Jackson 44CERPW Service Manual

MODEL 44 CE/RPW

40906

JUNE 1985

SINGLE TANK RACK CONVEYOR

DISHWASHERS

SERVICE MANUAL

INCLUDES:

-Warranty Policy -Sequence of Operation

-Installation Requirements -Basic Functions of Dishwasher

-Operating Instructions -Maintenance and Care

-Table Dimensions -Illustrated Parts List

-Wiring Diagrams -What's Not Covered by Warranty

-Troubleshooting Guide

WORLD HEADQUARTERS & MANUFACTURING OPERATIONS

Highway 25E, P.O. Box 1060

Barbourville, KY

888/800-JMSC

FAX [phone]

November 6,1998 P/N 7610-100-21-00 Rev A

INDEX

SPECIFICATIONS

3

GENERAL INSTRUCTIONS (Operation)

6

REPLACEMENT of SWITCHES in CONTROL PAN EL

9 THERMOSTAT ADJUSTMENT.

10

REPLACING SEAL and CERAMIC on WASH PUMPS

12

TROUBLESHOOTING GUIDE

14

CONVEYOR DRIVE ASSEMBLY and MOTOR

27

LOAD SENSOR HOLE LOCATION

32 WIRING of LOAD SENSOR SWITCH CIRCUIT

33

WARRANTY INSIDE FRONT COVER
GENERAL INSTRUCTIONS (Installation) 4

GENERAL INSTRUCTIONS (Preventive Maintenance) 7

LOWER WASH HEAD ASSEMBLY 8

UPPER WASH ASSEMBLY 8

FINAL RINSE ASSEMBLY 8
SERVICE INSTRUCTIONS (lncoming Water Solenoid Valve) 11

WASH PUMP ASSEMBLY 13
TORQUE-TAMER 22

PAWL BAR ASSEMBLY 26
CAM and CLUTCH ASSEMBLY 28

LOAD SENSOR SWITCH CONVERSION 29

CONVEYOR DRIVE ASSEMBLY 31

LOAD SENSOR SWITCH DETAILS 32
ELECTRICAL DRAWINGS 34

PARTS LIST 38

PARTS DISTRIBUTORS INSIDE BACK COVER

SPECIFICATIONS

OPERATING CAPACITY

Racks per hour (NSF Rated) 198

Dishes per hour 5000

Glasses per hour 5000

CONVEYOR SPEED

Feet per minute 5.5

WASH TANK CAPACITY

Gallons 24

WASH PUMP CAPACITY

Gallons per minute 240

THERMOMETER

Wash-°F 140-160
Rinse-°F 180-195

WATER REQUIREMENTS (NSF Rated)

Inlet Temperature °F 180

Gallons per hour 414

Flow pressure PSI 20

Flow GPM 6.9

Inlet-lPS 3/4"

Drain-IPS 1-1/2"

WASH PUMP MOTOR

Horsepower 1

CONVEYOR MOTOR

Horsepower 1/16

ELECTRIC HEAT WASH

KW 13

DIMENSIONS

Length (table to table) 44"

Width 25"

Height 55"

Standard table height ± 1/2" 34"
Maximum height for dishes 16"

STANDARD RACKS

Dish 19-3/4x19-3/4 4

Combination 2

SHIPPING WEIGHT BASIC MODELS

(approx.) 600

ELECTRICAL RATING

Volts: 208/220

Phase:1/3
Amps: (approx.)

Specifications subject to change without notice.

GENERAL INSTRUCTIONS

(INSTALLATION/DIMENSIONS) for 44CE SERIES

Note: Read the following instructions carefully. Proper installation of your

Jackson Dishwasher will assure proper machine operation.

1. Open the front door (hook open) and remove dish, cup, and glass racks, and set to one side for later use.
Remove the tape holding the overflow strainer, the pump intake strainer, and the wash head assembly
that are inside the machine.

2. Cut straps holding machine to base of crate, ease machine on to floor and slide into place of
installation.

3. Connect drain to bottom of machine (1 1/2" IPS female fitting on bottom of wash sump) with proper slope
to conform with local and/or national codes. Drain is a gravity feed system from machine.

4. Connect incoming 3/4" water line with capacity to supply 6.9 gallons per minute flow, at 20 PSI at a
temperature of 180°F+. This connection is just before the Y-strainer. Connect to conform with local
and/or national codes (STANDARDS).

