CONSERVER XL2
SERVICE MMANUAL
December 6, 2001 P/N 7610-002-18-36 (Revision A)
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DOUBLE RACK, CHEMICAL SANITIZING
DISHMACHINE
GENERAL PAGE
Specifications ............................................................................................... 1
INSTALLATION INSTRUCTIONS.............................................................................. 2
OPERATION INSTRUCTIONS................................................................................... 3
UNIT OPERATION
Cam Timer Operation................................................................................... 4
Timing Sequence ......................................................................................... 5
TROUBLESHOOTING............................................................................................... 6
PARTS DRAWINGS
Dimensions .................................................................................................. 9
Table Dimensions.......................................................................................... 10
Control Box Assembly................................................................................... 11
Peristaltic Pump Assembly............................................................................ 13
Hood Assembly............................................................................................. 14
Cantilever Arm Assembly.............................................................................. 15
Tub Assembly (Left front view)..................................................................... 16
Tub Assembly (Right front view)................................................................... 17
Frame Weldment........................................................................................... 18
Accumulator Assembly.................................................................................. 19
Incoming Plumbing Assembly....................................................................... 20
3/4” Solenoid and Vacuum Breaker Repair Parts Kits.................................. 21
Wash Arm Assembly..................................................................................... 22
Wash Manifold Assembly.............................................................................. 23
Pump and Motor Assembly........................................................................... 24
Door Assemblies........................................................................................... 25
Miscellaneous Parts...................................................................................... 26
ELECTRICAL DIAGRAMS
115 V, 60 Hz, 1 Phase Schematic................................................................. 27
TABLE OF CONTENTS
i
PERFORMANCE/CAPABILITIES
OPERATING CAPACITY (RACKS/HOUR)
RACKS PER HOUR 80
RACKS PER HOUR (OPTION) 96
DISHES PER HOUR 2000
GLASSES PER HOUR 2000
OPERATING CYCLE (SECONDS)
WASH TIME 35
RINSE TIME 20
TOTAL CYCLE TIME 90
TOTAL CYCLE TIME (OPTION) 72
TANK CAPACITY (GALLONS)
WASH TANK (MINIMUM) 3.1
WASH PUMP CAPACITY
GALLONS PER MINUTE 61
TEMPERATURES
WASH---°F (MINIMUM) 120
WASH---°F (RECOMMENDED) 140
RINSE---°F 120
RINSE---°F (RECOMMENDED) 140
ELECTRICAL REQUIREMENTS
(2) WASH PUMP MOTOR HORSEPOWER 3/4 ea.
VOLTS PHASE AMPS
115 1 25.0
WATER REQUIREMENTS
INLET TEMPERATURE (Minimum) 120°F
INLET TEMPERATURE (Recommended) 140°F
GALLONS PER HOUR 160
GALLONS PER HOUR (OPTION) 192
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 44 1/8”
DEPTH 25 13/16”
HEIGHT 66 1/4”
STANDARD TABLE HEIGHT 34”
MAXIMUM CLEARANCE 19”
SPECIFICATIONS for the CONSERVER XL2
1
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
XL2 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 25 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. The Conserver XL2 does not come with a
water pressure regulator as standard equipment.
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 XL2) 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 opening the control box lid. Install 3/4” conduit into the prepunched 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.
Tighten the connections and check that they are secure.
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
PREPARATION: Before proceeding with the start-up of the unit,
verify the following:
1. The sump strainer is in place and 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: Ensure that the delime switch is in the
NORMAL position, and place the power switch into the ON position. Push and hold the power switch in the FILL position to put
water in the sump. Stop filling when water level is between the two
rings on the drain stopper. Be careful not overfill the sump. Verify
that the drain stopper is preventing the wash tub water from pouring out excessively. It is normal to have some slight leakage from
the drain hole. Verify that there are no other leaks on the unit
before proceeding any further. The wash sump must be completely filled before operating the wash pump to prevent damage
to the pump and pump seal. Once the wash tub is filled, the unit
is ready for operation. NOTE: After the initial fill, water level will be
maintained automatically for all subsequent cycles.
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.
PREP ARING THE CHEMICAL FEEDER PUMPS: The Conserver
XL2 comes supplied with detergent, rinse aid, and sanitizer chemical feeder pumps, mounted on the right side of the control box.
