AJ-44T SERIES RACK CONVEYOR DISHMACHINE
INSTALLATION/OPERATION &
TECHNICAL MANUAL
AJ-44T SERIES
AJ-66T SERIES
AJ-80T SERIES
AJ-44TE
AJ-44TG
AJ-44TS
AJ-66TE
AJ-66TG
AJ-66TS
AJ-80TE
AJ-80TS
AND ASSOCIATED OPTION PACKAGES INCLUDING:
SIDE LOADER
Jackson MSC LLC.
P.O. Box 1060
Barbourville, KY. 40906
(606) 523-9795
Fax: (606) 523-9196
September 29, 2007
P/N 7610-003-07-21 (Revision C)
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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
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REVISION
DATE
MADE APPLICABLE
REVISION
DETAILS
BY
ECN
A
08-03-2005
MAW
7442
Initial release of manual.
Added gas exhaust fan schematic, updated electric exhaust fan
7600, 7558 schematic. Replaced rinse drain weldment 05700-021-68-28 with
7462, 7367 05700-002-51-12. Added wash, rinse and psi decals. Changed
B
02-13-2006
MAW
7463
the door assemblies. Added the rinse fill motor assembly. Added
Gas Models.
Change to new layout. Change themostats and add replacement
kits.
C
3-21-2006
04-19-2007
09-29-2007
MAW
MAW
MAW
7571
7898
N/A
PG. 100
Added 09905-003-32-20 fan load decal.
Updated dimension pages. Removed alternate table limit switch-
es.
4 thru 21, 91
i
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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 machine
Jackson MSC LLC. provides technical support for all
Model:
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.:
ii
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TABLE OF CONTENTS
SECTION
I.
DESCRIPTION
PAGE
SPECIFICATION INFORMATION
Operating Characteristics
2
Electrical Requirements
3
AJ-44T Electric - Left to Right
AJ-44T Electric - Right to Left
AJ-44T Gas - Left to Right
4
5
6
AJ-44T Gas - Right to Left
7
AJ-44T Steam - Left to Right
AJ-44T Steam - Right to Left
AJ-66T Electric - Left to Right
AJ-66T Electric - Right to Left
AJ-66T Gas - Left to Right
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
AJ-66T Gas - Right to Left
AJ-66T Steam - Left to Right
AJ-66T Steam - Right to Left
AJ-80T Electric - Left to Right
AJ-80T Electric - Right to Left
AJ-80T Gas - Left to Right
AJ-80T Gas - Right to Left
AJ-80T Steam - Left to Right
AJ-80T Steam - Right to Left
Side Loader (Left to Right) Dimensions
Side Loader (Right to Left) Dimensions
Side Loader (Installed) Dimensions
II.
INSTALLATION & OPERATION INSTRUCTIONS
Installation Instructions
26
29
30
31
32
34
35
Curtain Installation Diagram
Deliming Operations
Side Loader Installation & Operation Instructions
Dishmachine Operating Instructions
Detergent Control
Striker Plate Limit Switch Installation Instructions
III.
PREVENTATIVE MAINTENANCE
General Maintenance
37
38
39
Lubrication Chart for Drive Gear
Drive Motor Gear Reducer Preventative Maintenance
IV.
V.
TROUBLESHOOTING
41
PARTS SECTION
AJ-44T Control Box Assembly
AJ-66T/AJ-80T Control Box Assembly
Motor Overload Chart
Heater Box Assembly
Frame Weldments/Front Dress Panels
Prewash Plumbing Assembly
44
46
48
49
52
53
55
57
58
59
60
61
62
Incoming Plumbing Assembly
Incoming Plumbing Assembly (TG Series)
Solenoid Valve & Vacuum Breaker Repair Parts
Steam Unit Wash Tank Coil Assembly
Steam Plumbing (Left to Right Models)
Steam Plumbing (Right to Left Models)
Gas Coil Assembly (TG Models)
iii
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TABLE OF CONTENTS
SECTION
V.
