Jackson AJ-76CGP Service Manual

INSTALLATION/OPERATION &

TECHNICAL MANUAL

FOR JACKSON MODELS:

AND ASSOCIATED OPTION PACKAGES INCLUDING:

SIDE LOADER

D226 EXTERNAL STEAM BOOSTER

Jackson MSC LLC.

P.O. Box 1060

Barbourville, KY. 40906

(606) 523-9795

Fax: (606) 523-9196

www.jacksonmsc.com

AJ-54 RACK CONVEYOR DISHMACHINE SERIES

April 19, 2007 P/N 7610-002-30-91 (Revision E)

AJ-54CE

AJ-54CGP

AJ-54CS

AJ-76CE

AJ-76CGP

AJ-76CS

AJ-90CE

AJ-90CS

ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP, UNDER NORMAL USE AND OPERATION FOR A PERIOD OF (1) ONE YEAR FROM THE DATE OF PURCHASE, BUT IN NO EVENT TO EXCEED (18) EIGHTEEN MONTHS FROM THE DATE OF SHIPMENT FROM THE FACTORY.

Jackson MSC agrees under this warranty to repair or replace , at its discretion, any original part which fails under normal use due to faulty material or workmanship during the warranty period, providing the equipment has been unaltered, and has been properly installed, maintained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to the authorized service agency within the warranty period. This includes the use of factory specified genuine replacement parts, purchased directly from a Jackson authorized parts distributor or service agency. Use of generic replacement parts may create a hazard and void warranty certification.

The labor to repair or replace such failed part will be paid by Jackson MSC, within the continental United States, Hawaii and Canada, during the warranty period provided a Jackson MSC authorized service agency, or those having prior authorization from the factory, performs the service. Any repair work by persons other than a Jackson MSC authorized service agency is the sole responsibility of the customer. Labor coverage is limited to regular hourly rates, overtime premiums and emergency service charges will not be paid by Jackson MSC.

Accessory components not installed by the factory carry a (1) one year parts warranty only. Accessory components such as table limit switches, pressure regulators, pre rinse units, etc. that are shipped with the unit and installed at the site are included. Labor to repair or replace these components is not covered by Jackson MSC.

This warranty is void if failure is a direct result from shipping, handling, fire, water, accident, misuse, acts of god, attempted repair by unauthorized persons, improper installation, if serial number has been removed or altered, or if unit is used for purpose other than it was originally intended.

TRAVELLIMITATIONS Jackson MSC limits warranty travel time to (2) two hours and mileage to (100) one hundred miles. Jackson MSC will not pay for travel time

and mileage that exceeds this, or any fees such as those for air or boat travel without prior authorization. WARRANTY REGISTRATION CARD The warranty registration card supplied with the machine must be returned to Jackson MSC within 30 days to validate the warranty. REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the

factory, which ever occurs first. PRODUCT CHANGES AND UPDATES Jackson MSC reserves the right to make changes in design and specification of any equipment as engineering or necessity requires. THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON MSC. JACKSON’S LIABILITY ON ANY CLAIM OF ANY KIND, INCLUDING

NEGLIGENCE, WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER, SHALL IN NO CASE EXCEED THE PRICE OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM.

THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING FOR FITNESS OR MERCHANTABILITY, THATARE NOT SET FORTH HEREIN, OR THAT EXTEND BEYOND THE DURATION HEREOF. UNDER NO CIRCUMSTANCES WILL JACKSON MSC BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECT OR CONSEQUENTIAL, OR FOR THE DAMAGES IN THE NATURE OF PENALTIES, ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS.

ITEMS NOT COVERED This warranty does not cover cleaning or deliming of the unit or any component such as, but not limited to, wash arms, rinse arms or strain-

ers at anytime. Nor does it cover adjustments such as, but not limited to timer cams, thermostats or doors, beyond 30 days from the date of installation. In addition, the warranty will only cover the replacement of wear items such as curtains, drain balls, door guides or gaskets during the first 30 days after installation. Also, not covered are conditions caused by the use of incorrect (non-Commercial) grade detergents, incorrect water temperature or pressure, or hard water conditions.

MANUFACTURERS WARRANTY

ONE YEAR LIMITED PARTS & LABOR WARRANTY

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

iii

REVISION

DATE

MADEBYAPPLICABLE

ECN

DETAILS

B 02-19-04 CBW N/A

Combined AJ-54, AJ-76 and AJ-90 service and export manuals into one manual. Added data for 575 Volt & 600 Volt models.

C 03-16-05 MAW

6999, 7193 7217, 7064 7212, 7259 6685, 7096 6964, 7006

Updated drawings for limit switch actuators. Changed AJ-76 drain plumbing copper lengths. Added rack rail stabilizer kit. Replaced heater 04540-121-76-93 with 04540-002-29-82. Updated installation instructions. Added 3 instruction sheets for limit switches. Added instruction sheet for curtains. Added AJ-54CGP & AJ76CGP models.