Locate the ends of the chemical tubes with the tube stiffeners and
place each one in the appropriate chemical container (Red for
detergent, blue for rinse aid, and white for sanitizer). The other
ends of the chemical feed tubes are inserted through a bulkhead
fitting into the tub. Open the doors to the unit so that you may
observe when chemical flows from the tubes. The pumps are to
be primed by using the toggle switches on the side of the control
box, between the chemical feeder pumps. Depress and hold the
switches as per the labels to prime each chemical feeder pump.
The pumps are primed when chemical issues forth from the tube
ends inside the unit. The chemical feeder pumps dispense an
exact amount of chemical each cycle. Depending on the chemical
used and water conditions, it may become necessary to adjust the
timing of the chemical feeder pumps. The timing may be changed
by adjusting the appropriate cam on the timer in the control box.
The detergent pump is controlled by cam 7, rinse aid by cam 6,
and sanitizer by cam 8. Do not attempt to adjust chemicals yourself, contact your water treatment specialist and/or chemical supplier prior to allowing any changes to be made to the chemical
feeder pump settings.
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 sump
strainer may become clogged with soil and debris as the workday
progresses. Operators should regularly inspect the sump and
accumulator strainers to ensure they have 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 sump and allow the sump to drain
(NOTE: the wash sump water will be hot so caution is advised).
Once the wash sump is drained, remove the sump strainer.
Remove soil and debris from the strainer and set to the side.
Unscrew the wash 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. Reassembly 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
3
The Conserver XL2 cam timer is a 1 minute, 30 second, 8-cam timer 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 switch 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 de-energize cam 2, shutting down the wash pump.
NOTE: The last 6 cams are adjustable. The following instructions 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 contacts of cam 3. When the cycle is initiated, the micro switch will be
held open until it is allowed to drop into the notch of the cam. This energizes the energizes the drain solenoid which drains the machine.
After a 12 second delay the cam reverses the micro switch, 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 rinse cycle.
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 micro switch, 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 to rinse the rack. 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 TIMER OPERATION
4
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. T o 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 8: Cam 8 is a spare cam with no designated function.
CAM TIMER OPERATION (CONTINUED)
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. 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 INTO CYCLE
* Wash pump shuts down. Controlled by C2 cam.
* Drain solenoid is energized (opens). Wash water drains from
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 INTO 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 INT
O 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 INTO 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.
HELPFUL HINT
:
Each notch on the cam timer is
equal to 10 degrees or 2-1/2
seconds. For timer adjustment,
use the tool provided which is
taped to the inside of the control
box!
TIMING SEQUENCE
Problem: Dishmachine will not run, no voltage at wash relay terminals L1 and T1.
1. Service disconnect switch off or faulty. Turn disconnect on.
2. Branch circuit breaker tripped/fuse blown. Reset or replace.
3. Loose or broken connection to dishmachine. Tighten or replace connections.
Problem: Machine will not run in “ON” position unless cam timer is moved off the “home” position.
1. Door switch is shorted out. With the door open, check for voltage between ORANGE/WHITE door switch and neutral. If 120V,
replace door switch.
2. Faulty control relay. With the door open, check for voltage between connections #9 and #3 on control relay. If 120V, replace control
relay.
3. Faulty “cycle reset” microswitch in cam timer. Replace microswitch.
Problem: Machine will not cycle in “ON” position, works in Delime mode.
1. 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/WHITE wires on the cycle reset switch. If it is 120V, then the switch is open and should
be replaced.
2. Faulty cam timer motor. If cam timer is not rotating, check the voltage to the motor. If voltage is present when the door is closed,
replace the motor.
3. Faulty control relay. Check the voltage across contacts #9 and #6. If 120V when the door is closed, replace the relay.
4. Faulty NORMAL/DELIME switch. In the NORMAL position, check the voltage between WHITE/BLACK & WHITE/RED wires to
switch. If 120V, replace the switch.
Problem: Machine will not run. Wash pump motor will run if wash relay is depressed manually (nothing else works).
1. Open door switch. With door closed, measure voltage between BLUE and WHITE/BLACK wires on terminals #6 and #9 of the relay .
If 120V, replace relay.
2. Faulty control relay. Measure between the BLACK wires on terminals #6 and #9 of the relay. If 120V, replace the relay. Or, measure
between the WHITE/BLACK wire on terminal 4 and ORANGE/WHITE wire on terminal 7 of the relay. If 120V, replace the relay.
Problem: Machine will not run in “ON” position or in Delime mode.
1. Faulty Door Switch. With door closed, check for voltage between WHITE/BLACK and ORANGE/WHITE wires to the door switch. If
120V, replace open switch.
2. Faulty OFF/ON/FILL switch. With switch ON, check voltage between BLACK and WHITE/BLACK wires on switch. Replace the
switch if 120V.
