AJ-44 RACK CONVEYOR DISHMACHINE SERIES
INSTALLATION/OPERATION &
TECHNICAL MANUAL
FOR JACKSON MODELS:
AJ-44CE
AJ-44CEL
AJ-44CGP
AJ-44CS
AJ-66CE
AJ-66CEL
AJ-66CGP
AJ-66CS
AJ-80CE
AJ-80CEL
AJ-80CS
AJ-80CSL
AJ-44CSL
AJ-66CSL
Jackson MSC LLC.
P.O. Box 1060
Barbourville, KY. 40906
(606) 523-9795
Fax: (606) 523-9196
October 9, 2009
P/N 07610-001-76-22 (Revision I)
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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 PRODUIT NON- ENREGISTREE
ii
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REVISION/ REVISION
MADE APPLICABLE
DETAILS
PAGE
DATE
BY
ECN
D
05-14-2004
CBW
N/A
Added exhaust fan hook-up schematic.
Updated installation instructions. Added 3 instruction sheets for
limit switches. Added instruction sheet for curtain installation.
Changed layout.
E
03-08-2005
MAW
7096
F
01-13-2006
01-26-2006
CBW
MAW
7470
7600
Added service kits and maintenance instructions.
G
Added Gas Exhaust Fan Schematic & component kits.
Added themostat replacement kits. Added vent cowl assembly for
hooded side loader. Replaced rinse drain weldment. Added scrap
basket strainer kit.
7571, 7558
7634
H
03-21-2006
MAW
Added 09905-003-32-20 fan load decal to the exhaust fan control
kit. Added warranty pages and service centers listings.
98
04-19-2007
05-03-2007
MAW
MAW
MAW
KJS
7898
7913
N/A
Added instructions and all necessary information for change of
sanitization mode.
35 & 36
Updated dimension pages. Removed alternate table limit switch-
es.
5 thru 22, 111 08-29-2007
Changed the part from a weldment (05700-021-67-50) to a
casting (09515-003-58-12).
I
10-09-2009
8044
iii
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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 sanitizing machine
CSL = Steam heated, chemical sanitzing machine
CGP = Gas heated, hot water sanitizing machine
Model:
Jackson MSC LLC. provides technical support for all
of the dishmachines detailed in this manual. We
strongly recommend that you refer to this manual
before making a call to our technical support staff.
Please have this manual with you when you call so
that our staff can refer you, if necessary, to the prop-
er page. Technical support is available from 8:00
a.m. to 5:00 p.m. (EST), Monday through Friday.
Technical support is not available on holidays.
Contact technical support toll free at 1-888-800-
5672. Please remember that technical support is
available for service personnel only.
Serial No.:
Installation Date:
Service Rep. Name:
Phone No.:
iv
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TABLE OF CONTENTS
SECTION
I.
DESCRIPTION
PAGE
SPECIFICATION INFORMATION
Operating Characteristics
2
Electrical Requirements
3
D226 Steam Booster Parameters
AJ-44 Electric - Left to Right
AJ-44 Electric - Right to Left
AJ-44 Gas - Left to Right
4
5
6
7
AJ-44 Gas - Right to Left
8
AJ-44 Steam - Left to Right
AJ-44 Steam - Right to Left
AJ-66 Electric - Left to Right
AJ-66 Electric - Right to Left
AJ-66 Gas - Left to Right
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
AJ-66 Gas - Right to Left
AJ-66 Steam - Left to Right
AJ-66 Steam - Right to Left
AJ-80 Electric - Left to Right
AJ-80 Electric - Right to Left
AJ-80 Gas - Left to Right
AJ-80 Gas - Right to Left
AJ-80 Steam - Left to Right
AJ-80 Steam - Right to Left
Side Loader (Left to Right) Dimensions
Side Loader (Right to Left) Dimensions
Side Loader (Installed) Dimensions
D226 Steam Booster Dimensions
D226 Steam Booster Plumbing Line Drawings
Typical Electric and Gas Booster Dimensions
II.
INSTALLATION & OPERATION INSTRUCTIONS
Installation Instructions
30
33
34
40
41
42
44
46
48
50
51
Deliming Operations
Changing the AJ-44CE/CS Direction of Travel
Curtain Installation Diagrams
Side Loader Installation & Operation Instructions
D226 Steam Booster Installation & Operation Instructions
Gas Conveyor Hose Installation
Dishmachine Operating Instructions
Changing Dual Sanitizatio Mode
Detergent Control
Striker Plate Limit Switch Installation Instructions
III.
IV.
PREVENTATIVE MAINTENANCE
General Maintenance
D226 Maintenance
Lubrication Chart for Drive Gear
Drive Motor Gear Reducer Preventative Maintenance
53
54
55
56
TROUBLESHOOTING SECTION
Common Problems
D226 Common Problems
58
60
v
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TABLE OF CONTENTS
PARTS
V.