D 02-01-06 MAW 7600

Added gas exhaust fan hookup schematic, updated electric exhaust fan schematic and updated dimension drawings.

E 03-22-06 MAW

7571, 7330 7634, 7558 7367, 7428 7554, 7462

7463

Added thermostat replacement kits. Added vent cowl assembly for hooded side loader. Replaced rinse drain weldment. Added scrap basket strainer kit. Added new door weldments. Added pawl bar relacement kits. Added heater replacement kits. Added wash, rinse & psi decals. Added rinse fill motor assemblies.

PG. 115 04-19-07 MAW 7898 Added 09905-003-32-20 fan load decal.

NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL

AJ-54CS

AJ = AJ series of rack conveyors 54 = 54” wide machine

76 = 76” wide machine 90 = 90” wide machine

CE = Electrically heated, hot water sanitizing machine CS = Steam heated, hot water sanitizing machine CGP = Gas heated, hot water sanitizing machine

Model:

Serial No.:

Installation Date:

Service Rep. Name:

Phone No.:

Jackson MSC LLC. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer to this manual before making a call to our technical support staff. Please have this manual with you when you call so that our staff can refer you, if necessary, to the proper 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.

SECTION

DESCRIPTION PAGE

I. SPECIFICATION INFORMATION

Operating Characteristics 2 Electrical Requirements 3 D226 Steam Booster Parameters 4 AJ-54 Dimensions 5 AJ-76 (Left to Right) Dimensions 6 AJ-76 (Right to Left) Dimensions 7 AJ-90 (Left to Right) Dimensions 8 AJ-90 (Right to Left) Dimensions 9 Side Loader (Left to Right) Dimensions 10 Side Loader (Right to Left) Dimensions 11 Side Loader (Installed) Dimensions 12 D226 Steam Booster Dimensions 13 D226 Steam Booster Plumbing Line Drawings 14 Typical Electric and Gas Booster Dimensions 15

II. INSTALLATION & OPERATION INSTRUCTIONS

Installation Instructions 17 Deliming Operations 20 Curtain Installation Diagram 21 Side Loader Installation & Operation Instructions 22 D226 Steam Booster Installation & Operation Instructions 23 Gas Conveyor Hose Installation 25 Dishmachine Operating Instructions 27 Detergent Control 29 Photoelectric Limit Switch Installation Instructions 30 Striker Plate Limit Switch Installation Instructions 31 Whisker Limit Switch Installation Instructions 32

III. PREVENTATIVE MAINTENANCE

General Maintenance 34 D226 Maintenance 35 Drive Motor Gear Reducer Preventative Maintenance 36

IV. TROUBLESHOOTING SECTION

Common Problems 38 D226 Common Problems 40

V. SERVICE PROCEDURES

Replacing the Pump Gasket & Seal 42 Rack Rail Stabilizer Kit 45 Rinse Solenoid Valve Repair Parts Kit 46 Vacuum Breaker Repair Parts Kit 50 Drive Motor & Gear Reducer Replacement 52 Replacing the Wash Heater 57 Replacing the Conveyor Motor 61

VI. PARTS SECTION

AJ-54 Control Box Assembly 65 AJ-76/AJ-90 Control Box Assembly 67 Motor Overload Chart 69 Heater Assembly 70 Thermostats 72 Frame Weldments/Front Dress Panels 72

TABLE OF CONTENTS

VI. PARTS SECTION (CONTINUED)

Prewash Plumbing Assembly 73 Wash Section Plumbing 74 External Electric Booster Option Incoming Plumbing 75 External Electric Booster Option Outlet Plumbing 76 WPRK Plumbing Option 77 3/4” Solenoid Valve & 3/4” NPT Vacuum Breaker Repair Parts Kits 78 Steam Unit Wash Tank Coil Assembly 79 Steam Inlet/Outlet Plumbing (Left to Right) 80 Steam Inlet/Outlet Plumbing (Right to Left) 81 Gas Coil Assembly (CGP Models) 82 Rinse Booster Tank Assembly (CGP Models) 83 Recirculating Pump Assembly (CGP Models) 84 Hose Connections (CGP Models) 85 Wash/Fill Plumbing Assembly (CGP Models) 86 Rinse Header Plumbing Assembly (CGP Models) 87 AJ-54 Series Drain Plumbing Assemblies 88 AJ-76 Drain Plumbing Assemblies 89 AJ-90 Drain Plumbing Assemblies 90 AJ-76 Drain Plumbing Assembly (Left to Right) (CGP Models) 91 Drain Quench Assembly 92 Motor Assemblies 93 Prewash & Wash Pump Weldments 94 Prewash/Upper Wash Arm Assemblies 95 Lower Wash Arm Assembly 96 Curtains/Tub Magnets 97 Final Rinse Assembly 98 Drive Assembly 99 Lubrication Chart for Drive Gear 101 Door Assemblies 102 Pawl Bar Miscellaneous Components 103 AJ-54 Pawl Bar Assembly 104 AJ-76 Pawl Bar Assemblies 105 AJ-90 Pawl bar Assemblies 106 AJ-54 Rack Rail Assembly 107 AJ-76 Rack Rail Assemblies 108 AJ-90 Rack Rail Assemblies 109 Miscellaneous Parts & Weldments 110 Manifolds/Strainer Support Weldments 111 Strainers 112 Float Switch Covers/Scrap Basket Assembly 113 Vent Cowl Assembly/Vent Scoop Option 114 Exhaust Fan Control Option/Limit Switch Options 115

