Castle 7800A User manual
INSTALLATION INSTRUCTIONS
61301604981 Rev. B
7800A SERIES
FLOOR MOUNTED
CART & UTENSIL
WASHER
INSTALLATION INSTRUCTIONS
7800A SERIES
FLOOR MOUNTED
CART AND UTENSIL
WASHER
Getinge USA, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: (800) 950-9912
Facsimile: (800) 950-2570
INSTALLATION INSTRUCTIONS 61301604981
Rev. A (12/18/01)
Rev. B (09/29/03)
Related Publication:
Operator Manual 61301604768
Service Manual 61301605323
DESCRIPTION OF SYMBOLS AND NOTES IN MANUAL
The following symbols with related notes appear in this manual.
“Warning” notes alert the user to the possibility of personal injury.
WARNING
“Caution” notes alert the user to the possibility of damage to the equipment.
CAUTION
WARNING
NOTE
NOTE
CAUTION
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge USA, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge USA, Inc.
• POSSIBILITY OF INJURY: Misuse of equipment may result
in personal injury.
• POSSIBILITY OF EQUIPMENT DAMAGE: Misuse of
equipment may result in equipment damage.
The 7800A Washer is designed to clean and dry case carts,
stands, utensils, containers, tote boxes, and similar bulk items.
This equipment is NOT intended for use other than expressly
stated.
If the 7800A Washer is used in a manner not specified by
Getinge USA, Inc., the protection provided by the equipment
may be impaired.
Getinge® is a registered trademark.
Copyright ©2003 by Getinge USA, Inc.
ii
SAFETY LABELS USED ON THE EQUIPMENT. . . . . . . . . . V
Section 1 Installation Requirements
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 1–1
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
UTILITIES AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . 1–2
INSTALLATION ADVISORY . . . . . . . . . . . . . . . . . . . . . . . 1–3
WASHER OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Size (Load Length). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Floor Mount vs. Pit Mount . . . . . . . . . . . . . . . . . . . . . . 1–3
Left Side vs. Right Side Controls . . . . . . . . . . . . . . . . . 1–3
Left Hand vs. Right Hand Door Mounting . . . . . . . . . . 1–3
Barrier Flanges and Service Enclosure . . . . . . . . . . . . 1–3
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Vented vs. Non-vented . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Purified Water Rinse . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Seismic Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SHIPPING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . 1–4
TOOLS AND MATERIALS REQUIRED . . . . . . . . . . . . . . . 1–5
Table of Contents
Section 2 Installation
ASSEMBLE THE WASHER STRUCTURE . . . . . . . . . . . . 2–1
Install the Base/Sump Assembly . . . . . . . . . . . . . . . . . 2–1
Position the Mechanical Core . . . . . . . . . . . . . . . . . . . 2–3
Assemble the Washer Panels . . . . . . . . . . . . . . . . . . . 2–5
Channel Fillers and Threshold Assemblies . . . . . . . . 2–11
Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
INSTALL COMPONENTS ON THE OUTSIDE OF THE
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Return Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
Washer Light Assembly . . . . . . . . . . . . . . . . . . . . . . . 2–16
Spray Manifold Drive Motor . . . . . . . . . . . . . . . . . . . . 2–17
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
Dispenser Float Switch Junction Box, Detergent
Dispenser, and Rinse Aid Dispenser . . . . . . . . . . . . . 2–19
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . 2–21
Unload End Indicator Panel Box . . . . . . . . . . . . . . . . 2–22
Door Proximity Switches . . . . . . . . . . . . . . . . . . . . . . 2–23
61301604981 iii
INSTALL COMPONENTS ON TOP OF THE WASHER . 2–24
Power Floor Tilt Pulley System . . . . . . . . . . . . . . . . . 2–25
Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Exhaust Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28
Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
INSTALL COMPONENTS ON THE INSIDE OF THE
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35
Drive Chain Tension Idlers and Idler Bearing . . . . . . 2–35
Chain Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Spray Manifold Supports and Spray Manifolds . . . . . 2–38
Manifold Cover, Manifold Guard Tubes, Wash Cart
Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
Emergency Stop Switch Cable . . . . . . . . . . . . . . . . . 2–43
FINAL INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . 2–44
Final Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2–45
Dispenser Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Barrier Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–48
Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Service Area Enclosure (Option). . . . . . . . . . . . . . . . 2–50
Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51
Exhaust Connection . . . . . . . . . . . . . . . . . . . . . . . . . 2–52
Plumbing System Connections . . . . . . . . . . . . . . . . . 2–52
Electrical Supply Connection. . . . . . . . . . . . . . . . . . . 2–52
Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53
Section 3 Rough-In Drawings
Section 4 Seismic Anchoring Drawings
iv
Safety Labels Used on the Equipment
The following safety labels are used on the 7800A washer:
You must remove all power to the washer before removing the back cover
to the washer chamber light assembly.