PARTS SECTION
AJ-44 Control Box Assembly
62
AJ-66/AJ-80 Control Box Assembly
Motor Overload Chart
64
66
Heater Assembly
67
Thermostats/Dress Panels
69
Prewash Plumbing Assembly
70
Wash Section Plumbing
71
External Electric Booster Option Incoming Plumbing
External Electric Booster Option Outlet Plumbing
Water Hammer Arrestor OptionWPRK Plumbing Option
3/4” Solenoid Valve & 3/4” NPT Vacuum Breaker Repair Parts Kits
Steam Unit Wash Tank Coil Assembly
Steam Plumbing (Left to Right)
72
73
74
75
76
77
Steam Plumbing (Right to Left)
78
Gas Coil Assembly (CGP Models)
Rinse Booster Tank Assembly (CGP Models)
Recirculating Pump Assembly (CGP Models)
Hose Connections (CGP Models)
Wash/Fill Plumbing Assembly (CGP Models)
Rinse Header Plumbing Assembly (CGP Models)
AJ-44 Series Drain Plumbing Assemblies
AJ-66 Drain Plumbing Assemblies
AJ-80 Drain Plumbing Assemblies
AJ-66 Drain Plumbing Assembly (Left to Right) (CGP Models)
AJ-66 Drain Plumbing Assembly (Right to Left) (CGP Models)
Drain Quench Assembly
79
80
81
82
83
84
85
86
87
88
89
90
Motor Assemblies
91
Prewash & Wash Pump Weldments
Lower Wash Arm Assembly
92
93
Prewash Arm/Upper Wash Arm Assembly
Curtains/Tub Magnets
94
95
Final Rinse Assembly
96
Drive Assembly
97
Door Assemblies
99
Pawl Bar Miscellaneous Components
AJ-44 & AJ-66 Pawl Bar Assemblies
AJ-80 Pawl Bar Assemblies
AJ-44 Rack Rail Assembly
AJ-66 Rack Rail Assemblies
100
101
102
103
104
105
106
107
108
109
110
111
AJ-80 Rack Rail Assemblies
Miscellaneous Parts & Weldments
Manifolds/Strainer Support Weldments
Strainers
Float Switch Components/Scrap Baskets
Vent Cowl Assembly/Vent Scoop Option
Exhaust Fan Control/Table Limit Switch
SIDE LOADER SECTION
Side Loader Track Assembly/Leg Replacements/Strainer
Side LoaderPawl Bar Assemblies/Pawl Bar Bracket/Magnet
Side Loader Vent Cowl Option
112
113
114
D226 STEAM BOOSTER SECTION
Control Box Assembly
Plumbing Assembly
Go*Box Components
115
116
118
119
BC Ferries Options
vi
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TABLE OF CONTENTS
ELECTRICAL SCHEMATICS
VI.
ELECTRICAL SCHEMATICS
AJ-44CE/CEL
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/60 Hz, 3 Phase Primary Side
200-230 Volt, 50/60 Hz, 3 Phase Secondary Side
380-460-600 Volt, 60 Hz, 3 Phase Primary Side
380-460-600 Volt, 60 Hz, 3 Phase Secondary Side
380-415 Volt, 50 Hz, 3 Phase Primary Side
380-415 Volt, 50 Hz, 3 Phase Secondary Side
440 Volt, 50 Hz, 3 Phase Primary Side
121
122
123
124
125
126
127
128
129
130
131
132
440 Volt, 50 Hz, 3 Phase Secondary Side
440 Volt, 50 Hz, 3 Phase, 5 Wire Primary Side
440 Volt, 50 Hz, 3 Phase, 5 Wire Secondary Side
AJ-44CS/CSL
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/60 Hz, 3 Phase Primary Side
200-230 Volt, 50/60 Hz, 3 Phase Secondary Side
380-415-440-460-600 Volt, 60 Hz, 3 Phase Primary Side
380-415-440-460-600 Volt, 60 Hz, 3 Phase Secondary Side
133
134
135
136
137
138
AJ-66CE/CEL & AJ-80CE/CEL
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/60 Hz, 3 Phase Primary Side
200-230 Volt, 50/60 Hz, 3 Phase Secondary Side
380-460-600 Volt, 60 Hz, 3 Phase Primary Side
380-460-600 Volt, 60 Hz, 3 Phase Secondary Side
380-415-440 Volt, 50 Hz, 3 Phase Primary Side
380-415-440 Volt, 50 Hz, 3 Phase Secondary Side
139
140
141
142
143
144
145
146
AJ-66CS/CSL & AJ-80CS/CSL
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/60 Hz, 3 Phase Primary Side
200-230 Volt, 50/60 Hz, 3 Phase Secondary Side
380-415-440-460-600 Volt, 60 Hz, 3 Phase Primary Side
380-415-440-460-600 Volt, 60 Hz, 3 Phase Secondary Side
147
148
149
150
151
152
AJ-44CGP
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/ Hz, 3 Phase Primary Side
200-230 Volt, 50/ Hz, 3 Phase Secondary Side
460 Volt/60 Hz/3 Phase Primary Side
153
154
155
156
157
158
460 Volt/60 Hz/3 Phase Primary Side
AJ-66CGP, AJ-80CGP
200-230 Volt, 50/60 Hz, 1 Phase Primary Side
200-230 Volt, 50/60 Hz, 1 Phase Secondary Side
200-230 Volt, 50/60 Hz, 3 Phase Primary Side
200-230 Volt, 50/60 Hz, 3 Phase Secondary Side
460 Volt, 50/60 Hz, 3 Phase Primary Side
460 Volt, 50/60 Hz, 3 Phase Secondary Side
Conveyor Side Loader/D226 Steam Booster
Exhaust Fan Hook-Up Schematics
159
160
161
162
163
164
165
166
VIII.
