Jackson ConserverXL Service Manual
SERVICE MMANUAL
October 24, 2001 P/N 7610-002-10-23 (Revision B)
Visit Jackson on the Internet at:
www.jacksonmsc.com
CONSERVER XL
GENERAL PAGE
Specifications .............................................................................................. 1
INSTALLATION INSTRUCTIONS.............................................................................. 2
CHEMICAL DISPENSING EQUIPMENT................................................................... 3
OPERATIONAL INSTRUCTIONS.............................................................................. 4
UNIT OPERATION
Cam Timer Operation................................................................................... 5
Timing Sequence (Conserver XL)................................................................ 6
TROUBLESHOOTING SECTION............................................................................... 7
DRAWINGS
Dimensions.................................................................................................. 12
Table Dimensions......................................................................................... 13
Main Assembly............................................................................................. 14
Control Box Assembly.................................................................................. 16
8 Cam Timer................................................................................................. 18
Peristaltic Pump Assembly........................................................................... 19
Hood Assembly............................................................................................ 20
Cantilever Arm Assembly............................................................................. 21
Wash Tub Assembly..................................................................................... 22
Accumulator Assembly................................................................................. 23
Frame Assembly........................................................................................... 24
Incoming Plumbing Assembly...................................................................... 25
Solenoid Valve Repair Kits (3/4”, 110V)........................................................ 26
Vacuum Breaker Repair Kit (3/4” NPT)........................................................ 27
Wash Motor Assembly................................................................................. 28
Wash Arm Assembly.................................................................................... 29
Wash Manifold Assembly............................................................................. 30
Drain Solenoid Assembly.............................................................................. 31
Door Wrap Assembly.................................................................................... 32
ELECTRICAL DIAGRAMS
Schematic (115 Volt, 60 Hz, Single Phase).................................................. 33
TABLE OF CONTENTS
i
1
PERFORMANCE/CAPABILITIES
OPERATING CAPACITY (RACKS/HOUR)
RACKS PER HOUR 37
DISHES PER HOUR 925
GLASSES PER HOUR 925
OPERATING CYCLE (SECONDS)
WASH TIME 42
RINSE TIME 25
TOTAL CYCLE TIME 87
TANK CAPACITY (GALLONS)
WASH TANK (MINIMUM) 1.49
WASH PUMP CAPACITY
GALLONS PER MINUTE 61
TEMPERATURES
WASH---°F (MINIMUM) 120
WASH---°F (RECOMMENDED) 140
RINSE---°F(MINIMUM) 120
RINSE---°F (RECOMMENDED) 140
ELECTRICAL REQUIREMENTS
WASH PUMP MOTOR HORSEPOWER 3/4
VOLTS PHASE AMPS
115 1 11.4
WATER REQUIREMENTS
INLET TEMPERATURE (MINIMUM) 120
°F
INLET TEMPERATURE (RECOMMENDED) 140
°F
GALLONS PER HOUR 55.13
WATER LINE SIZE I.P.S. (Minimum) 3/4”
DRAIN LINE SIZE I.P.S. (Minimum) 2”
FLOW PRESSURE P.S.I. (Optimum) 20
MINIMUM CHLORINE REQUIRED (PPM) 50
FRAME DIMENSIONS
WIDTH 25 1/4”
DEPTH 25 1/4”
HEIGHT 65 1/2”
STANDARD TABLE HEIGHT 34”
MAXIMUM INSIDE CLEARANCE 19”
SPECIFICATIONS of CONSERVER XL
VISUAL INSPECTION: Before installing the unit, check the container and machine for damage. A damaged container is an indicator 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 there being 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.
UNPACKING THE DISHMACHINE: Once the machine has been
removed from the container, 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 to
have the missing item shipped to you.
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.
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.
CONNECTING THE DRAIN LINE: The drain for the Conserver XL
is a gravity discharge drain. All piping from the 2” MNPT connection on the waste accumulator must be pitched (1/4” per foot) to
the floor or sink drain. All piping from the machine to the drain
must be a minimum 2” I.P.S. and shall not be reduced. There must
also be an air gap between the machine drain line and the floor
sink or drain. If a grease trap is required by code, it should have a
flow capacity of 5 gallons per minute.