5. Electrical connections should be made through hole in back of control box to terminal board inside (to the
left lower side of control box). This terminal board is accessible by removing the lower cover plate. The
terminals are marked L1, L2 (requiring 208—230V, single phase), or L1, L2, L3 (requiring 208—230V,
three phase). There is a grounding lug inside of the control box on the bottom left. Be sure all
connections made are tightened properly. Refer to data plate for Voltage and Amperage totals.

6. Install the proper circuit breaker, wire, and conduit size to conform with local and/or national codes. Refer
to data plate for electrical loads.

7. DO NOT APPLY POWER UNTIL STEP 10.

8. Insert pump intake strainer, overflow strainer, runoff sheets, and lower wash manifold, then close door.

9. Turn on hand valve controlling water supply to machine; check for any leaks in plumbing and
connections.

10. To energize electrically, proceed as follows:
a. Turn on customer's circuit breaker controlling machine.
b. Check voltage at incoming terminal L1, L2, and L3 (if applicable). It should match data

plate voltage. Voltage at L1 and L2 should be checked to ground individually to ensure
that a high (or wild) leg is not connected to L1 or L2. (Voltage exceeding 150V to
ground would indicate high leg.)

c. If voltages are in required range, turn on 15 amp circuit breaker. The 15 amp circuit

breaker protects and controls the motors and control circuit only; it is not meant to protect or control

the wash heaters.
d. Insert a rack into the machine, be sure the curtains are in place.
e. Turn the fill handle on the front of the machine to supply the unit with water. It should

take less than four minutes to fill the wash tank. When the desired level is reached turn
the handle back to the original position.

f. Open the front door and check the water level. It should be 1/4" below overflow level. If

not, check the incoming water line making sure that the valve fully opens and closes as
the handle is turned on and off.

g. If the water is the proper level, close the front door and turn on the heat switch. The

heaters are in the wash tank and are utilized to maintain the wash water temperature at
150°.

h. Turn on the conveyor switch. This will set the conveyor pawl bar into motion to pull the

rack of ware through the unit.

i. The unit is now ready to proceed with the washing of dishes in accordance with the

operating instructions in this manual, and the instruction sticker on the front door of
the dishwasher.

Note: As the racks leave the unit do not allow them to accumulate more than three in a row.

GENERAL INSTRUCTIONS

(OPERATION) 44CE

Note: Read instructions carefully. Proper operation of your Jackson Dishwasher will assure

clean and sanitized glasses and dishes at optimum efficiency.

Dish Preparation

1. Scrape the dishes thoroughly.

2. Pre-rinse the dishes by soaking or by spraying off with a pre-rinse hose.

3. Place the dishes and cups in the dish rack with cups upside down.

4. Place the glasses and silverware in the combination glass-silverware rack with the
glasses upside down. Scatter the silverware loosely on the bottom of the rack. Do not put glasses on top
of the silverware.

NOTE: When silverware is in an upright position, it washes and rinses better than lying flat. These

compartment silverware racks are available through your dealer or service agency.

Machine Operation

1. Open the front door and insert the pump intake strainer, overflow strainer, runoff sheets, and lower wash
manifold.

2. Close the door.

3. Turn the fill valve handle on the front of the unit- It should take less than four minutes for the water level
to reach the top of the overflow. When the desired level is reached turn the handle back to the original
position.

4. Turn on the heat switch, letting the wash temperature reach 150°.

5. Slide in a rack of dirty dishes.

6. Add detergent* (see Detergent Recommendation). If an automatic detergent dispenser is used, follow
the manufacturer's instructions.

7. Start the wash cycle of the dishwasher by flipping the start switch in a up position.

8. To set the conveyor pawl bar assembly in motion flip the conveyor switch in the up position. The pawl
bar assembly automatically pulls the rack through the machine once it enters the opening.

9. When the rack leaves the other end of the machine it should be removed or not allowed to accumulate
more than three racks on the table. This will prevent the clutch from burning out.

10. Once the wash cycle is activated there is no need to turn it off until the end of the meal period. Repeat
steps 6, 8, and 9 for each rack of ware.

11. At the end of a meal period or the end of the day, shut off the heater, wash, and conveyor switch. Drain
the machine by removing the overflow strainer. Clean both strainers, the overflow and the inside
strainer, of all foreign debris and build-up and flush out the unit.

* Detergent Recommendation and Rinse Additives:

We suggest you contact your local detergent specialists for the correct detergent and rinse additives for the
area. To help until one can be reached, we suggest that you use a non-foaming dishwasher detergent,
approximately one-quarter cup in wash tank, when machine is filled the first time, then one level tablespoon
each cycle (or load) thereafter. This may have to be increased or decreased to obtain satisfactory results.

