Jackson ConserverII Service Manual

CONSERVER II

1060

40906

JMSC

CHEMICAL SANTIZING

DISHWASHER

SERVICE MANUAL

INCLUDES:

-Warranty Policy -Specifications

-Installation Requirements -Maintenance and Care

-Operating Instructions -Illustrated Parts List

-Description of Components -Electrical Diagrams

WORLD HEADQUARTERS & MANUFACTURING OPERATIONS

Highway 25E, P.O. Box

Barbourville, KY

888/800-

FAX 606/532-9196

April 4,1997 7610-100-24-00 Rev A

MANUFACTURERS WARRANTY

ONE YEAR LIMITED PARTS & LABOR WARRANTY

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.

TRAVEL LIMITATIONS 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, THAT ARE 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 adjustments to timer cams or thermostats, cleaning wash arms or strainers, or replacement of wear items such as curtains,

squeeze tubes, drain balls, door guides, or gaskets beyond 30 days from installation of unit. Also not covered are conditions caused by the use of incorrect (non commercial) grade detergents, excessive supply water temperature or pressure, or hard water conditions.

INDEX

WARRANTY

SPECIFICATIONS 3

GENERAL INSTRUCTIONS (Installation) 4

GENERAL INSTRUCTIONS (Operation) 6

GENERAL INSTRUCTIONS (Preventive Maintenance) 8

WASH/RINSE HEAD ASSEMBLY

TIMER ADJUSTMENTS 10

TIMER ASSEMBLY, SPANNER WRENCH TIMERMICRO SWlTCH, SIDE

VIEW of CAM

FUNCTION of SWITCHES, CIRCUIT BREAKER,INDICATOR LIGHTS and

CYCLE COUNTER

REPLACEMENT of SWITCHES in CONTROL PANEL 13

PERISTALTIC PUMP SANITIZING DISPENSING SYSTEM 14

SANITIZING AGENT INJECTOR 15

WASH/RINSE PUMPASSEMBLY 16

REPLACING SEAL and CERAMIC on WASH/RINSE PUMP 17

DRAIN VALVEASSEMBLY,STRAIGHTTHROUGH MODEL 18

SERVICE INSTRUCTIONS (Incoming Water Solenoid Valve) 19

INSTRUCTIONS for ADJUSTING TENSION of CANTILEVER

APPLYING NYLATRON STRIP to CONSERVER DOOR 22

TROUBLE SHOOTING GUIDE 23

PICTORIALS

BACKS1DEVIEW 25

INSIDE FRONT COVER

RIGHTSIDEVIEW 26

LEFTSIDEV1EW 27

INCOMING PLUMBING, VACUUM BREAKER, MERCURY RELAY 28

ANTI-FOAM VALVE 29

ELECTRICAL DRAWINGS 30,31

PARTSUST 32,33

NOTES

PARTS DISTRIBUTORS INSIDE BACK COVER

SPECIFICATIONS

Gal per hour

188 Width

44"

Operating Capacity

Racks per hour (NSF Rated) Dishes per hour 1900 Water Requirements (NSF Rated)

Glasses per hour 1900 Inlet Temperature - °F 140 Depth

Operating Cycle

Total Cycle - Sec Wash Tank Capacity

Gallons

Wash Pump Capacity (2 pumps)

Gal Per Min

Electrical Rating Volts

CONSERVER 115

4.0 Inlet IPS

Thermometers

Wash - °F

140

Flow Pressure PSI Flow GPM

Drain IPS Available Chlorine during rinse cycle Min. 50 ppm Racks

Wash Pump Motor

Horsepower (2)

16.5 3/4"

Phase Approximate 1 (3 wire) Total Load Amps

Dimensions 26

Height Standard Table Height

Maximum Clearance for Dishes

Dish, 19 3/4 x 19 3/4 Combination

Shipping Weight

Approx Basic Model 350 lbs.

25"

67 1/4" 34"

15"

Optional Optional

All dimensions and specifications are subject to change without notice.

GENERAL INSTRUCTIONS

(INSTALLATION)

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

will ensure proper machine operation.

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

2. Connect drain line to bottom of machine (2 IPS female fitting on front of machine) to conform with local and/or national codes. Drain is a gravity feed system from the machine. a. The Conserver is designed to accommodate an external scrap trap if one is shipped with the unit. The

scrap trap should be placed beneath the unit with the top opening to the right of the pump and motor mounting shelf so that the top hole of the scrap trap is in line with the drain opening from the machine.

b. Direct the drain line from the dishwasher to the top of the trap and plumb accordingly with 2" pipe of the

necessary length. Connect a 2" fitting to the back of the scrap trap and plumb to the drain line. The drain line is a gravity feed system from the dishwasher to the scrap trap and also from the scrap trap to the drain line. Scrap trap aids sluggish drains by containing machine water as it drains and letting it drain off slower.