CAUTION
High voltage is present inside the control box. You must remove all power to
the washer before opening the door to the control box.
CAUTION
7800A Series Floor Mounted Cart and Utensil Washer
If you change a fuse, you must use an equivalently rated replacement.
Refer to “Spare Parts” on page C-2 in the Operator Manual for a list of spare
fuses.
If you are inside the washer when someone closes the door, press firmly on
this label on the inside of either door to stop the washer, if applicable, and
open the door.
61301604981 v
vi
General Description
Section 1 Installation Requirements
The Getinge 7800A Series Floor Mounted Cart and Utensil Washer is a fully
automatic, large capacity, hydro-spray washer that is used to clean and dry
case carts, stands, utensils, containers, tote boxes, and similar bulk items.
The washer can be installed in a shallow pit or installed at floor level. When
installed in a pit, the floor of the washer's chamber is level with the room
floor, which allows the direct loading and unloading of carts. When the
washer is installed at floor level, the floor of the chamber is higher than the
room floor. Ramps are then provided as standard equipment to facilitate
loading and unloading.
The washer is designed for pass-through operation. Items to be cleaned are
placed in the washer’s compartment at the load end door. After cleaning, the
items are removed from the unload end door at the opposite end of the
washer.
The washer is generally installed in a facility’s decontamination room with
the unload end door opening out into a clean-preparation area. The unit is
available in three sizes, which are determined by compartment length: 80"
(2032 mm), 98" (2489 mm), and 112" (2845 mm), and which correspond to
models 78003A, 78004A, and 78005A, respectively.
Treatment solutions are delivered by separate oscillating (back and forth)
wash and rinse manifolds equipped with spray nozzles. Detergent and rinse
aid solutions are dispensed automatically as a standard feature.
A standard cycle consists of the following sequential phases: wash,
standard rinse (or optional purified rinse), drying, and exhaust. The length of
a cycle’s phase can be adjusted at the touch control panel.
Figure 1–1. 7800A Series Floor Mounted Cart and Utensil Washer
HW-001
61301604981 1–1
Installation Requirements
Model Identification
The rating plate for a 7800A washer is affixed to the inside of the control
box.
Record the model type and serial number (S/N) from the rating plate.
TYPE: _________________________________
SERIAL NO: ____________________________
Include the model type and serial number when communicating with
Getinge, USA.
Figure 1–2. Rating Plate Location
Utilities and Specifications
1–2
Utility requirements and specifications are included on sheet 2 of the
appropriate rough-in drawing (pit mounted or floor mounted version). Refer
to “Rough-In Drawings” on page 3-1.
Installation Advisory
Washer Options
7800A Series Floor Mounted Cart and Utensil Washer
A 7800A washer is assembled at the factory, tested, and then disassembled
for shipment. Extensive on-site reassembly is required. The installation
instructions in this manual are intended as the primary reference for
accomplishing this reassembly. Every effort has been made to make this
information as accurate as possible.
