Jackson / Dalton Dishwasher AJ-44CE Service Manual

MODELS COVERED IN THIS MANUAL:

AJ-44CE

AJ-44CEL

OPTIONS COVERED IN THIS MANUAL:

VAPOR VENT SCOOP

EXHAUST FAN CONTROL

E R V

N U

www.jacksonmsc.com

AJ-44 RACK CONVEYOR DISHMACHINES

(ELECTRICALLY HEATED)

January 21, 2002 P/N 7610-001-76-22 (Revision B)

SECTION DESCRIPTION PAGE

I. GENERAL SECTION

Specifications 1

II. INSTALLATION & OPERATION SECTION

Installation Instructions 2 Operation Instructions 3 AJ-44 Sequence of Operation 4

Field Modification of AJ-44 Direction 5 III. TROUBLESHOOTING SECTION 6 IV. DIMENSIONS 8 V. PARTS SECTION

Single Phase Control Box Assembly 9

Three Phase Control Box Assembly 11

Heater Box Assembly 13

Heater Box Covers/Thermostats 16

Wash Section Incoming Plumbing Assembly 17

3/4” Solenoid Valve & 3/4” NPT Vacuum Breaker Repair Parts Kits 19

Drain Plumbing Assembly 20

Drain Handle Weldment Assembly/Frame Weldment 21

Motors/Motor Support Bracket Assembly 22

Wash Pump Assembly 23

Wash Pump Weldment 24

Replacing Pump Gasket and Seal 25

Assorted Gaskets 26

Wash Heaters/Hood Weldments/Tub Weldments 27

Wash Manifold & Strainer Support Weldments 28

Upper Wash Arm Assembly 29

Lower Wash Arm Assembly 30

Final Rinse Assembly 31

Rinse Tray Assembly 32

Drive Assembly 33

Wash Door and Vent Cowl Assembly 37

Miscellaneous Door Assemblies 38

Rack Rail Assembly 39

Pawl Bar Roller Bracket 40

Pawl Bar Assembly 41

Miscellaneous Parts and Weldments 42

Strainers 45

Float Switch Assembly 46

Float Switch Cover/Dress Panel 47

Magnet Switch Assemblies 48

Curtains 49

Vent Scoop Option 50

Exhaust Fan Control Option 51

208 Volt/230 Volt - 60 Hz - Single Phase Schematic 52

208 Volt/230 Volt - 60 Hz - Three Phase Schematic 53

460 Volt - 60 Hz - Three Phase Schematic 54

SPECIFICATIONS

Drive Motor Prewash Motor Wash Motor Heater Load Total

Model Volts Phase Hz HP Amps HP Amps HP Amps KW Amps Amps

AJ-44CE/CEL 208 1 60 1/4 1.8 N/A N/A 2 8.5 15 72 82.3 AJ-44CE/CEL 230 1 60 1/4 1.8 N/A N/A 2 8.5 15 65.2 75.5 AJ-44CE/CEL 208 3 60 1/4 1.1 N/A N/A 2 5.6 15 41.7 48.4 AJ-44CE/CEL 230 3 60 1/4 1.1 N/A N/A 2 5.6 15 37.7 44.4 AJ-44CE/CEL 460 3 60 1/4 0.55 N/A N/A 2 2.8 15 18.8 22.2

RACKS PER HOUR:

AJ-44CE: 248 AJ44CEL: 234

DISHES OR GLASSES PER HOUR:

AJ-44CE: 6200 AJ44CEL: 5850

WASH TANK CAPACITY (GALLONS):

ALL MODELS: 15.4

WASH PUMP CAPACITY:

GALLONS PER MINUTE: 270

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

INPUT END: 200 OUTPUT END: 400 TOTAL: 600

CONVEYOR SPEED (FPM):

CE MACHINES: 6.9 CEL MACHINES: 6.5

GALLONS PER RACK:

CE MACHINES: .94 CEL MACHINES: 1.00

WATER TEMPERATURES (

F):

CE MODELS: WASH (MINIMUM) 160

RINSE (MINIMUM) 180 CEL MODELS: WASH (MINIMUM) 140

RINSE (MINIMUM) 140

FLOW PRESSSURE (PSI) 20 FLOWRATE (GPM) 3.9

MINIMUM CHLORINE (PPM) 50 (CEL MODELS ONLY)

Jackson MSC Inc. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer to this manual before making a call to our technical support staff. Please have this manual with you when you call so that our staff can refer you, if necessary , to the proper page. Technical support is avaliable from 8:00 a.m. to 5:00 p.m. (EST), Monday through Friday. Technical support is not available on holidays. Contact technical support toll-free at 1-888-800-5672. Please remember that technical support is available for service personnel only. Non-service personnel should refer to the list of provided service agencies in this manual for local service support.