3. Connect incoming 33/4" water line with capacity to supply 16.5 gallons per minute with a flow rate of 20 PSI at a temperature of 140°F. This connection is just before the Y-strainer. Connect to conform with local and/or national codes (standards). a. It is recommended that in areas where there is fluctuating water pressure a restrictor valve allowing 8

gallons of water per minute be installed. This will help to provide a steady fill rate. The restrictor should be located down the line from the Y-strainer.

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

5- The electrical connections are made to the terminal block located in the dispenser/control box on the

top of the machine. The terminal block is located on the back wall of the box with a grounding lug next to it. Three wires L1, N, and a ground wire should be passed through the hole in the back of the box and connected to the terminal block as marked.

6. Do not apply power until step #9.

7. Turn on water supply to machine; check for any leaks in plumbing and connections.

8. Place the open end of the red tube into a container of detergent; white, into a container of sanitizer; and blue, into a container of rinse additive.

9. To energize electrically, proceed as follows: a. Turn on customer's circuit breaker controlling the machine. b. Check voltage at incoming terminals L1 and N. It should match data plate voltage. Voltage at L1

should be checked to ground to ensure that a high (or wild) leg is NOT connected. (Voltage exceeding 150V to ground would indicate a high leg.)

c. If voltages are in required range, turn on circuit breaker on the side of the dispenser/control box.

10. To fill the unit with water: a. Located on the right side of the control box is a two-positioned momentary switch. To fill this unit

initially with water, push and hold the switch to the top of the unit until the water reaches the-top of the cut out for the drain opening. Release the switch and it will return to the off position.

b. After the unit is full of water, check for leaks and see if the solenoid valve opens and closes as the

fill switch is turned on and off.

c- After checking the plumbing lines for leaks, run the unit through a complete cycle to determine the

proper water level. The proper level for the water is the top of the cut out for the drain opening leading from the machine into the drain strainer and stopper. If this level is either not reached or is exceeded, please turn to the timer section of this manual to determine the proper adjustment of the timer that has to be made.

IN BACK)

115V,

CYCLE

230V,

CYCLE

230V,

CYCLE

DISPENSER PUMP, 115V,

CYCLE

10. 0012000

CIRCUIT BREAKER

OF CUTOUT FOR DRAIN

d. Above each peristaltic pump is a priming switch. After making sure that the feeder tubes to the

pumps are in their proper containers, as marked on the pumps, press the switch and hold it until there is a discharge of the fluid into the machine. This is to be done to each pump before the initial operation of the machine. Water must be in wash-rinse tub to prevent discoloration or deterioration of the stainless tub by chemicals.

e. The dishwasher is now ready to proceed with the washing of dishes in accordance with operating

instructions in this manual.

ITEM P/N DESCRIPTION

4. 0046500 DETERGENT DISPENSER PUMP

5. 0046500 RINSE ADDITIVE DISPENSER PUMP

0046000 DETERGENT DISPENSER PUMP

DRAIN OUTLET (2" GRAVITY FEED) INCOMING WATER CONNECTION (3/4"

CUSTOMER ELECTRICAL SERVICE CONNECTION (IN BACK)

115V, 60 CYCLE

0046000 RINSE ADDITIVE DISPENSER PUMP

6. 0046500 SANITIZING SOLUTION

0046000 SANITIZING SOLUTION

DISPENSER PUMP, 230V, 50 CYCLE

7. 0154300 PRIMING SWITCHES

8. 0154300 CONTROL SWITCHES

9. 0034000 COUNTER CYCLE

11. DISPENSING HOSES

12.

FILL LEVEL 5/16" ABOVE TOP

GENERAL INSTRUCTIONS

(OPERATION)

Note: Read the following instructions carefully. Proper operation of your Conserver Dishwasher

will ensure clean and sanitized glasses and dishes at optimum efficiency.

Dish Preparation:

1. Scrape dishes thoroughly.

2. Pre-wash by soaking or spraying with a pre-rinse hose.

3. Place dishes and cups in dish rack; cups, upside down.

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

Note: Silverware should be washed upright in a special compartment silverware rack for best

results.

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

Machine Operation:

1. Insert drain strainers.

2. Be sure the drain stoppers are in place.

3. Insert two racks of dishes and close all doors.

4. Check the levels of the detergent, rinse additive and sanitizing agent containers. Fill them if necessary.

5. To put the unit into operation at the beginning of the day or a meal period, make sure the circuit breaker on the right side of the dispenser/control box on top of the machine is on.

6. For the initial fill, push the fill switch on the right side of the dispenser/control box. Hold the switch in this position until the water level reaches 5/16" above the top of the cut out for the drain opening.