WATER SUPPLY CONNECTION: Ensure that you have read the
section entitled “PLUMBING THE DISHMACHINE” above before
proceeding. Install the water supply line (3/4” pipe size minimum)
to the dishmachine line strainer using copper pipe. 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 20 PSI “flow” pressure at the recommended temperature indicated on the data plate.
In areas where the water pressure fluctuates or is greater than the
recommended pressure, it is suggested that a water pressure regulator be installed.
Do not confuse static pressure with flow pressure. Static pressure
is the line pressure in a “no flow” condition (all valves and services
are closed). Flow pressure is the pressure in the fill line when the
fill valve is opened during the cycle.
It is also recommended that a shock absorber (not supplied with
the Conserver XL model) 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.
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. This will
require taking a phillips head screwdriver and removing the one(1)
screw on the front cover of the control box. Install 3/4” 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 & N) to the appropriate terminals as they are
marked on the terminal block. Install the grounding wire into the
lug provided.
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.
INSTALLATION INSTRUCTIONS
2
T
O PREPARE PUMPS FOR OPERATION
The Conserver XL dishmachine is supplied with detergent, rinse additive and sanitizer dispensing peristaltic-pumps. Locate the open
ends of the chemical tubes with the tube stiffeners and place each one in the appropriate container.
A. Red Tubing = Detergent
B. Blue Tubing = Rinse Aid
C. White Tubing = Sanitizer.
PRIMING PERIST
AL
TIC-PUMPS
Peristaltic pumps need priming when the machine is first installed or if for some reason the chemical lines have been removed and
air is allowed to enter.
CAUTION: Water must be in the sump and wash tank prior to the dispensing of chemicals. Sanitizer in concentration is
caustic and may cause damage without dilution.
1. Verify that the proper chemical tube stiffener inlet is in the proper container.
2. Use the toggle switches on the right side of control box to prime each pump. There are two (2) switches mounted by the peristaltic-pumps. One will prime the sanitizer pump only, and the second will prime either the detergent or rinse aid pump, depending
upon which way it is depressed.
3. To prime the pumps, hold the switch in the momentary position until chemical can be observed entering the sump.
4. Detergent is dispensed as required during the wash cycle by the cam timer. The amount of detergent may need to be increased or
decreased depending on water quality and type of detergent. It is adjusted by changing Cam 6 on the cam timer. See the timer
instructions on Page 5.
5. Rinse additive is dispensed as required into the final rinse. The amount of rinse aid may need to be adjusted depending on water
hardness and results. It can be changed by changing Cam 7 on the cam timer. See the timer instructions on Page 5
6. Chlorine based sanitizer is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on the concentration and type of sanitizer used. It is adjusted by changing Cam 5 on the cam timer. See the timer instructions on Page 5.
CHEMICAL DISPENSING EQUIPMENT
3
PREPARATION: Before proceeding with the start-up of the unit,
verify the following:
1. The sump strainer is in place and is clean.
2. The drain stopper is installed.
3. That the wash and rinse arms are screwed securely
into place and that their endcaps are tight. The wash
and rinse arms should rotate freely.
POWER UP: To energize the unit, turn on the power at the service
breaker. The voltage should have been previously verified as
being correct. If not, the voltage will have to be verified.
FILLING THE WASH TUB:For the initial fill, close doors and
depress and hold the OFF/ON/FILL rocker switch in the FILL
position for approximately 8 - 10 seconds. Open the doors and
verify that the water level is correct. Hereafter, the water level is
controlled by the timer that has been preset at the factory. Verify
that the drain stopper is preventing the wash tub water from pouring out excessively. There may be some slight leakage from the
drain hole. Verify that there are no other leaks on the unit before
proceeding any further. The wash tub must be completely filled
before operating the wash pump to prevent damage to the component. Once the wash tub is filled, the unit is ready for operation.
The water level was set at the factory. If the water level is not at
the level noted above, it will require adjustment. Check to ensure
that the recommended water pressure is being supplied to the
machine (20 PSI). If the water pressure is correct then the fill
valve will need adjustment. Use the following steps to adjust the
cam. Turn power off at the machine circuit breaker. Open the
control box cover. Locate the timer fill valve cam (Cam 4 from the
timer motor). Locate the spanner wrench taped to the electrical
panel. The spanner wrench is used to adjust the cam.
To increase the water level, open the notch of the adjustable cam.