3. Faulty NORMAL/DELIME switch. In the NORMAL position, check the voltage between WHITE/BLACK and WHITE/RED wires to
switch. If 120V, replace switch.
Problem: Machine cycles continuously.
1. Cycle reset switch loose. Reposition switch assembly, bend metal lever if necessary.
2. Faulty cycle reset switch. Measure between BLACK/YELLOW and 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.
Problem: Machine will not fill, other functions work.
1. Y-Strainer is plugged. Clean strainer.
2. Water valve(s) turned off. Turn on water valves.
3. Faulty solenoid valve diaphragm. Replace diaphragm, clean foreign material out of valve body and orifices.
4. Faulty solenoid coil. If coil has voltage but no continuity, replace coil (continuity is measured across coil connectors with wires
removed).
5. Faulty fill microswitch. Will not fill during cycle only . During fill, measure between ORANGE and WHITE/GREEN wires. If 120V, adjust
or replace switch.
6. Faulty OFF/ON/FILL switch. Depress switch, measure between BLACK and WHITE/GREEN wire. If 120V, replace switch.
Problem: Machine fills continuously even with no power applied to the machine.
1. Solenoid valve dirty or faulty. Clean valve, replace plunger and/or diaphragm.
TROUBLESHOOTING SECTION
6
Problem: Machine fills continuously, only when the power is on.
1. Faulty fill microswitch. Repair/replace switch.
2. 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.
3. 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.
Problem: Wash motor does not run, other functions work, motor runs only when the wash relay is manually pushed down.
1. Loose wire connection to the microswitch, relay, or contactor. Tighten wires.
2. Faulty wash cam microswitch. During wash cycle, check the voltage between ORANGE and BLACK/ORANGE wires on the
microswitch. If 120V, replace the switch.
3. Faulty delime switch. During wash cycle, check the voltage between the two BLACK/ORANGE wires (not jumpers). If 120V, replace
the delime switch.
4. Faulty control relay. Check the voltage across relay contacts #7 and #4. If 120V during the wash cycle, replace the relay.
5. Faulty wash relay. Check voltage at relay coil between ORANGE/BLACK and WHITE wires. If you read 120V, coil is faulty. Replace
the relay.
Problem: Wash motor does not run even when the wash relay is manually depressed; other functions work.
1. Loose wire connections to motor, delime switch, or from contactors. Tighten wires.
2. Mechanical binding in pump. If motor has correct incoming voltage, and its overload is tripping, repair or replace the pump.
3. Faulty wash motor. If the motor has the correct incoming voltage and the pump is okay, replace the motor.
4. Faulty wash relay. With the wash relay pushed in, check the voltage between T1 and L1 of the relay. If 120V, replace the relays.
5. High or low voltage problem. Check voltage at motor and at power terminal block. Compare to electrical specifications.
Problem: Wash motor runs continuously.
1. The NORMAL/DELIME switch is in the Delime position. Place the switch in the Normal position.
2. Wash relay contacts are welded closed. Turn machine off. If wash relay doesn’t release, replace contactor.
3. 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.
4. Wash motor microswitch faulty. Tighten connections, make sure switch makes contact, replace if necessary.
Problem: Machine runs with door open.
1. Door switch shorted out. With machine off, open doors, and with both wires to door switch unplugged, measure continuity between
wires on switch. If there is continuity, replace the switch.
2. Faulty wash relay (wash relay contacts welded close). Turn machine off, if wash relay doesn’t release, replace contactor.
3. Faulty control relay. With power off, remove WHITE/RED and BLACK/YELLOW wires from control relay terminals #9 and 6. If there
is continuity, replace relay.
Problem: Low pumped water pressure.
1. Water level is too low. Increase fill time on cam timer, or decrease drain timer, or increase incoming water pressure.
2. sump strainer is clogged. Clean strainer.
3. Wash arms clogged. Clean arms and jets.
4. Obstruction in pump housing or wash manifold. Disassemble and clear.
5. Pump impeller worn or broken. Replace the pump impeller.
Problem: Machine keeps tripping the service breaker.
1. Power supply shorted to ground. Check for loose wires or burned connections.
2. Faulty door switch or detergent safety switch. Check for loose or wet connections at switch and at wire connections. Bypass switch
to verify that switch is problem; replace if required.
3. Pump impeller jammed. Clear impeller.
4. Wash pump motor faulty. Check motor voltage and amp load. If amp load is over 12 amps, replace the motor.
5. Circuit breaker is too small. Replace with properly sized breaker. Refer to the data plate.
TROUBLESHOOTING SECTION
7
Problem: Machine will not drain.