6

GENERAL INSTRUCTIONS

(PREVENTIVE MAINTENANCE)

(THE FOLLOWING IS TO BE PREFORMED AS NEEDED.)

Note: Read carefully. Proper maintenance of your Jackson Dishwasher will ensure optimum

1. To remove all lime and corrosion dep osits.

g. Refill as it is ready for regular operation.

2. Clean strainers.

3. Clean Y -strainer on incoming water line. (Water to machine must be turned off for this operation).

a. Remove plug and clean strainer.

4. Clean rinse tubes.

c. If spray holes in the rinse tubes are clogged, they may be cleaned with a pointed tool.

5. Clean wash head assembly.

service with a minimum of down time.

a. Fill the machine with wash water as would ordinarily be done for washing.
b. Open door and place one cup or more of de-liming compound into the water. (Be sure

to follow manufacturer's directions if they vary from these being given) which is

available from your detergent supplier.
c. Turn on wash switch and allow to wash for five minutes.
d. Open door-and examine the interior. All lime should be removed and parts should be

shiny. If not, allow to wash for longer period­e. After the interior is clean, empt y the wash water by removing overflow strainer.
f. Replace overflow strainer. Refill machine and allow to run for two minutes, then, again

drain the wash reservoir.

a. Clean around overflow and pump intake strainer holes.
b. Clean around pump intake (toothbrush makes excellent tool for cleaning).

a. Remove end plugs on lower and upper rinse.
b. Clean all rinse tubes with special brush supplied.

a. If spray jets are plugged, use pointed tool to dislodge and flush with water.
b. If lodged items still remain in wash tubes, remove wash assembly by first removing

rinse assembly.

c. Clean assembly at sink by flushing water through spray jets. d. Reinstall wash and rinse

assemblies. (See page with instructions).

6. Clean any deposits which may have built up on exterior moving parts.

7

UPPER WASH ASSEMBLY

P/N 1990

ITEM P/N DESCRIPTION

1. 2035 WASH HEAD TUBE CAP

2. 2020 WASH HEAD TUBE

3. 2025 WASH HEAD SPRING CUP

4. 2030 WASH HEAD SCREWS
0203700 TUBE CAP W/"O" RING

FINAL RINSE ASSEMBLY

P/N 6137500

ITEM PIN DESCRIPTION

5. 1390 RINSE ASSEMBLY UPPER NOZZLES

6. 1395 RINSE ASSEMBLY LOWER NOZZLES

7. 1400 RINSE ASSEMBLY END PLUGS

8

REPLACEMENT of SWITCHES In

CONTROL PANEL

There are three switches installed in the control box cover panel. These are the conveyor, wash, and
heater switches.

Before working on machine, it is important that power be turned off at customer's circuit breaker to prevent
the possibility of electrical shock, trip breaker to "off" position. Then turn machine breaker "on" located right
side of control box.

Remove the control panel from the control box. The three switches are mounted in individual round holes
with a keyway. By using a pair of pliers or open end wrench, it is possible to loosen the inside nut enough
to allow the outside nut holding the switch to be removed by fingers. Push switch out of hole.

If a switch is found to be defective, replacement can be achieved by placing the new switch next to the old
one. To make sure the new switch is not upside down, line up with the keyways. Transfer wires one at a
time to the new switch. If this is not practical, pull wires off, one at a time and tag them for proper
replacement.

Put switches back into panel, make sure switch protrudes through panel properly, tighten both nuts, and
replace control panel on control box. Power can now be applied to dishwasher and run through cycles
checking all operations.

P/N 1575

1. CONNECTION TERMINALS

2. INSIDE NUT

3. PANEL PLATE

4. OUTSIDE NUT

5. BAT OR TOGGLE HANDLE

9

THERMOSTAT ADJUSTMENT

The thermostat can be adjusted by turning screw #1 (see picture) on the thermostat control box cover.
(Remember the present setting, in case the problems are elsewhere in the control circuit). A CW rotation
is used to obtain a lower temperature setting and a CCW rotation is used to obtain a higher temperature
setting. A 1/8 turn of screw #1 changes the temperature approximately 15°F. If screw #1 is turned all the
way to its stop in either direc tion; adjust screw #2 as follows. DO NOT TOUCH THE SCREW SEALED
WITH RED PAINT. When adjusting screw #2 power should be disconnected during adjustment.