DESCRIPTION
PAGE
PARTS SECTION (CONTINUED)
Rinse Booster Tank Assembly (TG Models)
Recirculating Pump Assembly (TG Models)
Hose Connections (TG Models)
AJ-44T Series Drain Plumbing Assemblies
AJ-66T Series Drain Plumbing Assemblies
AJ-80T Series Drain Plumbing Assemblies
AJ-66TG Series (Left to Right) Drain Plumbing Assembly
AJ-66TG Series (Right to Left) Drain Plumbing Assembly
Drain Quench Assembly
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
79
80
81
82
83
84
85
86
87
88
89
90
91
Motor Assemblies
Prewash & Wash Pump Weldments
Prewash Arm/Manifold Assembly
Wash Arm/Manifold Assembly
Final Rinse Assembly
Drive Assembly
Door Assemblies
Pawl Bar Roller Bracket
AJ-44T & AJ-66T Pawl Bar Assemblies
AJ-80T Pawl Bar Assemblies
AJ-44T Rack Rail Assembly
AJ-66T Rack Rail Assemblies
AJ-80T Rack Rail Assemblies
Miscellaneous Parts & Weldments
Strainers
Float Switch Components/Scrap Baskets
Curtains/Tub Magnets
Vent Cowl Assembly/Vent Scoop Option
Exhaust Fan Control/Limit Switch Options
SIDE LOADER SECTION
Side Loader Track Assembly/Leg Replacements
Side Loader Pawl Bar Assemblies/Strainer/Magnet
Side Loader Pawl Bar Associated Parts
Side Loader Vent Cowl Option
Rinse Fill Option
92
93
94
95
96
VI.
ELECTRICAL SCHEMATICS
AJ-44TE
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
AJ-44TG
98
99
100
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
AJ-44TS
101
102
103
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
AJ-66TE & AJ-80TE
104
105
106
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
107
108
109
iv
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TABLE OF CONTENTS
SECTION
VII.
DESCRIPTION
PAGE
ELECTRICAL SCHEMATICS
AJ-66TG & AJ-80TG
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
110
111
112
AJ-66TS & AJ-80TS
208-230 Volt, 60 Hz, 1 Phase
208-230 Volt, 60 Hz, 3 Phase
460 Volt, 60 Hz, 3 Phase
113
114
115
116
117
Conveyor Side Loader/Drain Quench Schematics
Exhaust Fan Hook-Up Schematics
VIII.
JACKSON MAINTENANCE & REPAIR CENTERS
118
v
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SECTION 1:
SPECIFICATION INFORMATION
1
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SECTION 1: SPECIFICATION INFORMATION
OPERATING CHARACTERISTICS
RACKS PER HOUR:
STEAM COIL TANK HEAT (TS MODELS ONLY):
STEAM INLET PRESSURE (PSIG)
AJ-44-66-80TE/TG/TS
204
10-20
3/4”
60
STEAM CONNECTION NPT
CONSUMPTION @ 15 PSIG (lbs/hr):
DISHES OR GLASSES PER HOUR:
AJ-44-66-80TE/TG/TS
5100
MOTOR ELECTRICAL CHARACTERISTICS:
PREWASH TANK CAPACITY (GALLONS):
DRIVE MOTOR HP
WASH MOTOR HP
POWER RINSE MOTOR HP
PREWASH MOTOR HP:
AJ-66TE/TG/TS MODELS
AJ-80TE/TG/TS MODELS
1/4
2
2
AJ-66TE/TG/TS
AJ-80TE/TG/TS
17.25
17.25
1
2
WASH TANK CAPACITY (GALLONS):
AJ-44-66-80TE/TG/TS
20.4
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.
PREWASH PUMP CAPACITY (GPM):
AJ-66TE/TG/TS
AJ-80TE/TG/TS
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-44-66-80TE/TG/TS MACHINES
5.7
.69
GALLONS PER RACK:
AJ-44-66-80TE/TG/TS MACHINES
WATER TEMPERATURES:
AJ-44-66-80TE/TG/TS MODELS:
PREWASH (RECOMMENDED) (AJ-66 & AJ-80) 110-140°F
WASH (MINIMUM)
RINSE (MINIMUM)
160°F
180°F
FLOW PRESSURE (PSI)
FLOWRATE (GPM):
20±5
AJ-44-66-80TE/TG/TS
3.1
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
2
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SECTION 1: SPECIFICATION INFORMATION
ELECTRICAL REQUIREMENTS
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 service contractor that your circuit protection is adequate
and meets all applicable national and local codes. These numbers are provided in this manual simply for reference
and may change without notice at any given time.
