Page 2 - MANUFACTURERS WARRANTY; ONE YEAR LIMITED PARTS & LABOR WARRANTY
ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROMDEFECTS IN MATERIAL OR WORKMANSHIP, UNDER NORMAL USE AND OPERATION FOR A PERIOD OF (1) ONEYEAR FROM THE DATE OF PURCHASE, BUT IN NO EVENT TO EXCEED (18) EIGHTEEN MONTHS FROM THE DATEOF SHIPMENT FROM THE FACTORY. Jacks...
Page 3 - ii; FAILURE TO DO SO WILL VOID THE WARRANTY!
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 PROD...
Page 4 - iii
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 forlimit switches. Added instruction sheet for curtain installation.Changed layout. F 01-13-20...
Page 5 - iv; NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL; AJ = AJ series of rack conveyors
iv NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL AJ-44CSL AJ = AJ series of rack conveyors 44 = 44” wide machine66 = 66” wide machine80 = 80” wide machine CE = Electrically heated, hot water sanitizing machineCEL = Electrically heated, chemical sanitizing machineCS = Steam heated, hot water san...
Page 6 - TABLE OF CONTENTS
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...
Page 7 - PARTS
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...
Page 8 - Conveyor Side Loader/D226 Steam Booster; MAINTENANCE & REPAIR CENTERS; ELECTRICAL SCHEMATICS; vii
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 - SPECIFICATION INFORMATION
Page 10 - SECTION 1: SPECIFICATION INFORMATION; OPERATING CHARACTERISTICS
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...
Page 11 - ELECTRICAL REQUIREMENTS
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 ...
Page 12 - ELECTRICAL REQUIREMENTS:; PHASE
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 ...
Page 13 - Left to Right; Dr; Left Si
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/ ...
Page 14 - Left Side
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)...
Page 18 - Right to Left; Drive Uni
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 ...
Page 20 - Drive Unit; Recommended Table Fabr
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 ...
Page 22 - Front View
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 23 - Le
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 24 - Driv
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-...
Page 26 - t V
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 28 - Ri
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 ...
Page 30 - Right to; Recom
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 31 - MINIMUM; CONVEYOR
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...
Page 32 - DISHWASHER
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 ...
Page 33 - Refer to chart above.; 3” SIDE LOADER DIMENSIONS; MODEL
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-44AJ-66AJ-80 MODEL AJ-44AJ-66AJ-80 DIMEN...
Page 34 - D226 STEAM BOOSTER DIMENSIONS
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 arefor reference only. 43 11 24 14 4 43” 11” 14” 4” 24” 11” 16” 16” 13” 6” 16”
Page 35 - D226 STEAM BOOSTER PLUMBING LINE DRAWINGS; Steam Booster Piping - Double Tank Machine
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 - SingleTank Machine
Page 36 - TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS; INLET; Electical connection; RIGHT SIDE VIEW
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 E...
Page 38 - SECTION 2: INSTALLATION/OPERATION 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 som...
Page 39 - Ensure that the power switch is in the OFF; VENTILATION OF DISHMACHINE:; Terminal Block
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 design...
Page 40 - by an authorized service agent.; CHEMICAL FEEDER EQUIPMENT:; the page entitled “Detergent Control”.
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
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 andfollow all instructions on the label of the delimin...
Page 42 - CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL; PREPARATION
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 toleft. Directio...
Page 43 - Remove the pawl bar and set to the side.
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 stepmay require that you have help as the bolts for securing the...
Page 47 - Conveyor Switch Chart:; SPECIAL PARTS
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 - CURTAIN INSTALLATION DIAGRAMS
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...
Page 49 - of the Side Loader and then reinsert the strainer.; SIDE LOADER INSTALLATION & 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...
Page 50 - D226 STEAM BOOSTER INSTALLATION & OPERATION INSTRUCTIONS
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 52 - GAS CONVEYOR HOSE INSTALLATION; Barbed Hose Fitting
Due to the fact that each customer may have different requirements for the orientation of the gas booster heater relative to themain dishmachine, the hose lengths that connect the two units must be customized during each installation. The appropriate3/4” hosing, fittings and gaskets have been provid...
Page 53 - GAS CONVEYOR HOSE INSTALLATION (CONTINUED)
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 - At the end of the workday, place the power switch in; 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 a...
Page 55 - 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 of steam to the machine and open the door(s). Open the drain valves and allow the machine to draincompletely. Remove the pawl bar assembly (clean as required). Remove t...
Page 56 - CHANGING DUAL SANITIZATION MODE; CAN NOT
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 - 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 thewash tank regulating thermostat (see diagram). The wash tank regulating thermostat will maintain the correctwash water temperature. NSF ...
Page 58 - 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 effic...
Page 59 - STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS; Installation Instructions:
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 - PREVENTATIVE MAINTENANCE
Page 61 - SECTION 3: 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 repairsnot specifically discussed in this manual should be perform...
Page 63 - LUBRICATION CHART FOR DRIVE GEAR
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 reducerthat is installed on the rack con...
Page 64 - DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE
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 isinstalle...
Page 65 - TROUBLESHOOTING SECTION
Page 66 - Exercise extreme caution at all times.; If test points are not easily accessible, disconnect power, attach; Problem: Pawl bar moves with no load, but does not move when loaded.; Clutch on drive assembly is out of adjustment. Adjust as required.; SECTION 4: TROUBLESHOOTING; COMMON PROBLEMS
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service per- sonnel. Certain procedures in this section require electrical tests or measurements while power is applied to themachine. Exercise extreme caution at all times. If test points are not e...
Page 67 - Relays
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 themotor.3. Pawl bar not properly installed. Verify that the pawl bar is instal...
Page 68 - Problem: Power light does not illuminate.
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 themachine. Exercise extreme caution at all times. If test points are not e...