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.. Y ou 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 throroughly 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: All piping from the machine to the drain must be a minimum 1-1/2” 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 30 gallons per minute.

WATER SUPPLY CONNECTION: Ensure that you have read the section entitled “PLUMBING THE DISHMACHINE” above before proceding. 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 models covered in this manual do not come with water pressure regulators 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 recommended that a shock absorber (not supplied) be installed in the incoming water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve as it operates, from causing damage to the equipment.

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

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

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

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

To install the incoming power lines, open the control box. Install conduit into the pre-punched holes in the back of the control box. Route power wires and connect to power block and grounding lug. Install the service wires (L1, L2, and L3 (3 phase only)) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. Tighten the connections. It is recommended that “DE-OX” or another similar anti-oxidation agent be used on all power connections.

VOLTAGE CHECK: Ensure that the power switch is in the OFF position and apply power to the dishmachine. Check the incoming power at the terminal block and ensure it corresponds to the voltage listed on the data plate. If not, contact a qualified service agency to examine the problem. Do not run the dishmachine if the voltage is too high or too low. Shut off the service breaker and mark it as being for the dishmachine. Advise all proper personnel of any problems and of the location of the service breaker. Replace the control box cover and tighten down the screws.

VENTILATION OF DISHMACHINE: The dishmachine should be located with provisions for venting into an adequate exhaust hood or ventilation system. This is essential to permit efficient removal of the condensation exhaust. Ensure that the exhaust system is acceptable in accordance with all applicable codes and standards.

NOTE: Damage caused by steam or moisture due to improper ventilation is NOT covered under the warranty.

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

Unload End: 400 CFM The exhaust system must be sized to handle this volume for the dishma-

chine to operate as it was designed to. ELECTRIC HEAT: The thermostats for the machines covered in this man-

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

INSTALLATION INSTRUCTIONS

CHEMICAL FEEDER EQUIPMENT: The AJ-44CEL is designed to operate with a third party chemical injection system. Jackson does not endorse any particular chemical injection system. The

system selected must be able to provide detergent and sanitizer in the required concentrations. The minimum chlorine concentration for proper sanitization is 50 PPM. Furthermore, the selected feeder needs to be able to operate against a head of 25 PSI and deliver 7.38 ml of a 10% chlorine sanitizer per minute.

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

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

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

All wires for the chemical injectors should be routed through the back of the control box.

Terminals in the control box marked “CVS” provide a constant voltage signal whenever the drive motor is operating.

Terminals in the control box marked “DET” provide a voltage signal whenever the wash motor is operating.

DELIMING OPERATIONS: In order to maintain the dishmachine at its optimum performance level, it will be required to remove lime and corrosion deposits on a frequent basis. A deliming solution should be available from your detergent supplier. Read and follow all instructions on the label of the deliming solution.

To proceed with the deliming operation, fill the dishmachine and add the correct amount of deliming solution as recommended by the deliming solution manufacturer. The water capacity of the various tanks of the dishmachine can be verified on the specification sheet(s) of this manual.

Perform the following operations to delime the dishmachine:

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

2. Disconnect or turn off all chemical feeder pumps.

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

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

5. Turn the unit off and open the doors.

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

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

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

9. Drain and re-fill the machine.

OPERATING INSTRUCTIONS

PREPARATION: Before proceeding with the start-up of the unit, verify the

following:

1. Close door(s) on dishmachine.

2. Close the drain valve(s).

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. The machine should fill automatically and shut off when the appropriate level is reached (just below the pan strainer). 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.

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 unscrapped 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 “PREPARATION” 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.

WASHING A RACK OF WARE: To wash a rack, simply slide a rack of soiled ware into the load end of the machine. Once the the machine is started, it should pull the rack through the machine and push it out the unload end. Once a rack has started through, you may put another rack in.

OPERATIONAL INSPECTION:Based upon usage, the pan strainers may become clogged with soil and debris as the workday progresses. Operators should reguarly inspect the pan strainers to ensure they have not become clogged. If the strainers do, they will reduce the washing capability of the machine. Instruct operators to clean out the pan strainers at regular intervals or as required by work load.

SHUTDOWN AND CLEANING: At the end of the workday, place the power switch in the OFF position and open the door(s). Open the drain valves and allow the machine to drain completely. Remove the pawl bar assembly (clean as required). Remove the pan strainers and, if equiped, the prewash strainers, run off sheets and scrap basket strainer. Remove the wash and, if equipped, the prewash arms and verify that the nozzles and arms are free from obstructions. Flush the arms with fresh water. Remove the pump suction strainers and clean out as required. Remove the rinse tray assembly and clean. Remove the curtains and scrub with a mild detergent and warm water. Wipe out the inside of the unit and then reassemble with the components previously removed.