To decrease the water level, close the notch. Care must be taken
that the set point does not extend into the home position of the
timer. Do not move the side of the cam that starts the fill; this will
change the sequence of cycle operation. With the door closed
turn the power circuit breaker on. Open and close the door to run
a cycle, then check the water level. Adjust as necessary then
close the control box cover.
The machine runs a complete cycle to drain and fill. If the
machine is not allowed to drain, the water will build up inside the
tub. After the initial fill, the rinse water for the current cycle will
become the wash water for the next cycle.
WARE PREPARATION: Proper preparation of ware will help
ensure good results and less re-washes. If not done properly,
ware may not come out clean and the efficiency of the dishmachine will be reduced. It is important to remember that a dishmachine is not a garbage disposal and that simply throwing
unscraped dishes into the machine simply defeats the purpose
altogether of washing the ware. Scraps should be removed from
ware prior to being loaded into a rack. Pre-rinsing and pre-soaking are good ideas, especially for silverware and casserole dishes.
Place cups and glasses upside down in racks so that they do not
hold water during the cycle. The dishmachine is meant not only to
clean, but to sanitize as well, to destroy all of the bacteria that
could be harmful to human beings. In order to do this, ware must
be properly prepared prior to being placed in the machine.
DAILY MACHINE PREPARATION: Refer to the section entitled
“PREP ARATION” at the top of this page and follow the instructions
there. Afterwards, check that all of the chemical levels are correct
and/or that there is plenty of detergent available for the expected
workload.
WARM-UP CYCLES: For a typical daily start-up, it is recommended to run the machine through 3 cycles to ensure that all of
the cold water is out of the system and to verify that the unit is
operating correctly. To cycle the machine, ensure that the power
is on and that the tub has filled to the correct level. Lift the doors
and the cycle light will illuminate. When the light goes out, close
the doors, the unit will start, run through the cycle, and shut off
automatically . Repeat this two more times. The unit should now be
ready to proceed with the washing of ware.
WASHING A RACK OF WARE: To wash a rack, open the doors
completely (being careful for hot water that may drip from the
doors) and slide the rack into the unit. Close the doors and the
unit will start automatically . Once the cycle is completed, open the
door (again watching for the dripping hot water) and remove the
rack of clean ware. Replace with a rack of soiled ware and close
the doors. The process will then repeat itself.
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, 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, close
the doors. When the unit completes the cycle, turn the power
switch to the OFF position and open the doors. Manually remove
the drain stopper from the tub and allow the tub to drain (NOTE:
the wash tank water will be hot so caution is advised). Once the
wash tub is drained, remove the pan strainer and the pump suction strainer. Remove soil and debris from the strainer and set to
the side. Unscrew the wash and rinse arms from their manifolds.
Remove the endcaps and flush the arms with water. Use a brush
to clean out the inside of the arms. If the nozzles appear to be
clogged, use a toothpick to remove the obstruction. Wipe the
inside of the unit out, removing all soil and scraps. Reassemble
the wash and rinse arms and replace them in the unit. The arms
only need to be hand tight, do not use tools to tighten them down.
Reinstall the strainers and close the doors.
OPERATION INSTRUCTIONS
4
The Conserver XL cam timer is a 1 minute, 30 second, 8-cam
timer (cam 8 is a spare) that controls the operation of the dishmachine. The following is a description of the set points for each cam
and the function of each switch.
CAM 1: Cam 1 is a cut cam with a single notch and serves as the
cycle/reset control.
FUNCTION: When the machine is in the operation mode the notch
is the home position. The machine will remain idle until the door is
opened, then cam 1 moves to the start position and holds until the
door is closed. The closing of the door will start the next cycle. The
cam will rotate a complete cycle, and return to the home position
and hold.
CAM 2: Cam 2 is a cut cam and provides the wash cycle timing.
FUNCTION: The wash cam works off the normally open contacts
of Cam 2. This requires the microswitch be held closed by the
cam. It will close and energize the wash pump 2 seconds after the
cycle switch is activated. The pump will operate through the wash
cycle (40 seconds) then shut down for the dwell period (20 seconds). As the cam rotates it energizes the pump for the rinse cycle
(25 seconds). When cam 1 reaches it’s home position it will deenergize cam 2, shutting down the wash pump.
NOTE: The last 6 cams are adjustable. The following instruc
tions will require that the timer position have the cams to the
front and the motor to the left.
CAM 3: Cam 3 is an adjustable cam and controls the drain valve.