SIDE LOADER SECTION

Side Loader Track Assembly/Leg Replacements/Strainer 116 Side Loader Pawl Bar Assemblies/Pawl Bar Bracket/Magnet 117 Side Loader Vent Cowl Option 118

D226 STEAM BOOSTER SECTION

Control Box Assembly 119

Plumbing Assembly 120 Go*Box Components 122 Rinse Fill Option 123

TABLE OF CONTENTS

VII. ELECTRICAL SCHEMATICS

AJ-54CE

208-230 Volt, 60 Hz, 1 Phase 125

208-230 Volt, 60 Hz, 3 Phase 126

460-575-600 Volt, 60 Hz, 3 Phase 127 AJ-54CS

208-230 Volt, 60 Hz, 1 Phase 128

208-230 Volt, 60 Hz, 3 Phase 129

460-575-600 Volt, 60 Hz, 3 Phase 130 AJ-76CE & AJ-90CE

208-230 Volt, 60 Hz, 1 Phase 131

208-230 Volt, 60 Hz, 3 Phase 132

460-575-600 Volt, 60 Hz, 3 Phase 133 AJ-76CS & AJ-90CS

208-230 Volt, 60 Hz, 1 Phase 134

208-230 Volt, 60 Hz, 3 Phase 135

460-575-600 Volt, 60 Hz, 3 Phase 136 AJ-54CGP

208-230 Volt, 60 Hz, 1 Phase 137

208-230 Volt, 60 Hz, 3 Phase 138

460 Volt, 60 Hz, 3 Phase 139 AJ-76CGP

208-230 Volt, 60 Hz, 1 Phase 140

208-230 Volt, 60 Hz, 3 Phase 141

460 Volt, 60 Hz, 3 Phase 142 Exhaust Fan Hook-Up Schematics 143 D226 Steam Booster/Drain Quench/Side Loader Schematics 144

VIII. MAINTENANCE & REPAIR CENTERS 146

TABLE OF CONTENTS

vii

SECTION 1:

SPECIFICATION INFORMATION

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

OPERATING CHARACTERISTICS

RACKS PER HOUR:

AJ-54-76-90CE/CS/CGP 270

DISHES OR GLASSES PER HOUR:

AJ-54-76-90CE/CS/CGP 6750

PREWASH TANK CAPACITY (GALLONS):

AJ-76CE/CS/CGP 16 AJ-90CE/CS/CGP 16

WASH TANK CAPACITY (GALLONS):

AJ-54-76-90CE/CS/CGP 20.4

PREWASH PUMP CAPACITY (GPM):

AJ-76CE/CS/CGP 120 AJ-90CE/CS/CGP 270

WASH PUMP CAPACITY

GALLONS PER MINUTE (ALL MODELS): 270

VENTING REQUIREMENTS (CFM)(100% CAP.):

INPUT END 200 OUTPUT END 400 TOTAL 600

CONVEYOR SPEED (FPM):

AJ-54-76-90CE/CS/CGP MACHINES 7.5

GALLONS PER RACK:

AJ-54-76-90CE/CS/CGP MACHINES 1.03

WATER TEMPERATURES: AJ-54-76-90CE/CS/CGP MODELS:

PREWASH (RECOMMENDED) (AJ-76/AJ-90) 110-140°F WASH (MINIMUM) 160°F RINSE (MINIMUM) 180°F

FLOW PRESSURE (PSI) 20±5 FLOWRATE (GPM):

AJ-54-76-90CE/CS/CGP 4.7

STEAM COIL TANK HEAT (CS/CSL MODELS ONLY):

STEAM INLET PRESSURE (PSIG) 10-20 STEAM CONNECTION NPT 3/4” CONSUMPTION @ 15 PSIG (lbs/hr): AJ-54-76-90CS/CSL 60

MOTOR ELECTRICAL CHARACTERISTICS:

DRIVE MOTOR HP 1/4 WASH MOTOR HP 2 POWER RINSE MOTOR HP 2 PREWASH MOTOR HP: AJ-76 MODELS 1 AJ-90 MODELS 2

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.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