1. Loose wire connection. Tighten wires to timer drain microswitch.
2. Drain hole/strainer obstructed. Clear obstructions.
3. Not enough time to drain. Adjust fill cam timer and/or drain cam.
4. Drain linkage binding. Repair drain parts.
5. Faulty drain microswitch on timer. With power off and the drain cam on the timer in the home position, remove the WHITE/YELLOW
wire from the microswitch. Or, measure the continuity between the ORANGE wire on the microswitch and the tab that the WHITE/YELLOW wire is attached onto. If there is not continuity, replace the microswitch.
6. Drain solenoid defective. Check for voltage at solenoid valve during the drain cycle. Replace if voltage is present.
Problem: Machine will not hold water.
1. Faulty drain ball. Replace drain ball.
2. Obstructed drain hole. Clear obstruction.
3. Drain Linkage is binding. Repair drain mechanism parts.
Problem: Sanitizer pump runs continuously.
1. Shorted sanitizer microswitch on cam timer. If there is not 120V between the ORANGE and GREY wires on the sanitization pump
motor microswitch when switch is out of the home position, replace the switch.
2. Shorted prime switch. If there is not 120V between GREY and WHITE/RED wires to prime switch, relace the switch.
Problem: Sanitizer pump does not run during the cycle, but runs when primed.
1. Loose or broken wire. Tighten connections to microswitch.
2. Faulty sanitizer microswitch on cam timer. When sanitizer cam is in home position, measure voltage between ORANGE and GREY
wires on the microswitch. If 1230V, replace switch.
Problem: Prime switch does not activate sanitizer pump.
1. Faulty prime switch. With the prime switch in the prime position, check for voltage between the GREY and WHITE/RED wires to
switch. IF 120V, replace the prime switch.
2. Faulty delime switch. With the delime switch in the DELIME position, check for voltage between the WHITE/BLACK and WHITE/RED
wires to the delime switch. If 120V, replace the delime switch.
Problem: Sanitizer pump doesn’t run during the cycle or through the use of the prime switch.
1. Loose motor terminal wire. Tighten connections.
2. Faulty sanitizer pump motor. If you read 120 V at the sanitizer motor terminals during the sanitizer feed cycle, replace the motor.
Problem: Detergent not feeding; rinse aid feeds okay.
1. Misadjusted cam. Adjust detergent cam on cam timer.
2. Faulty detergent microswitch on cam timer. When the detergent cam is in the home position, measure voltage between ORANGE
and GREY/WHITE wires. If 120V, replace the microswitch.
Problem: Rinse aid not feeding, detergent feeds okay.
1. Misadjusted cam. Adjust rinse aid cam on cam timer.
2. Faulty rinse aid microswitch on cam timer. When the rinse aid cam is in the home position, measure the voltage between the
ORANGE and ORANGE/YELLOW wires. If 120V, replace the microswitch.
Problem: Sanitizer does not run during the cycle, but runs when primed.
1. Loose or broken wire. Tighten connections to microswitch.
2. Faulty sanitizer microswitch on cam timer. When sanitizer cam is in home position, measure voltage between ORANGE and GREY
wires on the microswitch. If 120V, replace switch.
TROUBLESHOOTING SECTION
8
DIMENSIONS
9
25
7
8
"
4
1
2
" MIN
4
3
4
"
44"
BETWEEN TABLES
00000000
15
3
4
"
10
5
8
"
59"
20
5
8
"
61"
10
7
8
"
11
7
8
"
1"
13
1
8
"
34"
TABLE
HEIGHT
17
1
2
" MAX
CLEARANCE
66"
56
1
2
"
75
3
4
"
A. - WATER INLET -
3
4
" FNPT.
B. - DRAIN CONNECTION-1
1
2
" FNPT
C. - ELECTRICAL CONNECTION-11.4 AMPS @ 115 /60 /1
C
B
A
B
C
A
A
2
TABLE DIMENSIONS
10
TABLE DIMENSIONS
CORNER INSTALLA
TION
TABLE DIMENSIONS
CONNECTION TO DISHMACHINE
T
ABLE DIMENSIONS
STRAIGHT THROUGH INSTALLATION
20 1/2”
OPENING
25 1/4”
2 1/4”
4”
MIN.
2 1/2”
4”
MIN.