RINSE
HEATER
RATINGS
N/A
N/A
N/A
TYPICAL
TOTAL ELECTRICAL
MODEL
AJ-44TE
AJ-44TE
AJ-44TE
AJ-44TE
AJ-44TE
VOLTS
208
230
208
230
PH HZ
AMPS
97 A
89 A
57 A
49 A
25 A
CIRCUIT
125 AMP
125 AMP
80 AMP
70 AMP
35 AMP
1
1
3
3
3
60
60
60
60
60
N/A
N/A
460
AJ-44TG
AJ-44TG
AJ-44TG
AJ-44TG
AJ-44TG
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
12 A
12 A
8 A
8 A
5 A
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
AJ-44TS
AJ-44TS
AJ-44TS
AJ-44TS
AJ-44TS
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
11 A
11 A
7 A
7 A
4 A
15 AMP
15 AMP
15 AMP
15 AMP
15 AMP
AJ-66TE
AJ-66TE
AJ-66TE
AJ-66TE
AJ-66TE
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
103 A
95 A
61 A
52 A
26 A
150 AMP
125 AMP
80 AMP
70 AMP
35 AMP
AJ-66TG
AJ-66TG
AJ-66TG
AJ-66TG
AJ-66TG
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
18 A
18 A
12 A
12 A
7 A
25 AMP
25 AMP
15 AMP
15 AMP
15 AMP
AJ-66TS
AJ-66TS
AJ-66TS
AJ-66TS
AJ-66TS
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
17 A
17 A
11 A
11 A
6 A
25 AMP
25 AMP
15 AMP
15 AMP
15 AMP
AJ-80TE
AJ-80TE
AJ-80TE
AJ-80TE
AJ-80TE
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
106 A
97 A
63 A
58 A
29 A
150 AMP
125 AMP
80 AMP
80 AMP
40 AMP
AJ-80TG
AJ-80TG
AJ-80TG
AJ-80TG
AJ-80TG
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
19 A
19 A
13 A
13 A
7 A
25 AMP
25 AMP
20 AMP
20 AMP
15 AMP
AJ-80TS
AJ-80TS
AJ-80TS
AJ-80TS
AJ-80TS
208
230
208
230
460
1
1
3
3
3
60
60
60
60
60
N/A
N/A
N/A
N/A
N/A
19 A
19 A
13 A
13 A
7 A
25 AMP
25 AMP
20 AMP
20 AMP
15 AMP
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
3
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T ELECTRIC - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
4
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T ELECTRIC - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
5
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T GAS - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
6
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T GAS - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
7
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T STEAM - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
8
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SECTION 1: SPECIFICATION INFORMATION
AJ-44T STEAM - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
9
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T ELECTRIC - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
10
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T ELECTRIC - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
11
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T GAS - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
12
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T GAS - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
13
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T STEAM - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
14
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SECTION 1: SPECIFICATION INFORMATION
AJ-66T STEAM - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
15
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T ELECTRIC - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
16
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T ELECTRIC - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
17
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T GAS - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
18
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T GAS - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
19
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T STEAM - LEFT TO RIGHT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
20
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SECTION 1: SPECIFICATION INFORMATION
AJ-80T STEAM - RIGHT TO LEFT
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: 09-29-2007
21
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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”
29”
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
22
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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”
1 1/2” DRAIN. CONNECTED TO
DISHMACHINE DRAIN LINE
29”
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
23
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SECTION 1: SPECIFICATION INFORMATION
SIDE LOADER (INSTALLED) DIMENSIONS
23” SIDE LOADER DIMENSIONS
MODEL
AJ-44T
AJ-66T
AJ-80T
DIMENSIONS
75”
97”
111”
(Left to Right installation shown for reference.)
30” SIDE LOADER DIMENSIONS
MODEL
AJ-44T
AJ-66T
AJ-80T
DIMENSIONS
82”
104”
118”
NOTE: ALL DIMENSIONS ARE TYPICAL.
10”
4”
34”
23” or 30” depending on
the width of the side
loader.
Refer to chart above.
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
24
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SECTION 2:
INSTALLATION & OPERATION
INSTRUCTIONS
25
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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”.
PLUMBING THE DISHMACHINE: All plumbing connections must comply with all applicable local,
state, and national plumbing 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).
CONNECTING THE DRAIN LINE: The drain for the models covered in this
Adjusting screw
Locking nut
manual are gravity discharge drains. All piping from the machine to the drain
must be a minimum 1 1/2” NPT and shall 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 (1/2” 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-
vice. The water supply line is to be capable of 25 PSI “flow” pressure at the rec-
ommended temperature indicated on the data plate.
Incoming Plumbing Connection
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.
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.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS (CONTINUED)
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
Decal showing
“L1”, “L2”, & “L3”
and serial number.
(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
The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS (CONTINUED)
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 replacing it with the third party detergent injection fitting.
Remove the bulkhead plug in the side of the tub to install the deter-
gent concentration probe.
For more information concerning detergent concerns, please refer to
the page entitled “Detergent Control”.
Detergent Connection Point
(Machine rear view)
Brass Plug
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
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CURTAIN INSTALLATION DIAGRAMS
Please refer to the chart for
placement of the curtains.
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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 NORMAL/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.
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.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 is operated mechanically by the dishwasher it does not require any plumbing or elec-
trical connections.
This Side Loader does not require or add any additional electrical or mechanical devices to the unit which could create opera-
tional or maintenance problems. As designed the drive mechanism is powered by the conveyor drive motor on the dishma-
chine. An extension on the pawl bar provides the drive to push the racks into the unit.