FUNCTION: The drain solenoid works off the normally closed con-
tacts of cam 3. When the cycle is initiated, the microswitch will be
held open until it is allowed to drop into the notch of the cam. This
energizes the drain solenoid which drains the machine. After a 12
second delay the cam reverses the microswitch, de-energizing the
drain solenoid. This cam may require adjusting due to varying
water pressure. The drain solenoid must remain open long
enough to remove whatever water the fill valve solenoid allows in
the machine. This could vary due to the water supply line pressure.
SETTINGS: The right side of cam 3 must be set to pick up the
switch arm just before the wash/rinse cycle cam switch drops. It
will hold the drain solenoid open to drain all the water in the tank
from the unit during the dwell period. Any adjustment made to the
drain should be made to the left side of cam 3. The cam must be
moved back into the wash time until all of the water is drained from
the machine.
CAM 4: Cam 4 is an adjustable cam and controls the fill valve and
therefore the amount of water used.
FUNCTION: The fill valve cam works off the normally closed contacts of cam 4. This requires the switch to be held open by the
cam and allowed to drop into the notch to operate the fill valve.
This energizes the fill solenoid which opens to start filling the
machine with fresh water. After a 10 second delay, the cam
reverses the microswitch, de-energizing the fill solenoid. The fill
cam may require adjustment due to varying water pressure. The
fill solenoid must remain open a sufficient length of time to fill the
machine to the correct level.
SETTINGS: The right side of cam 4 must be set to allow the
switch arm to drop 2 seconds before the drain solenoid is de-energized which flushes the detergent residue from the unit. It will hold
the fill solenoid open until the cam switch arm is raised. At that
time the fill solenoid is de-energized, shutting off the incoming
water. The tub will be filled to the correct level. Any adjustment
made to the timing of the fill solenoid should be made with the left
side of cam 4. To increase the water level, open the notch of the
cam and for decreasing the level of the notch should be closed.
CAM 5: Cam 5 is an adjustable cam and controls the sanitizer
pump.
FUNCTION: The sanitizer pump cam works off the normally
closed contacts of cam 5. This requires the switch arm to be held
open by the cam and allowed to drop into the notch to operate the
pump. The time that the sanitizer pump will remain energized
must be determined in the field to suit the chemical used and
water conditions.
SETTINGS: The left side of cam 5 must be set to allow the switch
arm to drop in past the starting point of the fill cam and after the
drain solenoid has closed. The adjustment for sanitizer volume
must be made with the right side of the cam. To increase the volume the notch should be increased or to decrease the amount of
sanitizer the notch should be closed slightly in increments until the
correct level is reached.
CAM 6: Cam 6 is an adjustable can and controls the detergent
pump.
FUNCTION: The detergent pump cam works off the normally
closed contacts of cam 6. This requires the switch arm to be held
open by the cam and allowed to drop into the notch to operate the
pump. The time that the detergent pump will remain energized
must be determined in the field to suit the chemical used and
water conditions.
SETTINGS: The left side of cam 6 must be set to drop in past the
starting point of the wash pump cam. The adjustment for detergent volume must be made with the right side of the cam. To
increase the volume, the notch should be increased or to
decrease the amount of detergent the notch should be closed
slightly in increments until the correct level is reached.
CAM 7: Cam 7 is an adjustable cam and controls the rinse aid
pump.
FUNCTION: The rinse aid pump cam works off the normally
closed contacts of cam 7. This requires the switch arm to be held
open by the cam and allowed to drop into the notch to operate the
pump. The time that the rinse aid pump will remain energized
must be determined in the field to suit the chemical used and
water conditions.
SETTINGS: The left side of cam 7 must be set to drop in past the
starting point of the fill cam and after the drain solenoid has
closed. The adjustment for rinse aid volume must be made with
the right side of the cam. To increase the volume the notch should
be increased or to decrease the amount of detergent the notch
should be closed slightly in increments until the correct level is
reached.
CAM TIMER OPERATION
5
2 SECONDS INT
O CYCLE
*Wash pump starts, runs for 40 seconds, then shuts down. Controlled by C2 cam.
4 SECONDS INT
O CYCLE
*Detergent feed pump is energized. The length of time will be field determined. Time will depend on the detergent used and water
conditions. controlled by C6 cam.
10 SECONDS INT
O CYCLE
* Detergent feed pump shuts down. Controlled by C6 cam.