20 1/2”
OPENING
25 1/4”
“A”
3/4”
1 1/2” ROLL
OPENING "A" DIMENSION
20 1/2" 20 1/2"
27" 27"
4”
MIN
2 1/2”
25 1/4”
20 1/2”
OPENING
44”
CONTROL BOX ASSEMBLY
11
13
12
9
11
10
7
8 8 8
27
3
4
56
2
1
20
21
23
18
19
17
22
24
25
25
26
15
16
14
28
7
22
CONTROL BOX ASSEMBLY (CONTINUED)
12
ITEM QTY DESCRIPTION Mfg. No.
1 1 Control Box Weldment 5700-002-21-56
2 1 Decal, Control Box Fr ont 9905-002-20-46
3 1 Thermometer, 96 Lead 6685-111-68-49
4 1 Power Switch 5930-111-38-79
5 1 Cycle Light 5945-504-08-18
6 1 Power Light 5945-504-07-18
7 1 Cycle Counter 5990-111-35-38
8 3 Peri-Pump Kit Assembly 4320-121-37-10
9 1 Drip Shield 5700-031-34-80
10 1 Peri-Pump Mounting Plate 5700-021-33-70
11 4 Screw, 10-32 x 3/8" Long 5305-173-12-00
12 1 Switch, Detergent/R inse Aid Toggle 5930-011-35-27
13 1 Switch, On/Off, SPST 5930-111-38-21
14 1 Switch, Delime 5930-301-21-18
15 1 Timer Mounting Bracket 5700-021-82-26
1 Decal, Cam Timer 9905-011-37-21
16 1 8 Cam Timer 5945-111-35-32
1 Decal, Delime/Normal 9905-011-34-96
17 1 Contactor 5945-109-05-69
18 1 Ground Wire Lug 5940-200-76-00
19 1 Terminal Block 5940-500-09-61
1 Spacer, Terminal Block 5700-011-40-05
20 1 Hole Plug, 1/2" 4730-011-60-22
21 3 Control Relay 5945-111-35-19
22 2 Conduit Fitting, 1/ 2" x 45 DEG. 5975-011-45-23
23 1 Conduit Fitting, 1/ 2" x 90 DEG. 5975-011-45-14
24 1 Motor, Peri-P ump, 14 RPM 4320-111-35-13
25 2 Motor, Peri-P ump, 36 RPM 4320-111-35-14
26 1 Grommet 5325-011-46-73
27 4 Screw, 4-40 x 1/4" Long 5305-002-32-38
28 1 Terminal Board 5940-021-94-85
Other Parts Not Shown
Cotter Pin, 3/32 x 3/4" 5315-207-01-00
Decal, Warning-Disconnect Power 9905-100-75-93
Cover, Control Box 5700-002-04-62
Switch, Reed 5930-111-41-70
Switch Box, Side Weldment 5700-002-47-20
Switch Box, Front Weldment 5700-002-21-53
Grommet, 1/2" OD x 3/8" ID 5325-011-46-73
Switch, 20 AMP 5930-011-48-21
Plate, Switch Legend 5945-011-35-07
Hose, Drip Through Drain 5700-011-35-04
Tubing, 1/4" x 108" White 5700-000-96-78
Tubing, 1/4" x 120" White 5700-011-37-13
Tubing, 1/4" x 108" Red 5700-000-96-80
Tubing, 1/4" x 120" Red 5700-011-37-15
Tubing, 1/4" x 108" Blue 5700-000-96-79
Tubing, 1/4" x 120" Blue 5700-011-37-17
Tube, Tygon Sight 5700-111-34-91
Stiffener, Tube 17 3/8" 5700-011-35-23
Tube, 3/16 ID x 3/8" OD x 1.6" long 5700-111-35-33
Tube, 3/16 ID x 3/8" OD 5700-002-44-33
Decal, DET/RINSE Prime 9905-011-34-95
Decal, Sanitizer Prime 9905-011-34-98
Decal, Power Connections 9905-011-47-64
Decal, Copper Conductors 9905-011-47-35
PERISTALTIC PUMP ASSEMBLY
13
ITEM QTY DESCRIPTION Mfg. No.
1
2 Screw, 8-32 x 3/8" Phillips Flat Head 5305-011-37-07
2
1 Housing, Front 4320-111-37-08
3
1 Anko Roller 4320-111-36-70
4 1
Peri Pump Squeeze Tube 5700-011-76-41
5
4 Screw, 6-32 x 3/4" Phillips Pan Head 5305-011-37-05
6
1 Screw, 8-32 x 1/2" Phillips Flat Head 5305-011-37-06
7
1 Housing, Rear Assy 4320-111-37-09
8
1 Peri Pump Motor (14 RPM) Rinse A dditive 4320-111-35-13
9
2 Peri Pump Motor (36 RPM) Detergent & Sanitizer 4320-111-35-14
* Represents an item not shown.