INSTALLATION INSTRUCTIONS (CONTINUED)/OPERATING INSTRUCTIONS

REFER TO WIRING DIAGRAMS FOR ELECTRICAL FUNCTION AND REFERENCE DESIGNATIONS.

1. The door(s) are closed. Door switch (S2) closes.

2. Power Switch (S1) is activated. Red lamp (E1) comes on.

3. Machine will fill automatically: A. R7 is energized. B. Fill solenoid (WFS) opens allowing water into wash tank. C. When high level float switch (WFSW1) closes, R6 is energized. D. Fill solenoid (WFS) closes. E. R1 heat contactor is energized which activates the wash tank heater.

4. Slide dish rack into machine: A. Wash pump switch 1 (S3) closes energizing wash pump motor contactor (R3). B. Wash pump motor contactor (R3) N.O. contacts close energizing drive motor contactor (R2). C. Drive motor contactor (R2) is energized starting the conveyor drive motor (M1) D. Wash pump motor contactor (R3) closes starting wash pump motor (M2)

5. As dish rack moves into wash tank area: A. Wash pump switch 2 (S4) closes maintaining power to (R3). B. Wash pump switch 1 opens.

6. Dish rack moves into final rinse area: A. Final rinse switch (S5) closes energizing final rinse relay (R4). B. Contact closes energizing rinse solenoid (RS) and rinse aid signal relay (R5). C. R5 contact closes signaling rinse aid dispenser (provided by others). D. Wash pump switch (S4) opens de-energizing wash pump motor contactor (R3). E. Wash pump motor (M2) stops. F. Final rinse relay (R4) contact keeps drive motor contactor (R2) energized.

7. Dish rack exits machine: A. Final rinse switch (S5) opens. B. Final rinse relay (R4) is de-energized. C. R4 contact opens de-energizing final rinse solenoid (RS) and rinse aid signal relay (R5). D. Drive motor contactor (R2) is de-energized which stops conveyor drive motor (M1).

8. The wash tank heater (H1) has two (2) methods of protection to prevent damage to the heater. A. The heater high limit thermostat (TS1) disconnects power through heat contactor (R1) if wash heater sheath tempera

-ture exceeds 220 degrees F. When this occurs heater high limit light (E2) will light.

B. If the water level in the wash tank falls too low wash float switch 2 (WFSW2) will open . This de-energizes wash tank

fill relay (R6), heat contactor (R1) and heat contactor (R1). This de-activates wash heater (H1).

C. When this occurs a normally closed contact from wash tank fill relay (R6) energizes wash fill solenoid (WFS) which

opens allowing water to fill the wash tank to the proper level. D. Once the correct water level is reached wash float switch 1 closes energizing wash fill relay (R6). E. A normally open contact from R6 closes energizing heat contactor (R1) which activates wash heater (H1).

9. Access door is opened: A. Door safety switch (S2) opens. B. Door safety switch relay (R7), drive motor contactor (R2), wash pump motor contactor (R3) and final rinse relay (R4)

are de-energized. C. A normally open contact from R7 opens de-energizing wash fill solenoid (WFS) D. All devices within the dishwasher stop except for the tank heat. E. When access door is closed all relays and contactors are energized resuming machine operation.

AJ-44 SEQUENCE OF OPERATION

1. Remove the upper was arm (see page entitled “Upper Wash Arm Assembly’) from the wash manifold (see page entitled “Wash Manifold, Prewash Manifold & Strainer Support Weldments).

2. Remove the endcap (see page entiled “Upper Wash Arm Assembly”, item 6) and install on the opposite end of the wash arm weldment (same page, item 5).

3. Remove the upper wash arm bracket (see page(s) entitled “Miscellaneous Parts & Weldments”, refer to part number 5700-021-73-97) from the underside of the top of the hood. Reinstall the bracket onto the threaded studs on the opposite end of the wash hood.

4. Remove the splash shield ( see page(s) entitled “Miscellaneous Parts & Weldments”, refer to part number 5700-031-85-16) from the underside of the hood. Rotate the splach shield 180 degrees and reinstall it on the same studs.

5. Remove the pawl bar assembly (see page entitled “AJ-44 Pawl Bar Assembly”) and the lower wash arm ( see page entitled “Lower Wash Arm Assembly”).

6. Remove the lower wash arm support bracket (see page(s) entitled “Miscellaneous Parts & Weldments”, refer to part number 5700-011-71-20) which is mounted on the end of the pawl bar bracket.

7. Remove the lower rinse arm support bracket which is mounted on the end of the opposite pawl bar bracket.

8. Remove the entire final rinse assembly (see page entitled “Final Rinse Assembly”). You do not have to unscrew the rinse arms from the manifold.

9. Remove the rinse tray (see page entitled “Rinse Tray Assembly”) and the rinse tray strainer.

10. Remove the left and right side rinse tray locating brackets (see page(s) entitled “Miscellaneous Parts & Weldments”, referring to part numbers 5700021-92-37 and 5700-021-92-38).

