series technical manual 7610-003-07-21 issued: 03-21-2006 revised: n/a section 3: preventative maintenance 38 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 co...

  • Page 47

    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 48: Section 4:

    40 section 4: troubleshooting section.

  • Page 49

    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 50

    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...