1
2
3
4
5
6
7
8
HELPFUL HINT
:
Items 1,2, 3, 5, 6, & 7 all
come in a complete repair kit,
Mfg. No.: 4320-121-37-10
HOOD ASSEMBLY
14
ITEM QTY DESCRIPTION Mfg. No.
1
1 Hood Weldment 5700-002-21-67
2
4 Door Guide 5700-021-44-94
3
1 Door Guide, Left Back 5700-021-33-16
4
1 Door Guide, Right Back 5700-021-33-15
5
2 Arm Support Weldment 5700-011-43-52
6
2 Arm Support Gasket 5700-111-36-01
7
26 Screw, 1/4"-20 x 1/2" Long, Hex Head 5305-274-02-00
8
30 Washer, Flat, 1/4"-20 ID 5311-174-01-00
9
37 Locknut, 1/4"-20, Hex, S/S, with Nylon Insert 5310-374-01-00
10
4 Bolt, 1/4"-20 x 3/4" Long, Hex Head 5305-274-04-00
11
1 Hood Stiffener w/ Studs 5700-002-08-24
12
1 Door Catch 5700-011-46-50
13
2 Manifold L-Brackets 5700-011-34-63
*14
1 Stiffener, Hood Support 5700-002-47-39
*15
1 Front Door Stop 5700-021-60-27
1
2
*2
2
2
3
7
8
6
9
4
5
10
11
12
13
CANTILEVER ARM ASSEMBLY
15
ITEM QTY DESCRIPTION Mfg. No.
1
1 Hex Nut, 1/4"-20 w/ Nylon Insert, S/S 5310-374-01-00
2
1 Wear Strip UHMW 5700-011-34-50
3
1 Sleeve 5700-000-01-53
4
1 Bolt, 1/4"-20 x 1 -3/4", S/S 5305-274-10-00
5
1 Link, Spring to Cantilever Ar m 5700-021-34-49
6
1 Cantilever Spring 5340-111-35-22
7
1 Cantilever Eye Bolt
5700-011-45-99
8
1 Washer, Impeller 5311-176-02-00
9
2 Nut, 3/8"-16 Hex, S/ S 5310-276-01-00
10
1 Cantilever Arm 5700-031-45-38
11
2 Hex Head Bolt, 1/4"-20 x 1-1/ 2", S/S 5305-274-23-00
12
4 Washer, Flat 1/4", S/S 5311-174-01-00
13
2 Cantilever Arm Sleeve 5700-000-85-69
14
2 Hex Head Bolt, 1/4"-20 x 1/2", S/S 5305-274-02-00
15
2 Endcap, Cantilever Arm 5340-011-35-00
16
2 Bolt Spacer 5700-000-29-40
17
2 Cantilever Arm Lever 5700-011-90-99
18
2 U Bracket Assembly 5700-011-43-72
19
2 Bolt, Hex Head, 1/4"-20 x 3/ 4" 5305-274-04-00
20
5 Hex Nut, 1/4"-20 w/ Nylon Insert, Low Profile 5310-374-02-00
21
1 Bracket, Inner Half, U 5700-021-43-00
22
1 Bracket, Outer Half, U 5700-021-43-04
23
1 Sleeve Bearing 3120-011-43-53
*24
2 Retaining Ring 5340-011-33-62
11
10
12
13
14
12
15
16
20
17
20
1
2
3
4
5
6
7
8
9
18 U Bracket Assembly
19
21
23
20
22
*24
TUB ASSEMBLY (LEFT FRONT VIEW)
16
ITEM QTY DESCRIPTION Mfg. No.
1 2 Lower Wash Manifold Weldment 5700-031-46-00
2 2 Casting, Manifold Wedge 9515-011-46-61
3 4 Manifold Gasket 5700-111-35-03
4 1 Wash Tub Weldment 5700-002-21-50
5 2 Wash Motor Support Assembly 5700-021-66-48
1 Bracket, Pump Support Weldment 5700-021-66-47
1 Bracket, Lower Pump Support 5700-021-66-46
1 Nut, 1/4"-20 Serrated Nut 5310-011-66-49
6 2 Wash Motor 60 CY 6105-121-35-18
7 2 Fitting, 3/8" Barbed x 1/8" Male NPT 4730-111-35-02
8 2 Pump Inlet Nipple 5700-021-46-84
9 4 Hose Clamp, Regular, 1 5/16" - 2 1/4" 4730-719-01-37
10 4 Hose Clamp, Mini, 7/16" - 25/32" 4730-011-36-05
11 2 Hose, 3/8" ID x 8.5" Long 5700-011-45-30
12 2 Hose, 1.5" ID x 8.75" Long 5700-011-45-28
13
2 Hose Clamp, Regular, 5 5/8" - 6" 4730-011-34-90
1
2
3
4
5
13
6
7
8
9
10 11
12 10
9
* Represents an item not shown.