7. When the unit is full of water press the start switch and count to three. This activates the time cycle and the cycle light will come on.

8. When the light goes out, open the side doors and slide out the racks of clean dishes. Slide in two racks of soiled dishes and repeat steps #7 and #8.

9. At the end of the mealtime, shut off the circuit breaker on the dispenser/control box and drain the unit by pulling on the drain stoppers. Clean any food debris out of the basket strainers.

Note: If the unit is not operated for extended periods of time, the water will drain out or go

down in level. Be sure to check the water level before operating and if the level is down, see step #6

4. 0008600

CANTILEVER ARM

TIMER, 220V,

CYCLE

10. 0001210

OPERATIONS DECAL

ITEM P/N DESCRIPTION

2. 0169000 WASH-RINSE WATER THERMOMETER

5. 0171100

6. 0054106 DRAIN SOLENOID "T" STYLE, 115V

0152100 PUMP INTAKE STRAINERS (2)

0053813 DRAIN LINE STOPPERS (2)

0173200

TIMER, 115V, 60 CYCLE

ITEM P/N DESCRIPTION

9. 0087000 PUMP & MOTOR ASSEMBLY,

11. 0001211 TIMER DECAL AND DET, SAN,

12. 0001203 CLEAN STRAINER DECAL

0009000 CANTILEVER DOOR SPRING

FILL LEVEL 5/16" ABOVE TOP OF CUTOUT FOR DRAIN

RIN DECALS

GENERAL INSTRUCTIONS

(PREVENTIVE MAINTENANCE)

THE FOLLOWING IS TO BE PERFORMED AS NEEDED.

Note: Read the following instructions carefully. Proper maintenance of your Conserver

Dishwasher will ensure optimum service with a minimum of down time. Before removing the cover to the Dispenser/Control Box turn off the circuit breaker on the side of the box.

1. Remove all lime and corrosion deposits. (Weekly or as needed.)

a. Remove all three hoses for the pumps from their containers. b. Remove the three hoses from the sump on

the front of the machine and place them off to the side in another container- This will prevent the chemicals from entering the sump during the cycling of the machine.

c. Fill machine with wash water as would ordinarily be done for washing. d- Open door and place two cups or

less of deliming compound into water. (Be sure to follow the amount and directions given on the package or bottle of the compound used.) The

compound is available from your detergent supplier. e. Close door and push start switch. Run through four cycles. f. When cycle light goes out, open door and examine the interior. All lime should be removed

and parts should be shiny. If not, scrub stubborn deposits with brush and repeat operation.

(Protect hands with waterproof gloves.) g. After the interior is clean, turn off circuit breaker, empty wash water by removing the drain

stoppers. Remove basket strainers and flush away all debris and build-up. h. Replace the basket strainers. Turn circuit breaker on to refill the machine and allow it to

run through a cycle, then again drain as instructed in (f). i. Return the three hoses to the sump and install in the hose bracket. j. Return the three hoses to their proper containers and prime the pumps.

2. Clean the strainer baskets to provide for the maximum amount of water return to the pumps

possible. (Daily or as needed.)

a. Remove baskets from drain openings and brush away any debris or force it out of the strainer

openings with water.

3. Clean Y-strainer on incoming water line. (Yearly or as needed.) a. Water to machine must be turned off for this operation. b. Remove plug and clean strainers (as water is trapped near strainer and 120° - 140°F, use care in

removing plug and have container to catch water.

4. Clean Wash/Rinse tubes (Weekly or as needed.) (See drawing next page.)

a. Turn the circuit breaker to off position. b. Open door and drain machine by lifting drain stoppers. c. When empty, replace drain stoppers. d. Loosen the two thumb screws opposite each other on each the top and bottom

assemblies. e. Pull the assemblies out of the bases. f. Remove the hub assembly by loosening the nut with a wrench. g. After hub is off, remove the end plugs and either flush with clean water or a brush.

(A straightened paper clip makes an excellent tool for cleaning the nozzles.)

h. Clean the hub by either soaking or brushing with a deliming solution. (A toothbrush makes

an excellent tool.)

i. The bearings cannot be replaced separately; the whole hub must be replaced if it is needed. j. Reassemble the Wash/Rinse assembly by reversing steps d, e, f, and g.

5. Clean any deposits which may have built up on exterior moving parts. (Only as needed.)

a. Remove with clean cloth. (A stainless polish or oil may be used to loosen deposits.) b. Deposits around fill switch can be removed with a dry toothbrush.