MAINTENANCE & REPAIR CENTERS
177
vii
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SECTION 1:
SPECIFICATION INFORMATION
1
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SECTION 1: SPECIFICATION INFORMATION
OPERATING CHARACTERISTICS
RACKS PER HOUR:
AJ-44-66-80CE/CS/CGP
AJ-44-66-80CEL/CSL
STEAM COIL TANK HEAT (CS/CSL MODELS ONLY):
STEAM INLET PRESSURE (PSIG) 10-20
248
234
STEAM CONNECTION NPT
CONSUMPTION @ 15 PSIG (lbs/hr):
AJ-44-66-80CS/CSL
3/4”
DISHES OR GLASSES PER HOUR:
AJ-44-66-80CE/CS/CGP
AJ-44-66-80CEL/CSL
60
6200
5850
MOTOR ELECTRICAL CHARACTERISTICS:
DRIVE MOTOR HP
WASH MOTOR HP
1/4
2
PREWASH TANK CAPACITY (GALLONS):
AJ-66CE/CEL/CS/CSL/CGP
AJ-80CE/CEL/CS/CSL/CGP
16
16
POWER RINSE MOTOR HP
PREWASH MOTOR HP:
AJ-66 MODELS
2
1
2
WASH TANK CAPACITY (GALLONS):
AJ-80 MODELS
AJ-44-66-80CE/CS/CGP
15.4
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 protec-
tion than what is displayed here. Always verify with your
electrical service contractor that your circuit protection is
adequate and meets all applicable national and local
codes. These numbers are provided in this manual sim-
ply for reference and may change without notice at any
given time.
PREWASH PUMP CAPACITY (GPM):
AJ-66CE/CEL/CS/CSL/CGP
AJ-80CE/CEL/CS/CSL/CGP
120
270
WASH PUMP CAPACITY
GALLONS PER MINUTE (ALL MODELS):
270
VENTING REQUIREMENTS (CFM)(100% CAP.):
INPUT END
OUTPUT END
TOTAL
200
400
600
CONVEYOR SPEED (FPM):
AJ-44-66-80CE/CS/CGP MACHINES
AJ-44-66-80CEL/CSL MACHINES
6.9
6.5
GALLONS PER RACK:
AJ-44-66-80CE/CS/CGP MACHINES
AJ-44-66-80CEL/CSL MACHINES
.94
1.00
WATER TEMPERATURES:
AJ-44-66-80CE/CS/CGP MODELS:
PREWASH (RECOMMENDED)
WASH (MINIMUM)
110-140°F
160°F
RINSE (MINIMUM)
180°F
AJ-44-66-80CEL/CSL MODELS:
PREWASH (RECOMMENDED)
WASH (MINIMUM)
110-140°F
140°F
RINSE (MINIMUM)
140°F
FLOW PRESSURE (PSI)
20±5
FLOWRATE (GPM):
AJ-44-66-80CE/CS/CGP
AJ-44-66-80CEL/CSL
3.9
3.9
MINIMUM CHLORINE (PPM)
AJ-44-66-80CEL/CSL MODELS ONLY:
50
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
2
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SECTION 1: SPECIFICATION INFORMATION
ELECTRICAL REQUIREMENTS
AJ-44CE/CEL MODELS
AJ-66CE/CEL MODELS
TYPICAL
TYPICAL
TOTAL ELECTRICAL
TOTAL ELECTRICAL
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
55 A
49 A
51 A
29 A
28 A
28 A
CIRCUIT
70 AMP
70 AMP
70 AMP
40 AMP
35 AMP
35 AMP
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
58 A
53 A
54 A
31 A
34 A
33 A
CIRCUIT
80 AMP
70 AMP
70 AMP
40 AMP
45 AMP
45 AMP
208
220
230
380
415
440
3
3
3
3
3
3
208
220
230
380
415
440
3
3
3
3
3
3
208
230
1
1
60
60
83 A
76 A
110 AMP
100 AMP
208
230
1
1
60
60
89 A
82 A
125 AMP
110 AMP
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
47 A
49 A
45 A
29 A
23 A
19 A
60 AMP
70 AMP
60 AMP
40 AMP
30 AMP
25 AMP
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
51 A
52 A
48 A
31 A
24 A
22 A
70 AMP
70 AMP
60 AMP
40 AMP
30 AMP
30 AMP
AJ-44CGP MODELS
AJ-66CGP MODELS
TYPICAL