ELECTRICAL REQUIREMENTS

AJ-54CE MODELS

TYPICAL

TOTAL ELECTRICAL

VOL

TS PH HZ AMPS CIRCUIT

208 1 60 107 A 150 AMP 230 1 60 98 A 125 AMP

208 3 60 63 A 80 AMP 230 3 60 57 A 80 AMP 460 3 60 29 A 40 AMP 575 3 60 22 A 30 AMP 600 3 60 23 A 30 AMP

AJ-54CGP MODELS

TYPICAL

TOTAL ELECTRICAL

VOLTS PH HZ AMPS CIRCUIT

208 1 60 11 A 15 AMP 230 1 60 11 A 15 AMP 208 3 60 7 A 15 AMP 230 3 60 7 A 15 AMP 460 3 60 4 A 15 AMP

AJ-54CS MODELS

TYPICAL

TOTAL ELECTRICAL

VOL

TS PH HZ AMPS CIRCUIT

208 1 60 11 A 15 AMP 230 1 60 11 A 15 AMP

208 3 60 7 A 15 AMP 230 3 60 7 A 15 AMP 460 3 60 4 A 15 AMP 575 3 60 4 A 15 AMP 600 3 60 4 A 15 AMP

AJ-76CE MODELS

TYPICAL

TOTAL ELECTRICAL

VOL

TS PH HZ AMPS CIRCUIT

208 1 60 113 A 150 AMP 230 1 60 104 A 150 AMP

208 3 60 66 A 90 AMP 230 3 60 61 A 80 AMP 460 3 60 31 A 40 AMP 575 3 60 25 A 35 AMP 600 3 60 26 A 35 AMP

AJ-76CGP MODELS

TYPICAL

TOTAL ELECTRICAL

VOLTS PH HZ AMPS CIRCUIT

208 1 60 17 A 25 AMP 230 1 60 17 A 25 AMP 208 3 60 12 A 15 AMP 230 3 60 12 A 15 AMP 460 3 60 6 A 15 AMP

AJ-76CS MODELS

TYPICAL

TOTAL ELECTRICAL

VOL

TS PH HZ AMPS CIRCUIT

208 1 60 17 A 25 AMP 230 1 60 17 A 25 AMP

208 3 60 12 A 15 AMP 230 3 60 12 A 15 AMP 460 3 60 6 A 15 AMP 575 3 60 6 A 15 AMP 600 3 60 6 A 15 AMP

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

ELECTRICAL REQUIREMENTS (CONTINUED)/D226 STEAM BOOSTER PARAMETERS

AJ-90CE MODELS

TYPICAL

TOTAL ELECTRICAL

VOL

TS PH HZ AMPS CIRCUIT

208 1 60 115 A 150 AMP 230 1 60 106 A 150 AMP

208 3 60 68 A 90 AMP 230 3 60 63 A 80 AMP 460 3 60 32 A 40 AMP 575 3 60 25 A 35 AMP 600 3 60 26 A 35 AMP

AJ-90CS MODELS

TYPICAL

TOTAL ELECTRICAL

VOLTS

PH HZ

AMPS CIRCUIT

208 1 60 19 A 25 AMP 230 1 60 19 A 25 AMP

208 3 60 14 A 20 AMP 230 3 60 14 A 20 AMP 460 3 60 7 A 15 AMP 575 3 60 6 A 15 AMP 600 3 60 6 A 15 AMP

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.

D226 STEAM BOOSTER

ELECTRICAL REQUIREMENTS:

VOLTAGE (V) 208-230 FREQUENCY (HZ) 60 PHASE SINGLE

WATER REQUIREMENTS:

INCOMING WATER TEMPERATURE (MINIMUM) 110°F FLOW PRESSURE (PSI) 20±5

STEAM REQUIREMENTS:

INCOMING STEAM PRESSURE (PSIG) 15-25

HEAT EXCHANGER SPECIFICATIONS:*

TUBESIDE WORKING PRESSURE (PSI) 125 SHELLSIDE WORKING PRESSURE (PSI) 125 TUBESIDE HYDROSTATIC TEST PRESSURE (PSI) 250 SHELLSIDE HYDROSTATIC TEST PRESSURE (PSI)

188 MAXIMUM OPERATING TEMPERATURE 295°F MAXIMUM SHELLSIDE STEAM PRESSURE (PSI) 125

* - Indicates typical design criteria but is subject to change without notice. For more information, contact you authorized Jackson service representative.

WATER OUTLET SAFETY VALVE SET PRESSURE (PSI): 125 STEAM RELIEF VALVE SET PRESSURE (PSI): 50

Legend to Drawing

A - Machine water inlet 3/4" NPT, 180°F water min. Hi-temp,

minimum flow requirements 4.7 GPM, 279 GPH

C - Electrical connection (does not include booster

heater

B -

Drain connection-1 1/2" NPT

D - Vent collar 4" wide x 16" long x 7" high-

Optional

E - Vent collar - standard both ends

*F -

Incoming low pressure steam connection, 3/4" NPT

(gate valve supplied)-

Requires 60 lbs of steam per hour

*G - Condensate return connection, 3/4" NPT (return to

boiler feeder of open drain)

*Steam tank heat option only.

Note: All vertical dimensions are +/- 1/2" from floor due

Note: Utility connections are identical regardless of

direction of flow.