PREPARATION: Before proceeding with the start-up of the unit, verify that the Side Loader pan strainer is installed.
WARE PREPARATION: Proper preparation of ware will help ensure good results and less re-washes. If not done properly, ware
may not come out clean and the efficiency of the dishmachine will be reduced. It is important to remember that a dishmachine
is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether
of washing the ware. Scraps should be removed from ware prior to being loaded into a rack. Pre-rinsing and pre-soaking are
good ideas, especially for silverware and casserole dishes. Place cups and glasses upside down in racks so that they do not
hold water during the cycle. The dishmachine is meant not only to clean, but to sanitize as well, to destroy all of the bacteria
that could be harmful to human beings. In order to do this, ware must be properly prepared prior to being placed in the machine.
WASHING A RACK OF WARE: Once a rack is fully loaded it should be positioned against the front of the dish table. The rack
should then be moved into the Side Loader until it activates the actuator switch. Once the the machine is started, it should pull
the rack through the machine and push it out the unload end. Once a rack has started through, you may put another rack in.
OPERATIONAL INSPECTION: Based upon usage, the pan strainer may become clogged with soil and debris as the workday
progresses. Operators should regularly inspect the pan strainer to ensure it has not become clogged. If the strainer does
become clogged, it will reduce the washing capability of the machine. Instruct operators to clean out the pan strainer at regu-
lar intervals or as required by work load.
SHUTDOWN AND CLEANING: At the end of the workday, remove the pan strainer and clean as required. Wipe out the inside
of the Side Loader and then reinsert the strainer.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 as being correct. If not, the voltage will have to be verified.
POWER UP (GAS-HEATED MODELS): To energize the unit, turn on the power at the service breaker. The voltage should have
been previously verified as being correct. If not, the voltage will have to be verified. Ensure that the gas service is connected
and that gas is flowing to the machine. Without gas, the water will not reach the required minimum temperatures that the
machine is designed to operate at.
POWER UP (STEAM-HEATED MODELS): To energize the unit, turn on the power at the service breaker. The voltage should
have been previously verified as being correct. If not, the voltage will have to be verified. Ensure that the steam service is con-
nected and that steam is flowing to the machine. Without steam, the water will not reach the required minimum temperatures
that the machine is designed to operate at.
FILLING THE WASH TUB: Ensure that the delime switch is in the NORMAL position, and place the power switch into the ON
position. The machine should fill automatically and shut off when the appropriate level is reached (just below the pan strainer).
The wash tub must be completely filled before operating the wash pump to prevent damage to the component. Once the wash
tub is filled, the unit is ready for operation.
Machines equipped with prewash sections should not be run without water in those sections. This can cause
damage to components.
WARE PREPARATION: Proper preparation of ware will help ensure good results and less re-washes. If not done properly, ware
may not come out clean and the efficiency of the dishmachine will be reduced. It is important to remember that a dishmachine
is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether
of washing the ware. Scraps should be removed from ware prior to being loaded into a rack. Pre-rinsing and pre-soaking are
good ideas, especially for silverware and casserole dishes. Place cups and glasses upside down in racks so that they do not
hold water during the cycle. The dishmachine is meant not only to clean, but to sanitize as well, to destroy all of the bacteria
that could be harmful to human beings. In order to do this, ware must be properly prepared prior to being placed in the machine.
DAILY MACHINE PREPARATION: Refer to the section entitled “PREPARATION” at the top of this page and follow the instruc-
tions there. Afterwards, check that all of the chemical levels are correct and/or that there is plenty of detergent available for the
expected workload.
WASHING A RACK OF WARE: To wash a rack, simply slide a rack of soiled ware into the load end of the machine. Once the
the machine is started, it should pull the rack through the machine and push it out the unload end. Once a rack has started
through, you may put another rack in.
OPERATIONAL INSPECTION: Based upon usage, the pan strainers may become clogged with soil and debris as the work-
day progresses. Operators should regularly inspect the pan strainers to ensure they have not become clogged. If the strainers
do, they will reduce the washing capability of the machine. Instruct operators to clean out the pan strainers at regular intervals
or as required by work load.
NOTE: On units equipped with prewash sections (AJ-66 & AJ-80), operators should also take the time to inspect the prewash
section strainers and clean them as required by workload.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
DISHMACHINE OPERATION INSTRUCTIONS (CONTINUED)
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, the prewash strainers, run off sheets and scrap bas-
ket strainer. Remove the wash and, if equipped, the prewash arms and verify that the nozzles and arms are free from obstruc-
tions. Flush the arms with fresh water. Remove the pump suction strainers and clean out as required. Remove the rinse tray
assembly and clean. Remove the curtains and scrub with a mild detergent and warm water. Wipe out the inside of the unit and
then reassemble with the components previously removed.