ELECTRICAL
CIRCUIT
15 AMP
15 AMP
15 AMP
TYPICAL
ELECTRICAL
CIRCUIT
15 AMP
15 AMP
15 AMP
TOTAL
TOTAL
VOLTS PH
HZ
60
60
60
60
60
AMPS
12 A
11 A
8 A
7 A
5 A
VOLTS PH
HZ
60
60
60
60
60
AMPS
17 A
17 A
11A
11A
6 A
208
230
208
230
460
1
1
3
3
3
208
230
208
230
460
1
1
3
3
3
15 AMP
15 AMP
15 AMP
15 AMP
AJ-44CS/CSL MODELS
AJ-66CS/CSL MODELS
TYPICAL
ELECTRICAL
CIRCUIT
20 AMP
20 AMP
20 AMP
15 AMP
15 AMP
15 AMP
TYPICAL
ELECTRICAL
CIRCUIT
25 AMP
25 AMP
25 AMP
15 AMP
15 AMP
15 AMP
TOTAL
TOTAL
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
13 A
13 A
13 A
6 A
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
17 A
17 A
17 A
6A
208
220
230
380
415
440
3
3
3
3
3
3
208
220
230
380
415
440
3
3
3
3
3
3
7 A
6 A
7 A
6 A
208
230
1
1
60
60
11 A
11 A
15 AMP
15 AMP
208
230
1
1
60
60
18 A
18 A
25 AMP
25 AMP
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
7 A
7 A
7 A
6 A
4 A
4 A
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
12 A
12 A
12 A
12 A
7 A
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
7 A
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
3
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SECTION 1: SPECIFICATION INFORMATION
ELECTRICAL REQUIREMENTS (CONTINUED)/D226 STEAM BOOSTER PARAMETERS
AJ-80CE/CEL MODELS
D226 STEAM BOOSTER
TYPICAL
TOTAL ELECTRICAL
ELECTRICAL REQUIREMENTS:
VOLTAGE (V)
FREQUENCY (HZ)
PHASE
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
68 A
62 A
63 A
34 A
25 A
22 A
CIRCUIT
90 AMP
80 AMP
80 AMP
45 AMP
35 AMP
30 AMP
200-230
50/60
SINGLE
208
220
230
380
415
440
3
3
3
3
3
3
WATER REQUIREMENTS:
INCOMING WATER TEMPERATURE (MINIMUM)
FLOW PRESSURE (PSI)
110°F
20±5
208
230
1
1
60
60
91 A
84 A
125 AMP
110 AMP
STEAM REQUIREMENTS:
INCOMING STEAM PRESSURE (PSIG)
15-25
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
53 A
54 A
50 A
34 A
25 A
22 A
70 AMP
70 AMP
70 AMP
45 AMP
35 AMP
30 AMP
HEAT EXCHANGER SPECIFICATIONS:*
TUBESIDE WORKING PRESSURE (PSI)
SHELLSIDE WORKING PRESSURE (PSI)
TUBESIDE HYDROSTATIC TEST PRESSURE (PSI) 250
SHELLSIDE HYDROSTATIC TEST PRESSURE (PSI)
188
125
125
AJ-80CS/CSL MODELS
MAXIMUM OPERATING TEMPERATURE
MAXIMUM SHELLSIDE STEAM PRESSURE (PSI) 125
295°F
TYPICAL
ELECTRICAL
CIRCUIT
25 AMP
25 AMP
25 AMP
15 AMP
15 AMP
15 AMP
TOTAL
VOLTS PH
HZ
50
50
50
50
50
50
AMPS
19 A
19 A
19 A
7 A
* - Indicates typical design criteria but is subject to change
without notice. For more information, contact you authorized
Jackson service representative.
208
220
230
380
415
440
3
3
3
3
3
3
STEAM RELIEF VALVE SET PRESSURE (PSI):
WATER OUTLET SAFETY VALVE SET PRESSURE (PSI):
50
8 A
8 A
125
208
230
1
1
60
60
19 A
19 A
25 AMP
25 AMP
200
208
230
380
460
600
3
3
3
3
3
3
60
60
60
60
60
60
13 A
13 A
13 A
13 A
7 A
20 AMP
20 AMP
20 AMP
20 AMP
15 AMP
15 AMP
8 A
NOTE: Always refer to the machine data plate for specific
electrical and water requirements. The material provided
on this page is for reference only and may be subject to
change without notice.