TUB ASSEMBLY (RIGHT FRONT VIEW)
17
2
1
4
5
9
10
9
11
1
6
7
8
3
ITEM QTY DESCRIPTION Mfg. No.
1
7 Locknut, 10-24 S/S Hex w/ Nylon Insert 5310-373-01-00
2
1 Drain Solenoid 4810-200-11-00
3
1 Drain Solenoid Box 5700-021-37-53
4
1 Drain Solenoid Box Cover 5700-031-33-27
5
1
Locknut, 1/4"-20 S/S H ex w/ Nylon Insert
5310-374-01-00
6
1 Drain Link 5700-031-46-52
7
1 Drain Link Connector 5700-002-38-10
8
1 Hex Nut, 5/16" - 18 5310-275-01-00
9
2 Spillway Gasket 5700-111-34-52
10
1 Drain Seat Insert (S tainless Ring) 5700-021-34-38
11
1 Spillway Weldment 5700-031-37-86
*12
1 Cotter Pin, 1/8" x 1" 5315-011-60-09
*13
1 Solenoid Stop 5700-000-66-40
* Represents an item not shown.
To order the entire Drain Link Assembly
(part numbers 6, 7, & 8)
Mfg. No.: 5700-002-38-21
FRAME WELDMENT
18
Bullet Foot
Mfg. No.: 5340-108-01-03
Frame Weldment
Mfg. No.: 5700-031-45-16
ACCUMULATOR ASSEMBLY
19
Accumulator Strainer
Mfg. No.: 5700-021-47-17
Accumulator Stop Clip
Mfg. No.: 5700-011-49-11
Accumulator Weldment
Mfg. No.: 5700-031-66-24
Locknut, 10-24 S/S w/Nylon Insert
Mfg. No.: 5310-373-01-00
NOTE: This is a rear view of the accumulator as it would appear installed on the dishmachine.
INCOMING PLUMBING ASSEMBLY
20
1
2
3
4
5
4
6
7
8
9
10
11
ITEM QTY DESCRIPTION Mfg. No.
1 1 3/4" 3/4-14 NPS Locknut 4730-208-04-00
2 1 3/4" Male NPT x Female Slip Adapter 4730-401-11-01
3 1 3/4" x 6" Copper Tube 5700-011-37-55
4 2 3/4" NPT x 90 Degree Elbow 4730-406-42-01
5 1 3/4" Vacuum Breaker 4820-300-08-00
6 1 3/4" Male NPT x Male Slip Adapter 4730-401-10-01
7 1 3/4" Solenoid Valve 4810-100-53-00
8 1 3/4" NPT x 3" Nipple 4730-011-38-29
9 1 3/4" NPT "Y"- Strainer 4730-717-02-06
10 1 Bracket, Incoming Plumbing Support 5700-021-34-02
11 1 Diverter End Cap 5700-021-45-32
3/4” SOLENOID VALVE & 3/4” NPT VACUUM BREAKER REPAIR PARTS KITS
21
Screw
Data Plate
Coil & Housing
Valve Bonnet
Spring
4810-200-04-18
Plunger
4810-200-04-18
Spring position is moved
for clarity.
Goes below the plunger.
O-Ring
4810-100-10-18
Diaphragm
Retainer
Diaphragm
4810-100-10-18
Screen
Retainer
Mesh Screen
Valve Body
Complete 110 Volt Solenoid Valve Assembly
Mfg. No.: 4810-100-53-00
Coil & Housing only
Mfg. No.: 4810-200-01-18.
Complete 220 Volt Solenoid Valve Assembly
Mfg. No.: 4810-100-03-18
Coil & Housing only
Mfg. No.: 4810-200-02-18.
Complete 24 Volt Solenoid Valve Assembly
Mfg. No.: 4820-100-01-40
Coil & Housing only
Mfg. No.: 4810-100-06-18.