SHUTDOWN AND CLEANING (GAS-HEATED MODELS): At the end of the work day, shut down the gas booster in accor-
dance with manufacturer’s instructions. Place the power switch in the OFF position, secure the flow 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 the pan strainers and, if equipped, the prewash strainers, run off sheets and scrap basket strainer. Remove
the wash and, if equipped, the prewash arms and verify that the nozzles and arms are free from obstructions. Flush the arms
with fresh water. Remove the pump suction strainers and clean out as required. Remove the rinse tray assembly and clean.
Remove the curtains and scrub with a mild detergent and warm water. Wipe out the inside of the unit and then reassemble with
the components previously removed.
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 the pan strainers and, if equipped, the prewash strain-
ers, run off sheets and scrap basket strainer. Remove the wash and, if equipped, the prewash arms and verify that the nozzles
and arms are free from obstructions. Flush the arms with fresh water. Remove the pump suction strainers and clean out as
required. Remove the rinse tray assembly and clean. Remove the curtains and scrub with a mild detergent and warm water.
Wipe out the inside of the unit and then reassemble with the components previously removed.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 efficiency from your detergent, but you should still know some basics so you’ll
understand what they are talking about.
First, you must understand that hard water greatly effects the performance of the dishmachine. Water hardness is the amount
of dissolved calcium and magnesium in the water supply. The more dissolved solids in the water, the greater the water hard-
ness. Hard water works against detergent, thereby causing the amount of detergent required for washing to increase. As you
use more detergent, your costs for operating the dishmachine will increase and the results will decrease. The solids in hard
water also may build-up as a scale on wash and rinse heaters, decreasing their ability to heat water. Water temperature is
important in removing soil and sanitizing dishes. If the water cannot get hot enough, your results may not be satisfactory. This
is why Jackson recommends that if you have installed the machine in an area with hard water, that you also install some type
of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine.
Second, hard water may have you adding drying agents to your operating cycle to prevent spotting, when the real problem is
deposited solids on your ware. As the water evaporates off of the ware, the solids will be left behind to form the spotting and
no amount of drying agent will prevent this. Again, using treated water will undoubtedly reduce the occurrences of this prob-
lem.
Third, treated water may not be suitable for use in other areas of your operation. For instance, coffee made with soft water may
have an acid or bitter flavor. It may only be feasible to install a small treatment unit for the water going into the dishmachine
itself. Discuss this option with your qualified water treatment specialist.
Even after the water hardness problems have been solved, there still must be proper training of dishmachine operators in how
much detergent is to be used per cycle. Talk with your water treatment specialist and detergent vendor and come up with a
complete training program for operators. Using too much detergent has as detrimental effects as using too little. The proper
amount of detergent must be used for job. It is important to remember that certain menu items may require extra detergent by
their nature and personnel need to be made aware of this. Experience in using the dishmachine under a variety of conditions,
along with good training in the operation of the machine, can go a long way in ensuring your dishmachine operates as effi-
ciently as possible.
Certain dishmachine models require that chemicals be provided for proper operation and sanitization. Some models even
require the installation of third-party chemical feeders to introduce those chemicals to the machine. Jackson does not recom-
mend or endorse any brand name of chemicals or chemical dispensing equipment. Contact your local chemical distributor for
questions concerning these subjects.
Some dishmachines come equipped with integral solid detergent dispensers. These dispensers are designed to accommodate
detergents in a certain sized container. If you have such a unit, remember to explain this to your chemical distributor upon first
contacting them.
As explained before, water temperature is an important factor in ensuring that your dishmachine functions properly. The data
plate located on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank
and the rinse tank, depending on what model of dishmachine you have installed. These temperatures may also be followed by
temperatures that Jackson recommends to ensure the highest performance from you dishmachine. However, if the minimum
requirements are not met, the chances are your dishes will not be clean or sanitized. Remember, a dish can look clean, but it
may not be sanitized. Instruct your dishmachine operators to observe the required temperatures and to report when they fall
below the minimum allowed. A loss of temperature can indicate a much larger problem such as a failed heater or it could also
indicate that the hot water heater for your operation is not up to capacity and a larger one may need to be installed.
There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it
and that it operates at peak efficiency for many years. Discuss your concerns with your local chemical distributor and water
treatment specialist before there is a problem.
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS
Installation Instructions:
1. Wiring: The switch is wired common and nor-
mally open because of the hinge design. By
interrupting the line in series with the door
switches, the dishmachine ceases to operate.
Refer to the machine schematic for details on
how to wire the switch.
1/3 RACK WIDTH
INSTALL AT FAR END OF TABLE
2. Parts of the table switch are mounted in the
dishtable, at the end of the table and under the
table. See the drawing(s) for the relationship of
the switch to the table.