42 SECONDS INT
O CYCLE
* Wash pump shuts down. Controlled by C2 cam.
* Drain solenoid is energized (opens). wash water drains from the unit. Controlled by C3 cam.
51 SECONDS INT
O CYCLE
* Fill solenoid valve is energized (opened) starting to fill unit. Controlled by C4 cam.
53 SECONDS INT
O CYCLE
* Drain solenoid valve is de-energized (closed). Controlled by C3 cam.
54 SECONDS INT
O CYCLE
* Sanitizer pump is energized, injecting sanitizer into wash tank. Controlled by C5 cam.
* Rinse aid pump is energized, injecting rinse aid into wash tank. Controlled by C7 cam.
58 SECONDS INTO CYCLE
* Sanitizer pump is de-energized. The length of time that the sanitizer pump is activated will be determined in the field. Timing will
depend on the chemical used and water conditions. Controlled by C5 cam.
60 SECONDS INT
O CYCLE
* Rinse aid pump is de-energized. The length of time that the rinse aid pump is activated will be determined in the field. Timing will
depend on the chemical used and water conditions. Controlled by C7 cam.
62 SECONDS INT
O CYCLE
* Wash pump is energized for the rinse cycle.
* Fill solenoid valve is de-energized.
87 SECONDS INTO CYCLE
* Wash pump is de-energized.
* End of cycle.
TIMING SEQUENCE
6
TROUBLESHOOTING SECTION
7
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain
procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise
extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap
ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
Possible Cause A ction
Service disconnect switch off or faulty. Turn disconnect on.
Branch circuit breaker tripped/fuse blown. Reset or replace.
Loose or broken connection to dishmachine. Tighten or replace connections.
Door switch shorted out.
With the door open, check for voltage
between ORANGE/WHITE door switch and
neutral. If 120V, replace the door switch.
Faulty control relay.
With the door open, check for voltage
between connections #9 & #3 on control
relay. If 120V, replace control relay.
Faulty "cycle reset" microswitch in cam
timer.
Replace microswitch.
Faulty cycle reset cam microswitch.
With the switch in the Normal position,
rotate the cams manually off the home
position. Check the voltage between the
ORANGE and BLACK/W HITE wires on the
cycle reset switch.
If it is 120V, then t he switch is open and
should be replaced.
Faulty cam timer motor
If cam timer is not rotating, check the
voltage to the motor. I f voltage is present
when the door is closed, replace the motor.
Faulty control relay.
Check the voltage across contacts #9 and
#6. If 120V when the door is closed, replace
the relay.
Faulty NORMAL/DELIME switch.
In the NORMAL position, check the voltage
between WHITE/BLA CK & WHITE/RED
wires to switch. If 120V, replace the switch.
Open door switch.
With door closed, measure voltage bet ween
BLUE and WHITE/BLACK wires on
terminals #6 & #9 of the relay. If 120V,
replace the relay.
Faulty control relay.
Measure between the BLACK wires on
terminals #6 & #9 of the relay. If 120V,
replace the relay.
Measure between the WHITE/ BLACK wire
on terminal 4 and the ORANGE/WHITE wire
on terminal 7 of the relay. If 120V, replace
relay.
Faulty door switch.
With door closed, check for voltage between
WHITE/BLACK and OR ANGE/WHITE wires
to the door switch. If 120V, replace open
switch.
Machine will not run in "ON" position or in
Delime mode.
Machine will not run. Wash pump motor will
run if wash relay is depressed manually
(nothing else works).
Machine will not run in "ON" position unless
cam timer is moved off the "home" position.
Machine will not cycle in "ON" position,
works in Delime mode.
Symptom
Dishmachine will not run, no voltage at
wash relay terminals L1 and T1.
TROUBLESHOOTING SECTION
8
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain
procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise
extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap
ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
Possible Cause A ction
Faulty OFF/ON/FILL switch.
With switch ON, check voltage between
BLACK and WHITE/BLACK wires on switch.
Replace the switch if 120V.
Faulty NORMAL/DELIME switch.
In the NORMAL position, check the voltage
between WHITE/BLA CK & WHITE/RED
wires to switch. If 120V, replace the switch.
Cycle reset switch loose.
Reposition switch assembly, bend metal
lever if necessary.
Faulty cycle reset switch.
