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; MAW
iii REVISION REVISION DATE MADE BY APPLICABLE ECN DETAILS D 04-06-05 MAW 6999, 71937217, 70647212, 72596685, 70966964, 7006 Updated drawings for limit switch actuators. Changed AJ-86 drainplumbing copper lengths. Added rack rail stabilizer kit. Replacedheater 04540-121-76-93 with 04540-002-29-82. Up...
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 Model: Serial No.: Installation Date: Service Rep. Name: Phone No.: AJ-64CS AJ = AJ series of rack conveyors 64 = 64” wide machine86 = 86” wide machine100 = 100” wide machine CE = Electrically heated, hot water sanitizing machineCS = Steam heated...
Page 6 - TABLE OF CONTENTS
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 - PARTS
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 - Exhaust Fan Hook-Up Schematic; MAINTENANCE & REPAIR CENTERS; ELECTRICAL SCHEMATICS; vii
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 - SPECIFICATION INFORMATION
Page 10 - SECTION 1: SPECIFICATION INFORMATION; OPERATING CHARACTERISTICS
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 - ELECTRICAL REQUIREMENTS
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 - ELECTRICAL REQUIREMENTS:; PHASE
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 - ight Side; Left to Right; Dr; Left Side; mmended Table Fabrication
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° ...
Page 14 - Right to Left
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° ...
Page 18 - Left; Rec
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...
Page 19 - Lef
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 - Drive Unit
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...
Page 21 - Left to R; Recommended Table Fabr
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 - ight to Left
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 31 - MINIMUM; CONVEYOR
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 - DISHWASHER
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” MI...
Page 33 - SIDE LOADER INSTALLATION DIMENSIONS; Refer to chart above.; 3” SIDE LOADER DIMENSIONS; MODEL; Depending on the width of the
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-64AJ-86 AJ-100 MODEL AJ-64AJ-86...
Page 34 - D226 STEAM BOOSTER DIMENSIONS
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 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-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 - TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS; INLET; Electical connection; RIGHT SIDE VIEW
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 SID...
Page 38 - SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 G...
Page 39 - STEAM LINE CONNECTIONS:; Ensure that the power switch is in the OFF; VENTILATION OF DISHMACHINE:; Terminal Block
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 - by an authorized service agent.; CHEMICAL FEEDER EQUIPMENT:; Detergent may be introduced
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 - DELIMING OPERATIONS; Perform the following operations to delime the dishmachine:
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 - CURTAIN INSTALLATION DIAGRAMS
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...
Page 43 - 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 44 - 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 46 - GAS CONVEYOR HOSE INSTALLATION; Barbed Hose Fitting
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 themain ...
Page 47 - GAS CONVEYOR HOSE INSTALLATION (CONTINUED)
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 - 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 49 - 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 50 - 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 51 - STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS; Installation Instructions:
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 - PREVENTATIVE MAINTENANCE
Page 53 - 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 55 - LUBRICATION CHART FOR DRIVE GEAR
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 reducerthat is installed on the ...
Page 56 - DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE
Note: The maintenance procedures detailed here are manufacturer’s instructions for the WINSMITH brand of gear reducer thatis 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 le...
Page 57 - TROUBLESHOOTING SECTION
Page 58 - SECTION 4: TROUBLESHOOTING; COMMON PROBLEMS; 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.
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 - Relays
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 wi...
Page 60 - D226 TROUBLESHOOTING SECTION; Problem: Power light does not illuminate.
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...