Left to Right or Right to Left

23"

W/Doors

Open

4 1/2"

67"

7/8"

Drive

Unit

Left Side

Drive

Unit

Front View

84"

75 1/2"

1/4"

62 1/2"

34"

29"

10"

22"

10"

6 1/2"

54"

70"

"X"

Table to Table

Overall

25"

Opening

21"

Opening

25"

12"

34"

Right Side

21"

6 1/2"

4 1/2"

62"

10 1/2"

21" Opening

70"

4" wide x 16" long cutout in

Vent Cowl/Splash Shield.

Shipped with Cover Plate.

Floor Sink Or Drain With

3" Minimum Drain Line

12 1/2"

25"

54"

Table to Table

Table Turndown

Flange 3/4" Max

3/4"

21"

Rack Rail Height

Above Dishtable

1/4" - 5/16"

Rack Rail

Tub

Table

Use Silicone Sealer

Between Table and

Lip of Machine to

Prevent Leakage

Recommended Table Fabrication

to adjustable bullet feet.

Note: Tub Will Accept

a Table Flange

Up to 24 7/8"

30"

12"

(1.74 BHP)

Note: Maximum overall dimension of unit is 30", which

includes drain handle and counduit. Minimum door

required. - 30" wide x 78" high.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

AJ-54 MODEL DIMENSIONS

60 1/4"

4 1/2"

B J

67 1/2"

7/8"

84"

Drive

Unit

Left Side

w/Doors

Open

75 1/2"

62 1/2"

34"

29"

Drive

Unit

10"

27 1/2"

24"

10"

Front View

6 1/2"

34"

Right Side

8 1/2"

10 3/8"

25"

Opening

6 1/8"

23"

12"

21"

Opening

25"

26 1/4"

41"

76"

Table to Table

92"

Overall

4 1/2"

84"

10 1/2"

21"

Opening

92"

4"w. x 16" lg Cutout in

Vent Cowl/Splash Shield.

Shipped with Cover Plate.

Floor Sink or Drain With

3" Minimum Drain Line

12 1/2"

25"

76"

Table to Table

Note: Tub Will Accept

a Table Flange

Up to 24 7/8"

Table Turndown

Flange 3/4" Max

3/4"

21"

Left to Right Operation Shown

Legend to Drawing

A -

Machine water inlet 3/4" NPT, 180°F Hi-temp,

minimum flow requirements 4.7 GPM, 279 GPH

B -

3/4" NPT prewash water inlet, 140°F water max

C - Drain connection-1 1/2" NPT

F - Vent collar 4" wide x 16" long x 7" high- Optional

E - Vent cowl standard

*G - Incoming low pressure steam connection, 3/4" FPT

(gate valve supplied)-

Optional

*H -

Condensate return connection, 3/4" FPT (return to

boiler feeder or open drain)

J -

Cold water thermostat plumbing connection 3/4"

NPT- Optional

Steam tank heat option only

Note: All vertical dimensions are +/- 1/2" from floor due

to adjustable bullet feet

Recommended Table Fabrication

Rack Rail Height

Above Dishtable

1/4" - 5/16"

Rack Rail

Tub

Table

Use Silicone Sealer

Between Table and

Lip of Machine to

Prevent Leakage

Prewash Plan View

Section With Cold

Water Thermostat

18 1/4"

18 3/4"

D - Electrical connection - does not include booster heater

26 3/4"

24"

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

AJ-76 MODEL (LEFT TO RIGHT) DIMENSIONS

Right to Left Operation Shown

10"

60 1/4"

Left Side

75 1/2"

62 1/2"

34"

29"

Drive

Unit

10"

Front View

6 1/2"

Right Side

24 3/4"

42"

76"

Table to Table

92"

Overall

27 1/2"

24"

4 1/2"

84"

10 1/2"

21" Opening

92"

4"w. x 16" lg Cutout in

Vent Cowl/Splash Shield.

Shipped with Cover Plate.

Floor Sink or Drain With

3" Minimum Drain Line

12 1/2"

25"

76"

Table to Table

Note: Tub Will Accept

a Table Flange

Up to 24 7/8"

Table Turndown

Flange 3/4" Max

3/4"

21"

Legend to Drawing

Recommended Table Fabrication

Rack Rail Height

Above Dishtable

1/4" - 5/16"

Rack Rail

Tub

Table

Use Silicone Sealer

Between Table and

Lip of Machine to

Prevent Leakage

Prewash Plan View

Section With Cold

Water Thermostat

18 1/4"

18 3/4"

34"

8 1/2"

10 3/8"

25"

Opening

6 1/8"

12"

21"

Opening

25"

4 1/2"

B J

67 1/2"

7/8"

84"