Measure between BLACK/YELLOW &
ORANGE wires on "cycle reset" switch while
timer is rotating. As the switch lever drops
into home position you should measure
120V. If not, adjust or replace the switch.
Y-strainer plugged. Clean strainer.
Water valve(s) turned off. Turn on water valves.
Faulty solenoid valve diaphragm.
Replace diaphragm, clean foreign material
out of valve body and orifices.
Faulty solenoid coil.
If coil has voltage but no continuity, replace
coil (continuity is measured across coil
connectors with wires removed).
Faulty fill microswitch. Will not fill during
cycle only.
During fill, measure between the ORANGE
and WHITE/GREEN wires. If 120V, adjust
or replace switch).
Faulty OFF/ON/FILL switch.
Depress switch, measure between BLACK
and WHITE/GRE EN wire. If 120V, replace
switch.
Solenoid valve dirty or faulty.
Clean valve, replace plunger and/or
diaphragm.
Faulty fill microswitch. Repair/replace switch.
Cam timer stalled in fill position.
If cam timer is not rotating, check the
voltage to the timer motor. If 120V when
door is closed, replace the timer motor.
Shorted OFF/ON/ FILL switch.
Check voltage between BLACK and
WHITE/GREEN connections of the switch in
the "ON" position. If you do not read 120V,
replace switch.
Loose wire connection to microswitch, relay,
or contactor.
Tighten wires.
Faulty wash cam microswitch.
During wash cycle, check voltage between
ORANGE and BLACK/ ORANGE wires on
the microswitch. If 120V, replace the switch.
Faulty delime switch.
During wash cycle, check the voltage
between the two BLACK/ ORANGE wires
(not jumpers). If 120V, replace the delime
switch.
Symptom
Machine cycles continuously.
Machine will not run in "ON" position or in
Delime mode.
Machine will not fill, other functions work.
Machine fills continuously even with no
power applied to machine.
Machine fills continuously, only when the
power is on.
Wash motor does not run, other functions
work, motor runs only when the wash relay
is manually pushed down.
TROUBLESHOOTING SECTION
9
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain
procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise
extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap
ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
Possible Cause A ction
Faulty control relay.
Check the voltage across relay contacts #7
& #4. If 120V during the wash cycle, replace
the relay.
Faulty wash relay.
Check voltage at relay coil between
ORANGE/BLACK and W HITE wires. If you
read 120V, coil is faulty. Replace the relay.
Loose wire connections to motor, delime
switch, or from contactors.
Tighten wires.
Mechanical binding in pump.
If motor has correct incoming voltage, and
its overload is tripping, repair or replace the
pump.
Mechanical binding in pump.
On end of motor, opposite pump, remove
endcap. With large slot type screwdriver, fit
Faulty wash motor.
If the motor has the correct incoming
voltage and the pump is okay, replace the
motor.
Faulty wash relay.
With the wash relay pushed in, check the
voltage between T1 and L1 of the relay. If
120V, replace the relays.
High or low voltage problem.
Check voltage at motor and at power
terminal block. Compare to electr ical
specifications.
The NORMAL/DELIME switch is in the
Delime position.
Place the switch in the Normal position.
Wash relay contacts are welded closed.
Turn machine off. If wash relay
doesn't
release, replace contactor.
Cam timer stalled in wash or rinse cycle.
If cam timer is not rotating, check the
voltage to the timer motor. If no voltage
when the door is closed, check wires and/or
replace motor.
Wash motor microswitch faulty.
Tighten connections, make sure switch
makes contact, replace if necessary.
Door switch shorted.
With machine off, open doors, and with both
wiresto door switch unplugged, measure
continuity between wires on switch. If there
is continuity, replace the switch.
Faulty wash relay (wash relay contacts
welded closed).
Turn machine off, if wash relay
doesn't
release, replace contactor.
Faulty control relay.
With power off, remove WHITE/RED &
BLACK/YELLOW wires from control relay
terminals #9 & #6. If t here is continuity,
replace relay.
Water level is too low.
Increase fill time on cam timer, or decrease
drain timer, or increase incoming water
pressure.
Sump strainer clogged. Clean strainer.
Wash arms clogged. Clean arms and jets.
Machine runs with door open.
Wash motor does not run, other functions
work, motor runs only when the wash relay
is manually pushed down.
Wash motor does not run even when the
wash relay is manually depressed; other
functions work.
Wash motor runs continuously.
Low pumped water pressure.
Symptom
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