Where applicable, installers should refer to specifications contained in the
product information documents, such as Assembly drawings, that have
been forwarded to local Getinge USA product support personnel. Rough-in
drawings can be found in “Rough-In Drawings” on page 3-1.
There are a number of options that may be included with your washer.
These options affect the procedures that apply to your specific installation.
Size (Load Length) There are three models of the 7800A washer, each corresponding to a
different compartment size, or load length (all models are the same width):
• 78003A is 80" (2032 mm) long
• 78004A is 98" (2489 mm) long
• 78005A is 112" (2845 mm) long
All models have five or six side panels and three top panels. The middle
panel on the front (service) side, the end panels on the rear, and the top
panels at each end are common for all three washer lengths. The sizes of
the end panels on the front side, the middle panel on the rear side (if
applicable), and the middle top panel depend on the washer length.
Floor Mount vs. Pit Mount A floor mounted washer requires the installation of ramps to provide access
to the washer. The interior floor of a pit mounted washer is level with the
finished floor of the facility.
Left Side vs. Right Side Controls
Left Hand vs. Right Hand Door Mounting
Barrier Flanges and Service Enclosure
The location of controls on your washer also determines the location of the
service area, as well as the barrier flanges and service enclosure that may
be provided with your washer.
The orientation of the load and unload door mountings determines the doors
and door panels for your washer.
Your installation may have barrier walls at the load or unload end of the
washer, or both, as well as have a service enclosure.
Electrical Service The electrical service at your facility determines the specific high voltage
devices (motors, pumps, etc.), transformer, and control box provided with
your washer.
61301604981 1–3
Installation Requirements
Vented vs. Non-vented A vented washer has an automatic damper that connects directly to the
ventilation system of your facility. A non-vented washer has a condenser
(with associated electric and plumbing connections) mounted on the top of
the washer to remove moisture from the air that is exhausted from the
washer.
Purified Water Rinse An optional purified rinse phase uses water from the customer’s purified
water supply.
Printer If your washer has the printer option, the printer is already mounted on the
control box.
Seismic Anchoring If your washer has the seismic anchoring option, the sump assembly and
the mechanical core are secured to the floor.
Shipping Configuration
A disassembled 7800A washer is shipped on five pallets and one box of
various sizes. The maximum size of any one pallet may be as large as 130"
x 68", depending on the length of the unit. For stability during transit,
selected pallets are often pegged (with nails) to the floor of the truck.
Moving the disassembled washer from the truck to the installation site
requires the use of any available combination of the following:
• fork lift
• pallet jack
• dollies
• Johnson bars
A sufficient supply of commonly used fasteners (#10-32 and 1/4-20, for
example) is bagged for shipment. Speciality hardware and fasteners (door
latches and hinges, for example) are labeled and bagged separately for
shipment.
Many disassembled items, such as plumbing and panel sections, are
marked with handwritten numbers with black grease pen to identify their
location, orientation, or connection points. Take care not to inadvertently
smudge or erase these identifying marks.
1–4
Tools and Materials Required
7800A Series Floor Mounted Cart and Utensil Washer
The following tables list the specific tools and materials required at the
installation site. Items marked with an asterisk * are supplied by Getinge
USA.