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
4
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 ELECTRIC - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
5
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 ELECTRIC - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
6
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 GAS - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
7
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 GAS - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
8
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 STEAM - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
9
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SECTION 1: SPECIFICATION INFORMATION
AJ-44 STEAM - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
10
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 ELECTRIC - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
11
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 ELECTRIC - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
12
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 GAS - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
13
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 GAS - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
14
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 STEAM - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
15
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SECTION 1: SPECIFICATION INFORMATION
AJ-66 STEAM - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
16
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 ELECTRIC - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 ELECTRIC - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 GAS - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
19
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 GAS - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 STEAM - LEFT TO RIGHT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
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SECTION 1: SPECIFICATION INFORMATION
AJ-80 STEAM - RIGHT TO LEFT
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 09-29-2007
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SECTION 1: SPECIFICATION INFORMATION
SIDE LOADER (LEFT TO RIGHT) DIMENSIONS
1/2”
MINIMUM
DISHTABLE
NOTE: ALL DIMENSIONS ARE TYPICAL.
USE SILICONE
BETWEEN
TABLE AND LIP
OF SIDE
LOADER TO
PREVENT LEAK-
AGE.
WALL OF SIDE
LOADER
1/2”
25”
4 1/2”
MINIMUM
5”
DISHWASHER
SECTION “A-A”
12 1/2”
CENTER-LINE
DISHMACHINE
VENT CONNECTION
OPENING
CONVEYOR
DISHMACHINE
SPLASH SHIELD
A
A
1 1/2” DRAIN. CONNECTED
TO DISHMACHINE DRAIN
LINE
14 1/2”
* - 15” on 30” model
** - 30” on 30 “ model
29”
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 1: SPECIFICATION INFORMATION
SIDE LOADER (RIGHT TO LEFT) DIMENSIONS
DISHTABLE
1/2”
MINIMUM
NOTE: ALL DIMENSIONS ARE TYPICAL.
USE SILICONE
WALL OF SIDE
LOADER
BETWEEN TABLE
AND LIP OF SIDE
LOADER TO PRE-
VENT LEAKAGE
1/2”
25”
4 1/2”
MINIMUM
5”
DISHWASHER
SECTION “A-A”
12 1/2”
CENTER LINE
DISHMACHINE
VENT CONNECTION
OPENING
CONVEYOR
DISHMACHINE
SPLASH
SHIELD
A
A
14 1/2”
* - 15” on 30” model
** - 30” on 30 “ model
1 1/2” DRAIN. CONNECTED TO
DISHMACHINE DRAIN LINE
29”
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 1: SPECIFICATION INFORMATION
SIDE LOADER (INSTALLED) DIMENSIONS
23” SIDE LOADER DIMENSIONS
MODEL
AJ-44
DIMENSIONS
75”
AJ-66
97”
AJ-80
111”
(Left to Right installation shown for reference.)
30” SIDE LOADER DIMENSIONS
MODEL
AJ-44
AJ-66
DIMENSIONS
82”
104”
118”
AJ-80
NOTE: ALL DIMENSIONS ARE TYPICAL.
10”
4”
34”
23” or 30”
Refer to chart above.
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 1: SPECIFICATION INFORMATION
D226 STEAM BOOSTER DIMENSIONS
43”
11”
14”
4”
24”
NOTE: All dimensions are in inches and are
for reference only.
11”
16”
16”
16”
13”
6”
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 1: SPECIFICATION INFORMATION
D226 STEAM BOOSTER PLUMBING LINE DRAWINGS
Steam Booster Piping - Single
Tank Machine
Steam Booster Piping - Double Tank Machine
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 1: SPECIFICATION INFORMATION
TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS
Electric Booster Dimensions (Typical)
18”
30-1/2”
(
6”
24”
OUTLET
3/4" NPT
Coupling for
7-7/8”
1
3/4"
Temperature/Pressure
Relief Valve
18”
12”
(83 mm)
INLET
2”
Electical connection
from side or below
3/4" NPT Nipple
6”
SIDE VIEW
REAR VIEW
36”
20-3/4”
Alternate TPRV
Location
Electrical
Electrical
Water Outlet
Water Inlet
Gas Inlet
25-1/8”
Gas Water Water
Inlet Outlet Inlet
31-1/4”
6”
LEFT SIDE VIEW
Gas Booster Dimensions
(Typical)
Alternate
4" (102 mm)
Vent Adapter
TPRV
Flue
Location
Water Outlet
Water Inlet
Gas Inlet
Water Water Gas
Inlet Outlet Inlet
RIGHT SIDE VIEW
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 2:
INSTALLATION & OPERATION
INSTRUCTIONS
29
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION 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 some damage to the machine. If there is damage to both the container and machine, do not throw away
the container. The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new, undam-
aged condition. However, rough handling by carriers or others may result in damage to the unit while in transit. If such a situ-
ation occurs, do not return the unit to Jackson; instead, contact the carrier and ask them to send a representative to the site to
inspect the damage to the unit and to complete an inspection report. You must contact the carrier within 48 hours of receiving
the machine. Also, contact the dealer through which you purchased the unit.