6. If an external scrap trap is supplied with the unit, flush the drain line and the scrap trap. (Weekly or as

needed.)

a. Remove the 2" pipe nipple on the end of the fitting underneath the drain outlet. b. Insert a hose into the line and flush the line out with a steady stream of water.

c. Remove the scrap tray from the scrap trap and empty the food debris into a disposable container.

d. Before reinstalling the scrap tray, flush the line from the machine to the trap, then from

WASH RINSE HEAD ASSEMBLY

2. 0199402

BEARING SPINDLE

4. 0199404

BEARINGS

EACH)

WASH RINSE HEAD ASSEMBLY P/N

0199500

VEE JETS

(16)

the trap to the drain line.

e. Reinstall the scrap tray and replace the lid.

7. Never allow the main pump to be operated without water in the machine.

8. Inspect the peristaltic pumps on a weekly schedule for cracks in the tubes. On the right side of the dispenser/control box there is a counter to register each time the unit completes a full cycle. Anticipate about every 30,000 cycles having to replace the tubes in the peristaltic pumps. The tubes and instructions are available from your area parts distributor listed in the back of this manual.

NEW STYLE P/N 0199400 ITEM P/N DESCRIPTION

1. 0199401 TUBE AND HUB ASSEMBLY

3. 0199403 RETAINING RING OR CLIP

5. 0199501 END PLUGS

4 PER MACHINE ITEM P/N DESCRIPTION

1. 0199501 END PLUGS (4)

3. 0199503 TUBE (4)

6. 0199504 BEARINGS 4 EACH

7. 0199504 EXTERNAL SHAFT

0199504 INTERNAL SHAFT 0199504 HEX BUSHING COMPLETE UNIT

TIMER ADJUSTMENTS

The timer is a self-contained (frame-mounted) timer of the repeating cycle type. It is mounted in the control box on the top of the machine to control the automatic functions of the machine. The timer motor operates on 110 VAC, 60 cycles, taking 90 seconds to complete one full revolution. There are six micro switches which are controlled by rotating cams driven by the timer motor. Two of the cams are fixed and cannot be adjusted. The remaining four cams are adjustable and can be adjusted to either lengthen or shorten the desired operation.

Remove the power to the machine when making all timer adjustments. Included and taped in each control panel is a spanner wrench (as shown in the drawing). This wrench is

needed to adjust the cams on the timer. The cams are preset at the factory but may have to be readjusted for different conditions of the country and for the different brands of detergent, rinse additive and sanitizing solutions. On both sides of the four adjustable cams, there are holes into which the spanner wrench is placed to apply leverage to make the desired change. The left side of the cam will always start an operation and the right side will end it. The cam on the right side is the one that will be adjusted more often since this one determines the length of the operation.

When making adjustments to the timer cams, be sure that the first cam next to the timer motor is in its stop position in the notch. Place one hand over the timer motor with your thumb lodged next to or on the first cam so that it will not move when the other cams are being adjusted. To make the adjustment, place the wrench in the holes on the right side of the cam. If a longer operating time is desired, increase the gap between the left and right side of the cam. If a shorter operating time is desired, decrease the gap between the left and right side of the cam. At the extreme end from the timer motor, there is a cam marked in five-degree increments. Every four degrees equals one second of the timer's revolution.

Function of each micro switch starting from the timer motor and going left to right Timer Motor Micro Switch: controlled by a fixed cam that controls the total length of the cycle. It is

activated by engaging the fill/start switch in the start position. Detergent Micro Switch: controlled by an adjustable cam. It operates the peristaltic pump that

dispenses the detergent. By adjusting the right side of the cam, you can either increase or decrease your amount of detergents.

Drain Solenoid Micro Switch: controlled by a fixed cam. It opens the solenoid valve during the cycle that drains the wash water out of the unit.

Fresh Water Solenoid Valve Micro Switch: controlled by adjustable cam. It is important that the unit have two-and-a-half gallons of water in it during the wash and rinse cycles. The proper level indicator is the height of the cut out leading into the drain strainer and stopper. By adjusting the right side of the cam, you can either increase or decrease your water supply to meet this required level. Fill water is turned on before drain cycle ends to ensure machine is flushed before filling.

Rinse Agent Micro Switch: controlled by an adjustable cam. It operates the peristaltic pump that dispenses the rinse agent. By adjusting the right side of the cam, you can either increase or decrease your amount of rinse additive. It should activate during the fill cycle.

Sanitizing Agent Micro Switch: controlled by an adjustable cam. It operates the peristaltic pump that dispenses the sanitizer solution. By adjusting the right side of the cam, you can either increase or decrease your amount of sanitizer solution. It should activate during the fill cycle. When the timer is preset at the factory, it is set to dispense 24 milliliters of detergent, 18 milliliters of rinse additive and 16 milliliters (50 parts per million) sanitizing agent based on an 8.4% solution of Sodium Hypochlorite.

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