Table 1–1. Tools Required
Tool Quantity
Common Hand Tools Assorted
12' Pipe Clamp 2
C-Clamp 2
Johnson Bar 1
Pry/Pinch Bar 2
Caulking Gun 1
1/4-20 Tap, Short 1
10-32 Tap, Short 1
10-32 Tap, Long 1
#7 Drill Bit 2
#21 Drill Bit 2
Torpedo Level 1
4' Level 1
Scratch Awl 2
Tape Measure 1
Table 1–2. Materials Required
Material Quantity
* Silicone Adhesive 8 tubes
* Silicone Primer 1 pt
* Thinner 1 pt
* Polish 1 container
* Stainless Steel Nuts, Bolts,
Washers, Lock Washers
Assorted
* Wire Nuts, Tie Wraps Assorted
* 3" x 4" Stainless Steel Shims:
• 12 ga
• 14 ga
• 16 ga
• 18 ga
10
10
10
10
61301604981 1–5
Installation Requirements
Material Quantity
1" x 4" x 6" Wood Block 2
2" x 4" x 52" Wood Block 4
Four rigid 3/4" x 60" long pipes are recommended for use if a floor mounted
washer is to be assembled out-of-position, then moved to its intended
operational site. The pipe is used to roll the washer into position after
assembly.
1–6
Assemble the Washer Structure
This section contains procedures for assembling the basic structure of the
washer compartment. Refer to the following sections.
•“Install the Base/Sump Assembly” on page 2-1
•“Position the Mechanical Core” on page 2-3
•“Assemble the Washer Panels” on page 2-5
•“Channel Fillers and Threshold Assemblies” on page 2-11
•“Door Assembly” on page 2-12
Section 2 Installation
Install the Base/Sump Assembly
NOTE
General Instruction
If the load or unload end of the base is not marked, check the configuration
of the sump against the rough-in drawing (page 3-1) to determine the
correct orientation.
Some installation sites may have an existing wall in close proximity to the
non-service side of the washer that could interfere with the assembly of the
washer’s side panels. If this situation exists, you will have to seat the base
temporarily out-of-position until the side, top, and non-service side trim
panels are assembled. You can then maneuver the unit to its operating
position, where you can level and anchor it, if required.
Installation
1. Move the base into its operating position.
Figure 2–1. Base/Sump Assembly
SERVICE SIDE
SUMP
2. Check the base for level.
Use the 4' level to check from all sides of the base and in
all directions. Adjust the level if necessary using the
stainless steel shims that are provided.
61301604981 2–1
Installation
CAUTION
Failure to critically level the base will result in the misalignment of mounting
holes and will make assembly of the washer panels difficult.
If seismic anchoring is required, two 2 1/2" flanges (with anchor bolt holes)
must be bolted to the bottom frame of the base (one flange on each end of
the washer).
3. Drill holes for the anchors through the holes in the base
flange.
Table 2 –1. Drilling Specifications
Drill Bit Size 1/2”
Embedment 2 1/4” minimum
Torque 50 ft.-lb.
4. Secure the base to the floor using 1/2" bolt stud anchors
suitable for your floor structure.
NOTE
Figure 2–2. Track/Frame Assembly
TRACK/FRAME ASSEMBLY
FLOOR TILT
WELDMENTS
5. Lay the track/frame assembly into the base so that the floor
tilt weldments are on the non-service side of the washer.
6. Lay the floor grates in the track of the track/frame
assembly.
The 78003A model (88" long) has two 34" floor grates. The 78004A model
(106" long) has two 34" floor grates and one 16" floor grate. The 78005A
model (120" long) has two 34" floor grates and one 30 1/8" floor grate.
2–2
7. Lay the cardboard sheet over the floor grates to protect
from scratches while you complete the installation.
7800A Series Floor Mounted Cart and Utensil Washer
Position the Mechanical Core
Objective
Position the mechanical core in its approximate location on the side of the
washer.
Installation
Refer to Figure 2–3. Mechanical Core.
Figure 2–3. Mechanical Core
MOUNTING
BRACKET
HOLES
(4 PLACES
EACH SIDE)
WARNING
CAUTION
ADJUSTABLE LEGS
(4 PLACES)
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eyewear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place, less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.
Silicone primer stains/discolors clothing, stainless steel surfaces, flooring,
etc. Avoid accidental spills. Avoid spreading this substance onto cosmetic
surfaces of the washer.
61301604981 2–3
Installation
1. Using a fork lift, move the mechanical core into place on
the service side of the washer, approximately one inch
away from where the washer side walls will be.