UNPACKING THE DISHMACHINE: The machine should be unboxed and removed from shipping pallet prior to being installed.
Open the front door and remove all of the packing materials. Once unpacked, ensure that there are no missing parts from the
machine. This may not be obvious at first. If it is discovered that an item is missing, contact
Jackson immediately.
LEVEL THE DISHMACHINE: The dishmachine is designed to operate while being level. This is
important to prevent any damage to the machine during operation and to ensure the best results
when washing ware. The unit comes with adjustable bullet feet, which can be turned using a pair
of channel locks or by hand if the unit can be raised safely. Ensure that the unit is level from side
to side and from front to back before making any connections. You will be able to adjust the over-
all height of the unit by turning the bullet feet from between 75-1/2” to 76-1/2”.
Frame with Adjustable Foot
PLUMBING THE DISHMACHINE: All plumbing connections must comply with all applicable local, state, and national plumb-
ing codes. The plumber is responsible for ensuring that the incoming water line is thoroughly flushed prior to connecting it to
any component of the dishmachine. It is necessary to remove all foreign debris from the water line that may potentially get
trapped in the valves or cause an obstruction. Any valves that are fouled as a result of foreign matter left in the water line, and
any expenses resulting from this fouling, are not the responsibility of the manufacturer.
Water hardness should be a maximum of 6 grains per gallon. Harder water should be treated prior to using the machine. Iron
in the water supply can cause staining. A filter designed to remove iron from the supply water is highly recommended for sup-
plies in excess of 0.1 ppm (parts per million).
Adjusting screw
CONNECTING THE DRAIN LINE: The drain for the models covered in this
Locking nut
manual are gravity discharge drains. All piping from the machine to the drain
must be a minimum 1 1/2” NPT and should not be reduced. There must also be
an air gap between the machine drain line and the floor sink or drain. If a grease
trap is required by code, it should have a flow capacity of 30 gallons per minute.
WATER SUPPLY CONNECTION: Ensure that you have read the section enti-
tled “PLUMBING THE DISHMACHINE” above before proceeding. The supply
water temperature must meet the minimum requirements listed on the machine
data plate. Install the water supply line (3/4” pipe size minimum) to the dishma-
chine line strainer. It is recommended that a water shut-off valve be installed in
the water line between the main supply and the machine to allow access for ser-
Incoming Plumbing Connection
vice. The water supply line is to be capable of 25 PSI “flow” pressure at the rec-
ommended temperature indicated on the data plate.
If the water level is too low or too high, check the incoming water pressure. It should be 20 ± 5 PSI. Too high of pressure results
in too much water; too low of pressure results in too little water. To adust the regulator, loosen the nut at the top, this will allow
you to screw or unscrew the adjustment. With a screwdriver, turn the adjuster clockwise to increase pressure or counter clock-
wise to decrease it.
Do not confuse static pressure with flow pressure. Static pressure is the line pressure in a “no flow” condition (all valves and
services are closed). Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle.
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS (CONTINUED)
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 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 manufacturer’s instructions. Ensure that all applicable codes and
regulations are adhered to. See machine data plate for information concerning steam flow pressure.
GAS CONNECTIONS: Some machines covered in this manual are designed to use gas as an outside source of heat for wash
tank water. The machines come with connections by which an outside source needs to be connected. Connect all incoming gas
lines in accordance with the gas booster manufacturer’s instructions. Ensure that all applicable codes and regulations are
adhered to.
PLUMBING CHECK: Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been
installed. Check for any leaks and repair as required. All leaks must be repaired prior to placing the machine in operation.
ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with the 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 at the disconnect switch to indicate that you are working on the
circuit.
The dishmachine data plate is located on the right side and to
the front of the machine. Refer to the data plate for machine
operating requirements, machine voltage, total amperage load
and serial number.
Decal showing
“L1”, “L2”, & “L3”
(3 phase models
only).
To install the incoming power lines, open the control box. Install
conduit into the pre-punched holes in the back of the control box.
Route power wires and connect to power block and grounding
lug. Install the service wires (L1, L2, and L3 (3 phase only)) to
the appropriate terminals as they are marked on the terminal
block. Install the grounding wire into the lug provided. Tighten
the connections. It is recommended that “DE-OX” or another
similar anti-oxidation agent be used on all power connections.
Terminal Block
VOLTAGE CHECK: Ensure that the power switch is in the OFF
position and apply power to the dishmachine. Check the incom-
ing power at the terminal block and ensure it corresponds to the
voltage listed on the data plate. If not, contact a qualified service
agency to examine the problem. Do not run the dishmachine if
the voltage is too high or too low. Shut off the service breaker
and mark it as being for the dishmachine. Advise all proper per-
sonnel of any problems and of the location of the service break-
er. Replace the control box cover and tighten down the screws.