Drive

Unit

w/Doors

Open

A -

Machine water inlet 3/4" NPT, 180°F Hi-temp,

minimum flow requirements 4.7 GPM, 279 GPH

B -

3/4" NPT prewash water inlet, 140°F water max

C - Drain connection-1 1/2" NPT

F - Vent collar 4" wide x 16" long x 7" high-

Optional

E - Vent cowl standard

*G - Incoming low pressure steam connection, 3/4" FPT

(gate valve supplied)-

Optional

*H -

Condensate return connection, 3/4" FPT (return to

boiler feeder or open drain)

J -

Cold water thermostat plumbing connection 3/4"

NPT-

Optional

Steam tank heat option only

Note: All vertical dimensions are +/- 1/2" from floor due

to adjustable bullet feet

D - Electrical connection - does not include booster heater

41"

24"

24 1/4"

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

AJ-76 MODEL (RIGHT TO LEFT) DIMENSIONS

84"

w/Doors

Open

60 1/4"

Drive

Unit

Left Side

67 1/2"

29"

Drive

Unit

10"

Front View

Right Side

Opening

16"

38"

411/2"

12"

4 1/2"

98"

10 1/2"

21"

Opening

106"

4"w. x 16" lg Cutout in

Vent Cowl/Splash Shield.

Shipped with Cover Plate.

Floor Sink or Drain With

3" Minimum Drain Line

12 1/2"

25"

90"

Table to Table

Note: Tub Will Accept

a Table Flange

Up to 24 7/8"

Table Turndown

Flange 3/4" Max

3/4"

21"

Left to Right Operation Shown

Legend to Drawing

A -

Machine water inlet 3/4" NPT, 180°F Hi-temp,

minimum flow requirements 4.7 GPM, 279 GPH

B - 3/4" NPT prewash water inlet, 140°F water max

C - Drain connection-1 1/2" NPT

F - Vent collar 4" wide x 16" long x 7" high- Optional

E - Vent cowl standard

*G - Incoming low pressure steam connection, 3/4" FPT

(gate valve supplied)- Optional

*H - Condensate return connection, 3/4" FPT (return to

boiler feeder or open drain)

J -

Cold water thermostat plumbing connection 3/4"

NPT- Optional

Steam tank heat option only

Note: All vertical dimensions are +/- 1/2" from floor due

to adjustable bullet feet

Recommended Table Fabrication

Rack Rail Height

Above Dishtable

1/4" - 5/16"

Rack Rail

Tub

Table

Use Silicone Sealer

Between Table and

Lip of Machine to

Prevent Leakage

Prewash Plan View

Section With Cold

Water Thermostat

18 1/4"

18 3/4"

D - Electrical connection - does not include booster heater

90"

Table to Table

106"

Overall

15"

30"

47"

16"

12"

25"

21"

25"

75 1/2"

67"

62 1/2"

34"

6 1/2"

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

AJ-90 MODEL (LEFT TO RIGHT) DIMENSIONS

Right to Left Operation Shown

16"

84"

w/Doors

Open

34"

60 1/4"

67"

Drive

Unit

Left Side

75 1/2"

62 1/2"

67 1/2"

29"

10"

Front View

6 1/2"

Right Side

25"

Opening

15"

21"

Opening

25"

47"

90"

Table to Table

106"

Overall

16"

12"

38"

41 1/2"

12"

30"

4 1/2"

98"

10 1/2"

21" Opening

106"

4"w. x 16" lg Cutout in

Vent Cowl/Splash Shield.

Shipped with Cover Plate.

Floor Sink or Drain With

3" Minimum Drain Line

12 1/2"

25"

90"

Table to Table

Note: Tub Will Accept

a Table Flange

Up to 24 7/8"

Table Turndown

Flange 3/4" Max

3/4"

21"

Legend to Drawing

A -

Machine water inlet 3/4" NPT, 180°F Hi-temp,

minimum flow requirements 4.7 GPM, 279 GPH

B -

3/4" NPT prewash water inlet, 140°F water max

C - Drain connection-1 1/2" NPT

F - Vent collar 4" wide x 16" long x 7" high- Optional

E - Vent cowl standard

*G - Incoming low pressure steam connection, 3/4" FPT

(gate v alve supplied)-

Optional

*H - Condensate return connection, 3/4" FPT (return to

boiler feeder or open drain)

J -

Cold water thermostat plumbing connection 3/4"

NPT-

Optional

Steam tank heat option only

Note: All vertical dimensions are +/- 1/2" from floor due

to adjustable bullet feet

Recommended Table Fabrication

Rack Rail Height

Above Dishtable

1/4" - 5/16"

Rack Rail

Tub

Table

Use Silicone Sealer

Between Table and

Lip of Machine to

Prevent Leakage

Prewash Plan View

Section With Cold

Water Thermostat

18 1/4"

18 3/4"

D - Electrical connection - does not include booster heater

Drive

Unit

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

AJ-90 MODEL (RIGHT TO LEFT) DIMENSIONS

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

SIDE LOADER (LEFT TO RIGHT) DIMENSIONS

**23”

CONVEYOR

DISHWASHER

LENGTH

*8”

4 1/2”

MINIMUM

25”

DISHWASHER

5”

12 1/2”

14 1/2”

29”

1 1/2” TABLE

ROLL

20 3/4”

OPENING

1”

A A

1/2”

MINIMUM

1/2”

DISHTABLE

USE SILICONE BETWEEN T ABLE AND LIP OF SIDE LOADER TO PREVENT LEAKAGE.