NOTE
NOTE
NOTES
If your washer has a left-hand service area, one of the adjustable legs rests
on the pad on the right side of the sump box. If the washer has a right-hand
service area, one of the adjustable legs rests on the pad on the left side of
the sump box.
2. Clean mating surfaces on the dryer duct flange and around
the dryer duct cutout on the washer side panel with thinner,
and treat with silicone primer.
You will apply silicone caulk to the dryer flange after the washer walls are
assembled and just before you attach the mechanical core to the washer.
3. Set the washer light assembly on the dryer duct shelf.
• You will secure the light to the side panel after the washer panels are
assembled.
• If the return pump was shipped already attached to the sump, it may be
necessary to temporarily remove the pump until after the mechanical core
is positioned.
2–4
Assemble the Washer Panels Objective
Assemble the door, side, and top panels. Install the required number of
interior side panel seam cover strips.
The 7800A washers have five or six side panels and three top panels. The
middle panel on the front (service) side, the end panels on the rear, and the
top panels at each end are common for all three washer lengths. The sizes
of the end panels on the front side, the middle panel on the rear side (if
applicable), and the middle top panel depend on the washer length. The
service side middle panel provides the cutouts for the dryer air duct and for
the wash and rinse manifolds. The top panels at each end of the washer
provide the cutouts for the intake and exhaust assemblies.
Each side panel carries a number that matches the number on the base’s
frame. The width of a top panel is the width of the washer (52"). The side
panels have 7/16" diameter holes that carry 3/8" thru bolts (five on each
side of the washer) to hold the panels together. The top panels have holes
to carry two thru bolts.
There is no established order to follow for panel assembly. You can start
from the load or the unload end. You can assemble all the vertical panels
first, followed by the top panels; or you can add individual top panels as you
erect the vertical panels. The method illustrated below starts from the load
end and progressively adds top panels as the vertical panels are erected.
7800A Series Floor Mounted Cart and Utensil Washer
NOTE
WARNING
CAUTION
Installation
You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant. This includes
all instances where panels are secured to the washer base or to other
panels, as well as the seam cover strips inside the washer.
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eyewear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place, less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.
Silicone primer stains/discolors clothing, stainless steel surfaces, flooring,
etc. Avoid accidental spills. Avoid spreading this substance onto cosmetic
surfaces of the washer.
61301604981 2–5
Installation
1. Attach the load end door panels to the base.
There are two vertical panels, each with three mounting
holes at the top to attach to the horizontal panel.
a. Position a vertical panel and use a C-clamp to hold the
panel in place temporarily.
b. Secure the bottom of the panel to the base frame with
four 1/4-20 fasteners (1/2" hex head bolts and lock
washers) and remove the clamp.
c. Repeat steps a and b for the other vertical panel.
Figure 2–4. Door Panels
2–6
d. Secure the horizontal panel between the two vertical
panels with 1/4-20 fasteners (six each 1/2" hex head
bolts and lock washers).
e. Plumb and square the door opening.
2. Attach the load end rear (non-service side) side panel to
the base and to the load end door.
a. Position the load end side panel.
b. Partially insert five 3/8" diameter thru rods through the
7/16" diameter holes to stabilize and align the side
panel with the door panel.
c. Use pipe clamps to draw the panels tight.
d. Secure the bottoms of the side panel to the base frame
with 1/4-20 fasteners (1/2" hex head bolts and lock
washers).
7800A Series Floor Mounted Cart and Utensil Washer
Figure 2–5. Side Panels
THRU BOLTS
(5 EACH SIDE)
NOTE
Skip step 3 below if the washer does not have middle panel sections.