Incoming Power Connection
VENTILATION OF DISHMACHINE: The dishmachine should be located with provisions for venting into an adequate exhaust
hood or ventilation system. This is essential to permit efficient removal of the condensation exhaust. Ensure that the exhaust
system is acceptable in accordance with all applicable codes and standards.
NOTE: Any damage that is caused by steam or moisture due to improper ventilation is NOT covered under the war-
ranty.
This units covered in this manual have the following exhaust requirements:
Load End:
Unload End:
200 CFM
400 CFM
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS (CONTINUED)
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-44CEL/CSL, AJ-66CEL/CSL, and AJ-80CEL/CSL are designed to operate with a
third party chemical injection system. Jackson does not endorse any particular chemical injection system. The system select-
ed must be able to provide detergent and sanitizer in the required concentrations. The minimum chlorine concentration for prop-
er sanitization is 50 PPM. Furthermore, the selected feeder needs to be able to operate against a head of 25 PSI and deliver
7.38 ml of a 10% chlorine sanitizer per minute.
Detergent may be introduced into the unit through the removal of the
bulkhead plug in the rear of the tub and replacing it with the third
party detergent injection fitting. Remove the bulkhead plug in the
side of the tub to install the detergent concentration probe.
For more information concerning detergent concerns, please refer to
the page entitled “Detergent Control”.
Brass Plug
Detergent Connection Point
(Machine rear view)
The 1/8” brass plugs on the incoming plumbing rinse injector may be removed to install
sanitizer and rinse aid injection fittings.
Brass Plugs
Back of Control Box
All wires for the chemical injectors should be routed
through one
of the extra openings in the back of the control box.
Terminals in the control box marked “CVS” provide a constant voltage signal whenever the
drive motor is operating.
Terminals in the control box marked “DET” provide a voltage signal whenever the wash motor
is operating.
Aid Connection Points
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 and
follow all instructions on the label of the deliming solution.
To proceed with the deliming operation, fill the dishmachine and add the correct amount of deliming solution as recommended
by the deliming solution manufacturer. The water capacity of the various tanks of the dishmachine can be verified on the spec-
ification sheet(s) of this manual.
Perform the following operations to delime the dishmachine:
1. Turn the AUTOMATIC/DELIME switch on the back of the control box to the DELIME position.
2. Disconnect or turn off all chemical feeder pumps.
3. Close all doors (after adding the deliming solution).
4. Run the machine for the recommended period of time.
5. Turn the unit off and open the doors.
Delime Switch
6. Wait five minutes, then inspect the inside of the machine. If the machine is not delimed, run another time cycle as per the
deliming solution’s instructions.
7. When clean, drain and re-fill the machine.
8. Run in MANUAL for 10 minutes to remove residual deliming solution.
9. Drain and re-fill the machine.
This equipment is not recommend for use with deionized water or other aggressive fluids. Use of deionized water or
other aggressive fluids will result in corrosion and failure of materials and components. Use of deionized water or
other aggressive fluids will void the manufacturer's warranty.
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL
The AJ-44 dishmachine has the ability to have its
2. Read these instructions thoroughly before attempt-
direction of travel changed from left to right, or from right to ing this maintenance evolution. Become familiar with the parts
left. Direction of travel is determined by which end the rack of and what actions need to be taken. This will save time in the
ware is put into the machine and which end the rack comes long run!
out.
There may come times when it is necessary to
change the direction of travel after the unit is installed. The
instructions provided here are for maintenance personnel only.
Unauthorized persons should not attempt any of the steps
contained in these instructions.
STEPS
1. Remove the upper wash arm assembly by loosening the
spin nut. The spin nut has a stop so it will not come off. Once
it is loosened, the wash arm assembly should slide off.
Warning: many of the instructions and steps
within this document require the use of tools and may
also require that personnel change the wiring of the
machine. Only authorized personnel should ever perform
any maintenance evolution on the dishmachine!
PREPARATION
1. Power must be secured to the unit at the service
breaker. Tag or lock out the service breaker to prevent acci-
dental or unauthorized energizing of the machine.
2. Disconnect incoming water at the water pressure
regulator or Y-strainer.
3. Disconnect the service drain line from the drain
plumbing of the dishmachine itself. Ensure that the unit is
completely drained before doing this.
Spin nut
4. Remove the locking screw from the control box.
5. Remove the front dress panel.
2. Remove the end cap from the wash arm assembly and
place in the opposite end, securing it snugly.
TOOLS REQUIRED
The following tools will be needed to perform this
maintenance evolution:
1. 5/16” nutdriver
2. 7/16” nutdriver
3. 7/16” combination wrench
4. 7/16” socket with drive ratchet and 4” extension
5. 12” pipe wrench
6. 10” adjustable wrench
7. Wire cutters
8. Phillipshead screwdriver
TIME REQUIRED
It is estimated that it will take (1) person three hours
to perform this task, not including all of the items indicated in
the section entitled “PREPARATION”.