WALL OF SIDE LOADER

SECTION “A-A”

CENTER-LINE DISHMACHINE

SPLASH SHIELD

VENT CONNECTION OPENING

1 1/2” DRAIN. CONNECTED TO DISHMACHINE DRAIN LINE

CONVEYOR

DISHMACHINE

* - 15” for 30” Model ** - 30” for 30” Model

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

SIDE LOADER (RIGHT TO LEFT) DIMENSIONS

14 1/2”

29”

*8”

**23”

CONVEYOR

DISHMACHINE

LENGTH

4 1/2” MINIMUM

12 1/2”

25”

DISHWASHER

5”

1 1/2” TABLE

ROLL

20 3/4”

OPENING

1”

1/2”

MINIMUM

DISHTABLE

1/2”

WALL OF SIDE LOADER

USE SILICONE BETWEEN TABLE AND LIP OF SIDE LOADER TO PREVENT LEAKAGE

SECTION “A-A”

CONVEYOR

DISHMACHINE

CENTER LINE DISHMACHINE

VENT CONNECTION OPENING

SPLASH SHIELD

1 1/2” DRAIN. CONNECTED TO DISHMACHINE DRAIN LINE

* - 15” for 30” Model ** - 30” for 30” Model

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

SIDE LOADER INSTALLATION DIMENSIONS

Refer to chart above.

34”

23” or 30”

10”

4”

23” SIDE LOADER DIMENSIONS

30” SIDE LOADER DIMENSIONS

MODEL

AJ-54 AJ-76 AJ-90

MODEL

AJ-54 AJ-76 AJ-90

DIMENSIONS

85” 107” 121”

DIMENSIONS

92”

114”

128”

(Left to Right installation shown for reference.)

NOTE: ALL DIMENSIONS ARE TYPICAL.

Depending on the width of the

side loader.

14 4

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

D226 STEAM BOOSTER DIMENSIONS

NOTE: All dimensions are in inches and are for reference only.

43”

11”

14”

4”

24”

11”

16”

13”

6”

16”

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

D226 STEAM BOOSTER PLUMBING LINE DRAWINGS

Steam Booster Piping - Single Tank Machine

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 1: SPECIFICATION INFORMATION

TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS

/" NPT Coupling for Temperature/Pressure Relief Valve

30 /

" (775 mm)

24" (610 mm)

INLET

REAR VIEW

OUTLET

SIDE VIEW

Electical connection

from side or below

4/ " NPT Nipple

7/"

(200 mm)

18" (457 mm)

(152 mm)

6" (152 mm)

3/"

(83 mm)

36" (914 mm) PMG-200

RIGHT SIDE VIEW

Water Outlet

Water Inlet

Gas Inlet

Alternate Flue Location

TPRV

4" (102 mm) Vent Adapter

Water Outlet

Water Inlet

Gas Inlet

Water Outlet

Electrical

Water Inlet

Gas Inlet

36" (914 mm) PMG-200

LEFT SIDE VIEW

Water Outlet

Water Inlet

Gas Inlet

Alternate TPRV Location

Electric Booster Dimensions (Typical)

30-1/2”

24”

18”

6”

12”

6”

7-7/8”

2”

Gas Booster Dimensions (Typical)

36”

25-1/8”

20-3/4”

31-1/4”

6”

SECTION 2:

INSTALLATION/OPERATION

INSTRUCTIONS

NOTE: THE INSTRUCTIONS PROVIDED HEREIN, UNLESS OTHERWISE SPECIFIED ARE FOR THE DISHMACHINES ONLY. THERE ARE SEPARATE DIRECTIONS FOR THE GAS BOOSTER.

VISUAL INSPECTION: Before installing the unit, check the container and machine for damage. Adamaged 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, undamaged condition. However, rough handling by carriers or others may result in damage to the unit while in transit. If such a situation 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.

UNP ACKING 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 overall 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. Afilter designed to remove iron from the supply water is highly recommended for supplies in excess of 0.1 ppm (parts per million).

CONNECTING THE DRAIN LINE: The drain for the models covered in this manual are gravity discharge drains. All piping from the machine to the drain must be a minimum 1 1/2” NPT and should not be reduced. There must also be an air gap between the machine drain line and the floor sink or drain. If a grease trap is required by code, it should have a flow capacity of 30 gallons per minute.

WATER SUPPLY CONNECTION: Ensure that you have read the section entitled “PLUMBING THE DISHMACHINE” above before proceeding. The supply water temperature must meet the minimum requirements listed on the machine data plate. Install the water supply line (3/4” pipe size minimum) to the dishmachine 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 service. The water supply line is to be capable of 25 PSI “flow” pressure at the recommended temperature indicated on the data plate.