3. Attach the rear middle side panel to the base and to the
load end panel.
a. Remove the pipe clamps.
b. Position the middle rear side panel.
c. Extend the five thru bolts to stabilize and align the
panels with the load end side panel.
d. Attach the pipe clamps to draw these panels tight.
e. Secure the bottoms of the middle side panel to the
base frame with 1/4-20 fasteners (1/2" hex head bolts
and lock washers).
f. To ensure side panel alignment, attach C-clamps and
2x4" wooden blocks across the top edge of the
adjoining panels at the vertical seam.
61301604981 2–7
Installation
4. Attach the unload end rear side panel to the base and to
the middle side panels.
a. Remove the pipe clamps.
b. Position the unload end rear side panel.
c. Extend the five thru bolts to stabilize and align this
panels with the previously erected panels.
d. Attach the pipe clamps to draw these panels tight.
e. Secure the bottom of the side panel to the base frame
with 1/4-20 fasteners (1/2" hex head bolts and lock
washers).
f. Move the C-clamp and 2" x 4" wooden block
assemblies to the vertical seams created by the
installation of these panels.
5. Repeat steps 2 through 4 to install the front (service side)
load, middle, and unload side panels, respectively.
6. Attach the unload end door panel to the base and to the
unload end side panels.
a. Remove the pipe clamps.
b. Position one vertical panel.
c. Extend the thru bolts on that side.
d. Attach the pipe clamps to draw the door panel tight.
e. Repeat steps b through d for the other vertical panel.
f. Secure the horizontal panel between the two vertical
panels with 1/4-20 fasteners (six each 1/2" hex head
bolts and lock washers).
g. Plumb and square the door opening.
h. Secure the thru bolts at both ends of the washer with
3/8" acorn nuts and flat washers.
i. Secure the bottom legs of the panel to the base frame
with four 1/4-20 fasteners (1/2" hex head bolts and lock
washers).
2–8
7800A Series Floor Mounted Cart and Utensil Washer
7. Attach the load end top panel to the door panel and to the
load end side panels.
a. Position the load end top panel.
b. Secure the top panel to the door and load end side
panels with 1/4-20 fasteners (1-3/4" hex head bolts,
flat washers, and lock washers).
c. Partially insert the two remaining 3/8" diameter thru
bolts through the 7/16" diameter holes in the panel.
NOTE
Skip step 8 below if the washer does not have middle panel sections.
8. Attach the middle top panel to the load end top panel and
to the middle side panels.
a. Position the middle top panel.
b. Extend the two thru bolts.
c. Secure this panel to the middle side panels with 1/4-20
fasteners (1-3/4" hex head bolts, flat washers, and lock
washers).
9. Attach the unload end top panel to the unload end side
panels and to the unload end door panel.
a. Remove the C-clamp assemblies.
b. Position the unload end top panel.
c. Extend the two thru bolts.
d. Secure this panel to the unload end door and side
panels with 1/4-20 fasteners (1-3/4" hex head bolts,
flat washers, and lock washers).
e. Secure the thru bolts at both ends of the washer with
3/8" acorn nuts and flat washers.
61301604981 2–9
Installation
10. Secure the mechanical core to the side panels.
a. Use the adjustable legs to align the holes in the
mounting bracket and in the dryer duct flange with the
corresponding holes in the side of the washer.
b. From inside the washer, apply silicone sealant to the
surface of the dryer flange.
c. Secure the mechanical core to the washer with eight
sets of 1/4-20 hardware.
d. Secure the dryer duct flange to the cutout in the
washer side panel with eight sets of 1/4-20 hardware.
NOTE
The mechanical core assembly will slowly move into place as you tighten
the fasteners.
11. Inside the washer, attach the panel seam cover strips over
the vertical seams between adjoining side panels using
#10-32 screws and lock washers.
2–10
7800A Series Floor Mounted Cart and Utensil Washer
Channel Fillers and Threshold Assemblies
Objective
Install a channel filler on the floor just inside each washer door. Install a
threshold assembly just outside each washer door.
Installation
Refer to Figure 2–6. Channel Fillers and Threshold Assemblies.