Set screw #1 so that it can be turned-equal distances in either direction, then:

— if screw #1 stopped while turning in CW direction, turn screw #2 in CW direction slowly and only

1/8 of a turn or less per complete cycle of the unit.

— if screw #1 stopped while turning in CCW direction, turn screw #2 in CCW direction slowly and

only 1/8 of a turn or less per complete cycle of the unit.

Three-fourths of a turn will bring the thermostat to approximately the same setting obtained where
screw #1 stopped. Check the present temperature setting before attempting any further adjustments.
Use screw #1 for any further adjustments.

NOTE: Making large moves in adjusting may cause misalignment thus increasing

the chances that further adjustment cannot be made and the thermostat
will have to be replaced.

10

SERVICE INSTRUCTIONS

(INCOMING WATER SOLENOID VALVE)

To Take The Valve Apart
Disassembly - These valves may be taken apart by unscrewing the

bonnet and the enclosing tube assembly from the valve body assembly.
See Fig. 3. After unscrewing, carefully lift off the bonnet and enclosing
tube assembly. Don't drop the plunger. The "0" ring seal and diaphragm
cartridge can now be lifted out.

Be careful not to damage the machined faces while the valve is apart.
To Reassemble - Place the diaphragm cart ridge in the body with the

pilot port extension UP. Hold the plunger with synthetic seat against the
pilot port. Make sure the "0" ring is in place, then lower the bonnet and
enclosing tube assembly over the plunger. Screw bonnet assembly
snugly down on the body assembly.

11

Possible Problems
Pilot Port extension #1 clogged

Hole #2 clogged

Remedy

Pass heated straight pin through hole #2 or
clean hole #1

REPLACING SEAL and CERAMIC

on WASH PUMPS

Function:

The pump is part of the total motor-pump system and utilizes one shaft seal and ceramic to prevent the
pump from leaking around the impeller and shaft. One gasket is used to prevent leakage between the
pump mounting plate and the machine pump plate.

Replacement of Seal and/or Ceramic:

1. Remove the power source to the machine by turning the circuit breaker to its "off" position on the side of
the control box.

2. Drain the machine by removing the overflow strainer in the wash tank.

3. Support the motor—remove the four nuts holding the pump/motor to the machine's pump plate.

4. Carefully pull motor outward, move from side to side as required to remove from machine.

5. Set motor and pump on a sturdy stand clos e to machine or remove wires and conduit to allow
motor/pump to be moved to a better work station.

6. Insert a firm object into the blades of the fan and use 1 5/16" ratchet to remove bolt holding impeller.
After the bolt is removed, pull the impeller up and off of the shaft.

7. The ceramic is imbedded in the pump mounting plate and usually does not need
replacement, but the seal normally would when water leaks around the motor shaft area.
If replacement of either is required, proceed as follows:
a. Remove the four bolts holding the pump mounting plate to the motor.

b. Slide the mounting plate up and off of the shaft and motor. The imbedded ceramic and shaft seal will

be removed with the mounting plate.

c. Turn over the plate and push the seal and/or ceramic out of the housing carefully. It may be

necessary to break the ceramic to remove it.
d. Clean the hole where the ceramic was installed.
e. Lightly coat with a lubricant around the new ceramic's edges and "0" ring. Gently press the ceramic

into place against the snap ring in the housing. Make sure that the grooved side of the ceramic faces

the motor and housing snap ring, leaving the smooth side toward the impeller.
f. Make sure that the woodruff key is in place in the shaft and then set the plate back

on the motor over the shaft.

Note: A field tool can be made (to ease installation of seal) from a pipe or tube (3/4" CPVC

typical example) that has proper outside and inside dimensions. It must fit over step
down in shaft, but be close to larger shaft size on outside - To accommodate woodruff,
cut long slot in tube. Lubricate tube slip seal over tube onto shaft.

g. Lightly coat with a lubricant the new seal face and gently press it into place over the shaft with seal

face against the ceramic. SEE NOTE ABOVE.
h. Place the spring over the shaft with the metal cap up. Press the impeller down onto the shaft, aligning

the keyway of the impeller with the woodruff key.
i. Tighten the impeller washer, lockwasher, and bolt into place. Replace the four bolts that hold the

mounting plate to the motor.

8. Reinstall the pump and motor in the unit by reversing steps one through eight (it is suggested that a new
pump gasket be installed).

Impeller Rotation:

When facing the impeller after mounting it on the motor shaft, the impeller should turn in a CCW
direction.

12