Complete Vacuum Breaker Assembly
Mfg. No.: 4820-300-08-00.
Components of
Repair Kit
4820-001-60-57
Cap Screw
Data Plate
Cap
O-Ring
Plunger
Body
Cap Retainer
22
The entire wash arm assembly (without endcaps) may be ordered from the manufacturer using part number 5700-021-87-46.
To order the assembly with endcaps, use manufacturer number 5700-021-50-96.
Wash Arm Bearing
Mfg. No.: 5700-021-35-97
Wash Arm End Cap
Mfg. No.: 5700-011-35-92
Wash Arm Weldment
Mfg. No.: 5700-021-39-22
WASH ARM ASSEMBLY
WASH MANIFOLD ASSEMBLY (ES-4000)
23
ITEM QTY DESCRIPTION Mfg. No.
1
4 Bolt, 3/8"-16 x 7/8", Hex H ead, S/S 5306-011-36-95
2
2 Casting, Upper Wash Manifold 5700-031-34-82
3
8 3/8" Lockwasher 5311-276-01-00
4
8 3/8"-16 Hex Nut, S/S 5310-276-01-00
5
2 Bolt, 3/8"-16 x 2 1/4" Long 5306-011-95-12
6
2 Bolt, 3/8"-16 x 1 3/4" Long 5306-011-36-94
7
2 Weldment, Lower Wash Manifold 5700-031-46-00
8
4 Gasket, Wash Manifold 5700-111-35-03
9
2 Wedge, Manifold Casting 9515-011-46-61
10
4 Washer, 3/8" Bevel, Square 5311-011-35-36
11
2 Manifold Tube 5700-031-34-59
12
4 O-Ring 5330-111-35-15
8
12
12
1
2
3
4
6
7
8
9
10
3
4
11
5
PUMP & MOTOR ASSEMBLY
24
1
2
3
4
5
7
6
8
9
10
11
12
13
14
The entire assembly may be ordered using manufacturer number 6105-121-35-18.
ITEM QTY DESCRIPTION Mfg. No.
1
2 Pipe Plug, 1/4" NPT, SS N/A
2
1 Volute (only available as an assembly) N/A
3
1 Hex Head Bolt, 1/4"-20 x 3/8" 5305-274-01-00
4
1 Flat Washer, 1/4", SS 5311-174-01-00
5
1 Impeller, Stainless N/A
6
1 Gasket 5330-002-00-31
7
1 Pump Seal 5330-002-06-21
8
4 Hex Head Bolt, 3/8"-16 x 3/4", SS N/A
9
4 Hex Head Bolt, 3/8"-16 x 1-1/ 4", SS N/A
10
1 Bracket, Motor to Pump N/A
11
1 Slinger, Pump Shaft N/A
12
1 Shaft Adapter/Connector N/A
13
2 Allen Head Setscrew, 1/4"-20 x 1/4" N/A
14
1 Pump Motor, 115/230V, 3/ 4 HP, 3450 RPM N/A
DOOR ASSEMBLIES
25
Left Door Assembly
Mfg. No.: 5700-002-21-60
Left Door Weldment
Mfg. No.: 5700-002-21-61
Door Stop
Mfg. No.: 5700-011-46-30
Right Door Assembly
Mfg. No.: 5700-002-21-63
Right Door
Mfg. No.: 5700-021-63-62
Front Door Assembly
Mfg. No.: 5700-002-21-58
Front Door Weldment
Mfg. No.: 5700-002-21-59
8-32 Hexnut w/Nylon Insert
Mfg. No.: 5310-272-02-00
Magnet
Mfg. No.: 5930-111-51-68
Door Guides
Mfg. No.: 5700-111-33-59
MISCELLANEOUS PARTS
26
Reed Switch
2 per machine
Mfg. No.: 5930-111-41-70
Stand Pipe Weldment
Mfg. No.: 5700-021-33-29
Intake Pump Strainer Weldment
Mfg. No.: 5700-031-45-26
Stand Pipe Assembly
Mfg. No.: 5700-031-35-55
Stand Pipe Stopper
Mfg. No.: 5700-021-33-54
Rack Weldment
Mfg. No.: 5700-031-35-55
Chemical Injection
Tube Weldment
Mfg. No.: 5700-002-21-52
Chemical Injection
Tube Gasket
Mfg. No.: 5700-011-45-36
Chemical Injection
Tube 3/4” Bushing
Mfg. No.: 5975-002-47-54
CONSERVER XL2
ELECTRICAL DIAGRAM
115 volt - 60 hertz - single phase
27
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