If the water level is too low or too high, check the incoming water pressure. It should be 20 ± 5 PSI. T oo high of pressure result s 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 clockwise to decrease it.

Do not confuse static pressure with flow pressure. Static pressure is the line pressure in a “no flow” condition (all valves and services are closed). Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

Adjusting screw

Locking nut

Incoming Plumbing Connection

Frame with Adjustable Foot

It is also recommended that a shock absorber (not supplied) be installed in the incoming water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve as it operates, from causing damage to the equipment.

STEAM LINE CONNECTIONS: Some machines covered in this manual are designed to use low pressure steam as a source of heat for wash tank water. The machines come with lines by which outside source steam needs to be connected. Connect all incoming steam lines in accordance with the steam booster manufacturer’s instructions. Ensure that all applicable codes and regulations are adhered to. See machine data plate for information concerning steam flow pressure.

GAS CONNECTIONS: Some machines covered in this manual are designed to use gas as an outside source of heat for wash tank water. The machines come with connections by which an out side source needs to be connected. Connect all incoming gas lines in accordance with the gas booster manufacturer’s instructions. Ensure that all applicable codes and regulations are adhered to.

PLUMBING CHECK: Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been installed. Check for any leaks and repair as required. All leaks must be repaired prior to placing the machine in operation.

ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with the applicable portions of the National Electrical Code ANSI/NFPA 70 (latest edition) and/or other electrical codes.

Disconnect electrical power supply and place a tag at the disconnect switch to indicate that you are working on the circuit.

The dishmachine data plate is located on the right side and to the front of the machine. Refer to the data plate for machine operating requirements, machine voltage, total amperage load and serial number.

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.

VOLTAGE CHECK: Ensure that the power switch is in the OFF position and apply power to the dishmachine. Check the incoming 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 personnel of any problems and of the location of the service breaker. Replace the control box cover and tighten down the screws.

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 warranty.

This units covered in this manual have the following exhaust requirements: Load End: 200 CFM

Unload End: 400 CFM

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS (CONTINUED)

Incoming Power Connection

Decal showing “L1”, “L2”, & “L3” (3 phase models only).

Terminal Block

The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to. ELECTRIC HEAT: The thermostats for the machines covered in this

manual are factory set. They should not be adjusted except by an authorized service agent.

CHEMICAL FEEDER EQUIPMENT: Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting. Remove the bulkhead plug in the side of the tub to install the detergent concentration probe.

For more information concerning detergent concerns, please refer to the page entitled “Detergent Control”.

The 1/8” brass plugs on the incoming plumbing rinse injector may be removed to install rinse aid injection fittings.

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.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS (CONTINUED)

Connection Points

Detergent Connection Point

(Machine rear view)

Brass Plug

Brass Plugs

DELIMING OPERA TIONS: 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. Adeliming 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 specification sheet(s) of this manual.

Perform the following operations to delime the dishmachine:

1. Turn the AUTOMATIC/DELIME switch on the back of the control box to the DELIME position.

2. Disconnect or turn off all chemical feeder pumps.

3. Close all doors (after adding the deliming solution).

4. Run the machine for the recommended period of time.

5. Turn the unit off and open the doors.

6. Wait five minutes, then inspect the inside of the machine. If the machine is not delimed, run another time cycle as per the deliming solution’s instructions.

7. When clean, drain and re-fill the machine.

8. Run in MANUAL for 10 minutes to remove residual deliming solution.

9. Drain and re-fill the machine.

This equipment is not recommend for use with deionized water or other aggressive fluids. Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components. Use of deionized water or other aggressive fluids will void the manufacturer's warranty.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

DELIMING OPERATIONS

Delime Switch

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

CURTAIN INSTALLATION DIAGRAMS

L R

LS SLL

21" 12" 12"21"21" 21" 21" 12"12"

LLSS

21" 21" 12"12"21"

LLSSL

12"

L R

SSLL

12" 12"21"21"

12"

L R

SSL

12" 12"21"

21" 12"

12"24.5"

LSSXL

GAS MACHINES

24.5"

XLS

12"

L R

LS SLL

21" 12" 12"21"21"

21" 21" 12"

12"21"

LLSSL

HOODED SIDE LOADER

UNHOODED SIDE LOADER

HOODED SIDE LOADER

ELECTRIC & STEAM MACHINES

Please refer to the chart for placement of the curtains.

This accessory assists in the delivery of a full dish rack from the break down (scrapping) table to the dishmachine. It will convert 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 electrical connections.

This Side Loader does not require or add any additional electrical or mechanical devices to the unit which could create operational or maintenance problems. As designed the drive mechanism is powered by the conveyor drive motor on the dishmachine. 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 regular 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.

AJ-54C Series Technical Manual 7610-002-30-91

Issued: 03-22-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

SIDE LOADER INSTALLATION & OPERATION INSTRUCTIONS

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