3. Move the limit switch as far down on the two
slots as possible and see that the limit switch is
straight on the base plate. This might require
adjustment of the nut on the connector for the
limit switch.
4. Then adjust the inside and the outside con-
nector nuts for the connector box so that it lines
up even with the limit switch and the base plate.
5. Tighten down the nuts for the seal so that
they are tight.
6. If you have any difficulty you might have to adjust the
connectors to the seal, screwing in or screwing out
until the installation is straight on the table and the limit
switch is actuated correctly by the rack.
TABLE LIMIT SWITCH THROUGH ROD HOLES
TABLE
SWITCH RODS
STRIKE PLATE
STRIKE PLATE BOLTS
3.00
2.00
MOUNTING BOLTS
TABLE BOTTOM
Ø0.75
1.875
Ø0.25
1.50
Unless noted, all dimensions are in
inches.
TABLE BOTTOM
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SECTION 3:
PREVENTATIVE MAINTENANCE
36
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SECTION 3: PREVENTATIVE MAINTENANCE
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 repairs
not specifically discussed in this manual should be performed by QUALIFIED SERVICE PERSONNEL ONLY. Performing main-
tenance on your dishmachine may void your warranty if it is still in effect, so if you have a question or concern, do not hesitate
to contact Jackson.
There are many things that operators can do to prevent catastrophic damage to the dishmachine. One of the major causes of
component failure has to do with prescrapping procedures. A dishmachine is not a garbage disposal; any large pieces of mate-
rial that are put into the machine shall remain in the machine until they are either broken up (after spreading out on your ware!)
or physically removed. Strainers are installed to help catch debris, but they do no good if they are clogged. Have operators reg-
ularly inspect the pan strainers to ensure (1) that they are free of soil and debris and (2) they are laying flat in the tub.
When cleaning out strainers, do NOT beat them on waste cans. The strainers are made of metal and can be forgiving; but once
severe damage is done, it is next to impossible for the strainer to work in the way it was designed to. Wipe out strainers with
a rag and rinse under a faucet if necessary. For stubborn debris, a toothpick should be able to dislodge any obstructions from
the perforations. Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub.
You may wish to also refer to the page entitled “Detergent Control” in order to learn more about how your water hardness will
effect the performance of your machine. Hard water makes dishmachines work harder and decreases efficiency.
Again, it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larg-
er problems or even cause harm to the operator. If a problem is discovered; secure the dishmachine using proper shut down
procedures as listed in this manual and contact Jackson.
Some problems, however, may having nothing to do with the machine itself and no amount of preventative maintenance is
going to help. A common problem has to do with temperatures being too low. Verify that the water temperatures coming to your
dishmachine match the requirements listed on the machine data plate. There can be a variety of reasons why your water tem-
perature could be too low and you should discuss it with Jackson to determine what can be done.
By following the operating and cleaning instructions in this manual, you should get the most efficient results from your machine.
As a reminder, here are some steps to take to ensure that you are using the dishmachine the way it was designed to work:
1. Ensure that the water temperatures match those listed on the machine data plate.
2. Ensure that all strainers are in place before operating the machine.
3. Ensure that all wash and/or rinse arms are secure in the machine before operating.
4. Ensure that drains are closed/sealed before operating.
5. Remove as much soil from dishes by hand as possible before loading into racks.
6. Do not overfill racks.
7. Ensure that glasses are placed upside down in the rack.
8. Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations.
9. Clean out the machine at the end of every workday as per the instructions in the manual.
10. Always contact Jackson whenever a serious problem arises.
11. Follow all safety procedures, whether listed in this manual or put forth by local, state or national codes/regulations.
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SECTION 3: PREVENTATIVE MAINTENANCE
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 conveyors covered in this manual.
Ambient Temperature
Final Stage Worm Speed1
ISO Viscosity Grade
AGMA Lubricant No.