End cap
IMPORTANT NOTES
3. With the end cap securely in the opposite end of the wash
arm assembly, set the assembly gently to the side. Go back
inside the unit to where the upper wash arm assembly secured
in the unit and turn the spin nut so that it is all the way down.
This needs to be done because in a further step, if the spin nut
is out, it will get in the way. Do not over-tighten the spin nut as
it only needs to be out of the way, not secured.
1. Do not lose hardware! Place hardware in a safe
spot away from the machine, ensuring that it does not fall
loose into the machine tub. Hardware that is drawing into the
suction of the wash pump will damage the equipment. If you
do need more hardware, contact your JACKSON representa-
tive to purchase new items.
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL (CONTINUED)
4. Remove the upper wash arm assembly bracket. This step
may require that you have help as the bolts for securing the
bracket to the top of the inner hood are the same bolts that
hold the control box to the hood top. Do not remove the bolts
once the nuts are taken off. Once the bracket is removed,
place the nuts immediately back on the bolts. To hold the bolts
(to keep them from spinning), a 7/16” combination wrench or
7/16” nutdriver will be required in order to hold the bolt head
inside the control box.
Removing and turning splash shield
6. Remove the pawl bar and set to the side.
Removing bracket (bottom view)
Remove the pawl bar by grasping firmly and
lifting up.
7. Remove the lower wash arm assembly by turning the lock-
ing screw to unlatch it. The entire assembly should then lift
out.
Removing bracket (control box view)
Remove the locknuts from the opposite bolts used to hold
down the control box (do not remove the bolts) and secure the
bracket to underside of the hood. The folded part of the brack-
et should be facing the rear of the machine. Immediately tight-
en down the locknuts.
Locking screw
8. Remove the lower wash arm support bracket. Place it to the
side with its locknuts.
5. Remove the splash shield, which is bolted to the underside
of the hood next to the wash manifold and turn it 180°.
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL (CONTINUED)
Removing the bracket nut
Removing the locknuts for the lower wash arm
support bracket.
9. Remove the lower rinse arm support bracket, which is 12. Remove the nuts from the rinse manifold mounting brack-
mounted directly opposite of the lower wash arm support et located on the underside of the hood. These nuts are
bracket.
mounted directly to the rinse injector weldment on the hood
top.
Removing the locknuts from the rinse mani-
fold mounting bracket
Removing the lower rinse arm support bracket
13. The rinse manifold must be removed. This may prove dif-
10. Remove the lower and upper rinse arms by unscrewing ficult while the rinse injector is still mounted. With great care,
them and then gently pulling them out.
it is possible to gently lift the rinse injector off of the hood to
allow the rinse manifold to be removed from the unit. Ensure
that the gasket in the underside of the hood stays with the
rinse manifold as it must be replaced when re-installing the
manifold. If the gasket becomes lost or torn, order a new one
immediately.
Unscrewing and removing the lower rinse arm
11. Behind the rinse manifold, remove the nut on the bracket.
Lifting the rinse injector to make room
14. Remove the entire rinse tray assembly, including the pan
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL (CONTINUED)
and the strainer within in. The assembly should lift right out. mantling the plumbing by removing the tee with the wash drain
(See next page for photograph detailing this step)
barb in it. Put the plumbing back together, after ensuring that
the rinse drain tee has been rotated. Use thread tape to pro-
15. Remove the front and rear rinse pan locator brackets. tect the threads while putting the plumbing back together.
Note: the brackets are mounted to the bolts that secure Ensure that the wash drain barb is in the exact same position
the tub weldment to the frame. Once the locknuts are it was prior to this step.
removed, pull the locator brackets off and immediately replace
the locknuts back onto the bolts. Failure to do so at a minimum 18. On the underside of the tub, remove the rinse drain weld-
may cause excessive leaking of the tub once the unit is placed ment and the rinse drain plug. Switch their locations so that
back in operation.
the rinse drain weldment is in the spot that the rinse drain plug
was in.
Lifting out the rinse tray assembly
Removing the rinse drain weldment
Removing a rinse tray guide bracket
16. On the drain plumbing, the rinse drain tube needs to be
removed from the plumbing, as well as the wash drain tube.
Both of these tubes are secured with hose clamps. Loosen the
hose clamps and pull the tubes off.
Removing the rinse drain plug
19. Reconnect the rinse drain hose and the wash drain hose
to the drain plumbing.
20. On the opposite end from where they were removed,
install the front and rear rinse pan assembly locating brackets.
Note: the brackets are mounted to the bolts that secure
the tub weldment to the frame. Install the brackets one at a
time and ensure that they are firmly tightened down once
installed.
21. Remove the hole cover weldment from the top of the hood.
The cover is located on the end of the hood opposite of the
rinse injector weldment. Once removed, set to the side along
with its gasket.
Loosening the rinse drain hose from the rinse
drain nipple
17. The tee that the rinse drain nipple is in must be turned 180°
so that it is facing the opposite direction. This may require dis-
AJ-44C Series Technical Manual 7610-001-76-22
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