Figure 2–6. Channel Fillers and Threshold Assemblies
CHANNEL FILLER
(1 EACH END)
THRESHOLD ASSEMBLY
(1 EACH END)
1. Position one channel filler at each end of the washer and
secure each to the base with two #10-32 x 3/8" phillips
head screws.
2. Position one threshold assembly at each end of the washer
with the gasket facing toward the inside of the washer and
secure each to the base with two #10-32 x 3/8" phillips
head screws.
61301604981 2–11
Installation
Door Assembly Objective
Attach hardware to the doors and related door panels. Install the load and
unload end doors on the washer. Plumb and square both door openings.
Installation
Refer to Figure 2–7. Door Assembly.
Figure 2–7. Door Assembly
WARNING
DOOR LATCH
(2 PER DOOR)
HINGE MOUNT
(3 PER DOOR)
DOOR LATCH
RETAINERS
(2 PER DOOR)
DOOR HANDLE
DOOR HINGE
(3 PER DOOR)
A washer door is heavy and awkward to handle. Take care to
avoid crushing or strain injuries.
2–12
NOTE
The washer may be shipped with all of the hardware (hinges, latches, striker
plates, etc.) already mounted on both the doors and the door panels. If so,
start with step 3 below.
7800A Series Floor Mounted Cart and Utensil Washer
1. Attach the following items to each door panel:
a. Attach three hinge mounts using 1/4-20 fasteners (nine
1" phillips head screws).
b. Attach two door latch retainers, two door latch shims,
and two spacers using 5/16-18 fasteners (four each 2"
hex head cap screws and lock washers).
c. Attach the striker plate assembly using 1/4-20
fasteners (four 2" phillips head screws).
2. Attach the following items to the door:
a. Attach two door latches using 5/16-18 fasteners (four
each 1" hex head cap screws and lock washers).
b. Attach three hinges using 1/4-20 fasteners (twelve
each 1” phillips head screws).
c. Attach the door handle using 5/16-18 fasteners (four
each 1" hex head cap screws and lock washers).
NOTE
3. Check the door opening for plumb and square. If
necessary, use the shims that are provided.
4. Mount the door on the washer.
a. Raise and maneuver the door until its hinge posts are
in vertical alignment over the three hinge mounts
attached to the door panel.
b. When aligned, lower the door and properly seat all
three posts in their respective mounts.
c. Check for correct operation of the door.
Repeat steps 1 through 4 for the other door assembly.
After the plumb and square of all doors is checked and corrected, it may be
easier to lift the doors off their hinges and set them aside until the washer
installation is complete.
61301604981 2–13
Installation
Install Components on the Outside of the Washer
This section provides instructions for installing equipment on the outside of
the washer. The procedures are presented in a recommended order (some
larger components are easier if they are done earlier, for example). Refer to
the following sections.
•“Return Pump” on page 2-15
•“Washer Light Assembly” on page 2-16
•“Spray Manifold Drive Motor” on page 2-17
•“Control Box” on page 2-18
•“Dispenser Float Switch Junction Box, Detergent Dispenser, and Rinse
Aid Dispenser” on page 2-19
•“Emergency Stop Switch” on page 2-21
•“Unload End Indicator Panel Box” on page 2-22
•“Door Proximity Switches” on page 2-23
2–14
Return Pump Objective
Install the return pump.
Installation
7800A Series Floor Mounted Cart and Utensil Washer
NOTE
The return pump may be shipped from the factory already installed in the
sump.
Refer to Figure 2–8. Return Pump.
Figure 2–8. Return Pump
RETURN PUMP
1. Slide the low suction collar over the bottom of the return
pump and position the pump in the sump.
2. Secure the pump to the flange on the front sump cover by
attaching the two ends of the metal strap with 5/16"-18
fasteners (2" hex head cap screws and lock washers) to
the flange.
61301604981 2–15
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