-30 - 15°F
up to 2000 FPM
220
5S
16 - 50°F
up to 2000 FPM
460
51 - 95°F
up to 450 FPM
680
51 - 95°F
above 450 FPM
460
96 - 131°F
up to 450 FPM
680
96 - 131°F
above 450 FPM
460
7S
#7 Compounded
#8 Compounded
#7 Compounded
8S
Mobil
SHC 630
600W Super
Cylinder
Extra Hecla Super
600W Super
Cylinder
SHC 636
SHC 634
American Lubricants
Castrol
SHC-90W
AGMA #7 Gear Oil
Tribol 1105-7C
Cylinder Oil W460
Inca Oil 460
AGMA #8 Gear Oil
Tribol 1105-8C
Cylinder Oil W680
Inca Oil 680
AGMA #7 Gear Oil
Tribol 1105-7C
Cylinder Oil W460
Inca Oil 460
N/A
N/A
Tribol 800/220
Tegra 220
Tribol 800/680
Tegra 680
N/A
Tribol 800/460
Tegra 460
Chevron
Conoco
Syncon R & O
220
Syncon R & O
460
Exxon (Esso)
Teresstic SHP220
Spartan EP 460
Spartan EP 680
Spartan EP 460
Teresstic SHP 680
Teresstic SHP
460
Fiske Brothers
Shell
SPO-MG
SPO-277
SPO-288
SPO-277
N/A
N/A
Omala RL 220
Pinnacle 220
Valvata J 460
Vanguard 460
Valvata J 680
Vanguard 680
Valvata J 460
Vanguard 460
Omala RL 680
Pinnacle 680
Omala RL 460
Pinnacle 460
Texaco
(1) The sliding velocity in feet per minute (FPM) for standard ratios is determined by multiplying the speed of the worm in RPM by
the factor from the table below. For selecting proper lubricant, use the speed of the worm in the final stage (input RPM divided by
the first stage ratio).
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SECTION 3: PREVENTATIVE MAINTENANCE
DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE
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 for the standard mounting position that you
will find it in on the unit. The oil level should be checked and adjusted (if necessary) prior to operation, using the oil level plug provided
and while the unit is oriented in its operating position.
Ambient temperature - If the operating ambient temperature is other than 51 - 95°F, then refer to the lubrication chart and refill the unit
with the correct grade based on actual ambient temperature and operating speed. See “Oil changing” below for additional information.
Oil changing - When changing the oil for any reason, it should be remembered that oils of various types may not be compatible.
Therefore, when changing to a different oil, it is recommended that the housing be completely drained and thoroughly flushed with a
light flushing oil prior to refilling with the appropriate lubricant. The oil level should be rechecked after a short period of operation and
adjusted, if necessary. When changing double reduction models, each housing should be drained and filled independently, even though
there may be a common level.
Initial oil change: The new oil in a speed reducer should be changed at the end of 250 hours of operation. This is equivalent
to 30 days of operation for 8 hours per day; 15 days of operation for 16 hours per day, or 10 days of operation for 24 hours per day.
Subsequent oil changes: Under normal conditions, after the initial oil change, the oil should be changed after every 2500
hours of operation, or every 6 months, whichever occurs first. Under severe conditions (rapid temperature changes, moist, dirty or cor-
rosive environment) it may be necessary to change oil at intervals of one to three months. Periodic examination of oil samples taken
from the unit will help establish the appropriate interval.
Synthetic oils: Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable, have a much
longer life, and operate over a wider temperature range. These oils are appropriate for any application but are especially useful when
units are subjected to low start-up temperatures or high operating temperatures. However, continuous operation above 225°F may cause
damage to seals or other components. It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation
to remove metal particles that accumulate during break-in. Subsequent oil changes should be made after 5000 hours operation if units
are operating in a clean environment. This can be extended to 10,000 hours if using new reformulated Mobil SHC lubricants (orange in
color) and the lubricant remains free of contamination over this period. See comments under “Subsequent oil changes” for discussion
of severe ambient conditions.
Long term storage or infrequent operation: If a speed reducer is to stand idle for an extended period of time, either prior to
installation or during use, it is recommended that the unit be filled completely with oil to protect interior parts from rust and corrosion due
to internal condensation. Be sure to drain the oil to the proper level before placing the speed reducer in service.
Grease fittings: Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash.
These fittings must be lubricated every 3 - 6 months depending on operating conditions. bearing greases must be compatible with the
type of gear lubricant being used (i.e. mineral, synthetic, food grade, etc.). For mineral oils, use a high quality lithium base NLGOI #2
bearing grease. For synthetic oils, use a synthetic bearing grease such as Mobil Synthetic Universal grease, Mobilith SHC 100 or a suit-
able equivalent. For food grade lubricants, use Chevron FM grease, NGLI 2, or equivalent.
Low input speeds (under 1600 RPM): When input speeds are less than 1600 RPM, grease fittings will be required to lubri-
cate any bearings not partially covered by the normal oil level.
Oil temperature: Speed reducers in normal operation can generate temperatures up to 200°F depending on the type of reduc-
er and the severity of the application 9loading, duration of service, ambient temperatures). Excessive oil temperatures may be the result
of several factors including overloading, overfilling, underfilling or inadequate cooling.
Nominal Ratio
Size
5
7.5
10
15
20
25
30
40
50
60
80
100
920
0.347
0.263
0.225
0.216
0.202
0.191
0.215
0.200
0.188
0.182
0.164
0.161
Lubricant selections are provided by the lubricant manufacturer based on AGMA recommended viscosity grades. Viscosity grades are
based on Lubrication Standard ANSI/AGMA 9005-D94.
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
39
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SECTION 4:
TROUBLESHOOTING SECTION
40
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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 the
machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach
test equipment and reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker
Problem: Nothing on dishmachine operates. The power switch is ON and the power indicator light is OFF.
1. Machine is not wired correctly to incoming power source. Have an electrician verify wiring.
2. Machine circuit breaker is tripped. Reset the circuit breaker. If it trips again, contact an electrician to verify the machine amp
draw.
3. Service breaker is tripped. Reset the service breaker. If it trips again, contact an electrician to verify the machine amp draw.
Problem: Machine will not fill. The power switch is ON and the power indicator light is ON.
1. No water supply to machine. Verify that water lines have been connected to the machine.
2. Dishmachine doors are not closed. Close doors completely.
3. Incoming water solenoid valve damaged/faulty. Verify that the valve is operating. If not, replace.
4. Tank floats faulty. Verify the wiring of the floats. Verify that no debris is jamming the floats. Replace if necessary.
Problem: Machine fills, but fill is weak.
1. Low incoming water pressure. Verify that incoming water pressure during fill is 20 ±5 PSI.
2. Incoming water solenoid is clogged. Verify that debris is not entrapped in valve. If so, remove debris.
Problem: Low wash tank temperature.
1. Low incoming water temperature. Verify that the incoming water temperature matches what is indicated on the machine data
plate.
2. Heater not energizing. Verify that the wash tank heater is operating. If not, replace.
3. Low incoming voltage. Have an electrician verify that the power coming to the machine is the same as indicated on the data
plate.
Problem: Low wash arm pressure, poor spray pattern.
1. Clogged wash arm nozzles. Verify that nozzles are not clogged with debris. If so, remove debris.
2. Clogged wash tank or wash pump strainers. Clean out strainers if necessary.
3. Worn wash pump impeller. Verify status of impeller, replace if necessary.
Problem: Low prewash arm pressure, poor spray pattern.
1. Clogged prewash arm nozzles. Verify that nozzles are not clogged with debris. If so, remove debris.
2. Clogged prewash tank or prewash pump strainers. Clean out strainers if necessary.
3. Worn prewash pump impeller. Verify status of impeller, replace if necessary.
Problem: Inadequate rinse.
1. Low incoming water pressure. Verify that incoming water pressure during fill is 20 ±5 PSI.
2. Incoming water solenoid is clogged. Verify that debris is not entrapped in valve. If so, remove debris.
Problem: Pawl bar moves with no load, but does not move when loaded.
1. Clutch on drive assembly is out of adjustment. Adjust as required.
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
41
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SECTION 4: TROUBLESHOOTING
COMMON PROBLEMS
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 installed correctly.
Problem: Racks go through the machine, but results are poor.
1. Verify that detergent is being dispensed into the machine at the appropriate quantities for the water volume. If not, get deter-
gent to appropriate level and review results of washing ware.
2. Clogged strainers/scrap basket. Clean out strainers and scrap basket and replace.
3. Ware not being properly prescrapped. Review paragraph entitled “Ware Preparation” in Operating Instructions.
4. Wash or rinse arms missing end plugs or caps. Verify and replace as required.
5. Low tank heat.
6. Inadequate rinse.
7. Incorrect voltage coming to the machine. Verify that the voltage matches that on the machine data plate.
8. Wash pump cavitation due to low water level. Verify that the drains are shut and that the water level is correct.
Problem: Spotting of silverware, glasses and dishes.
1. Incorrect final rinse temperature. Verify that the rinse water temperature matches that which is listed on the machine data
plate.
2. Clogged wash and/or rinse nozzles and arms. Remove the arms and verify that they and their nozzles are from debris.
3. Excessively hard water. Install a water softener to reduce hardness.
4. Loss of water pressure due to clogged/obstructed wash pump. Turn the power off to the machine at the source. Drain the
wash tank of water and verify that the pump intake is free from debris.
5. Improper scrapping procedures. Review the paragraph entitled “Ware Preparation” in Operating Instructions.
6. incorrect detergent/chemical concentrations. Verify that the detergent/chemical concentrations are correct for the associat-
ed water volume.
TORQUE SETTINGS
When replacing components either in the control box or the heater box area, the manufacturer has suggestions on how
much to torque the screws and nuts used in securing items to the machine. Refer to the table below for the torque specifica-
tions:
ITEMS
TORQUE SPEC
Relays
16 In/lbs
35 In/lbs
16 In/lbs
50 In/lbs
Heater Contactor
Heater Nuts
Terminal Block
AJ-44T Series Technical Manual 7610-003-07-21
Issued: 03-21-2006 Revised: N/A
42
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