11. On the drain plumbing, remove the tubing from the rinse nipple weldment (see page entitled “AJ-44 Drain Plumbing Assembly”, item 4). Once the tubing is removed, rotate the tee the rinse nipple is mounted in 180 degrees so that the rinse nipple weldment is facing the opposite direction.

12. Remove the rinse drain plug and rinse drain weldment (see page(s) entitled “Miscellaneous Parts & Weldments”, part numbers 5700-021-68-28 and 5700-011-68-59) and replace at the ends opposite thay they were. (Don’t forget to install the gasket!)

13. Reinstall the tubing that was on the rinse nipple weldment. As of this step, the rinse drain should be reconnected on the end opposite that it orginally was, while the other end is plugged.

14. Reinstall the left and right rinse tray locating brackets to the end where the rinse tray is to be installed.

15. Remove the hole direction cover weldment (see page(s) entitled “Miscellaneous Parts & Weldments”, refer to part number 5700-002-32-50) on top of the wash hood.

16. Seperate the rinse plumbing assembly (see page entitled “Wash Section Incoming Plumbing”) from the rest of the plumbing by lossening the union. Once loosened, remove the rinse section.

17. Remove, from the plumbing still connected to the unit, the section of union still attached. On the opposite end, remove the Y-strainer (item 19). Place the union section on the end where the Y-strainer was, and place the Y-strainer on the end where the union half was at.

18. Reinstall the rinse section plumbing by attaching at the new end where the union half is at. The rinse injector should set in the hole from where you removed the hole direction cover weldment. (Ensure that you have a gasket under the rinse injector before you reinstall it.

19. Reinstall the hole direction cover weldment at the opposite end of the wash hood (where the rinse plumbing was originally installed).

20. Reinstall the rinse tray assembly and its strainer and the lower rinse arm support bracket to the pawk bar support bracket on the end that the rinse manifold is to be reinstalled. Reinstall the rinse manifold.

21. Reinstall the lower wash arm support bracket on the pawl bar support bracket on the opposite end from the rinse section.

22. Reinstall the lower wash arm assembly and the pawl bar assembly.

23. Reinstall the upper wash arm assembly.

24. Remove the front dress panel from the machine to expose the heater box; remove the heater box cover.

25. Locate the black lead wires for the front and rear magnet switches (the switches that sense the position of a rack within the machine) at the point where they connect to the terminal board. Remove these connections from the terminal board, reverse their placement, and reinstall them on the terminal board.

26. Reinstall the heater box cover and the front dress panel.

FIELD MODIFICATION OF AJ-44 DIRECTION

Problem: Nothing on dishmachine operates. The power switch is ON and the power indicator light is OFF.

1. Machine is not wired correctly to incoming power source. Have an electrician verify wiring.

2. Machine circuit breaker is tripped. Reset the circuit breaker. If it trips again, contact an electrician to verify the machine amp draw.

3. Service breaker is tripped. Reset the service breaker. If it trips again, contact an electrician to verify the machine amp draw.

Problem: Machine will not fill. The power switch is ON and the power indicator light is ON.

1. No water supply to machine. Verify that water lines have been connected to the machine.

2. Dishmachine doors are not closed. Close doors completely.

3. Incoming water solenoid valve damaged/faulty. Verify that the valve is operating. If not, replace.

4. Tank floats faulty. Verify the wiring of the floats. Verify that no debris is jamming the floats. Replace if necessary.

Problem: Machine fills, but fill is weak.

1. Low incoming water pressure. Verify that incoming water pressure during fill is 20 PSI.

2. Incoming water solenoid is clogged. Verify that debris is not entrapped in valve. If so, remove debris.

Problem: Low wash tank temperature.

1. Low incoming water temperature. Verify that the incoming water temperature matches what is indicated on the machine data plate.

2. Heater not energizing. Verify that the wash tank heater is operating. If not, replace.

3. Low incoming voltage. Have an electrician verify that the power coming to the machine is the same as indicated on the data plate.

Problem: Low wash arm pressure, poor spray pattern.

1. Clogged wash arm nozzles. Verify that nozzles are not clogged with debris. If so, remove debris.

2. Clogged wash tank or wash pump strainers. Clean out strainers if necessary.

3. Worn wash pump impeller. Verify status of impeller, replace if necessary.

Problem: Low prewash arm pressure, poor spray pattern.

1. Clogged prewash arm nozzles. Verify that nozzles are not clogged with debris. If so, remove debris.

2. Clogged prewash tank or prewash pump strainers. Clean out strainers if necessary.

3. Worn prewash pump impeller. Verify status of impeller, replace if necessary.

Problem: Inadequate rinse.

1. Low incoming water pressure. Verify that incoming water pressure during fill is 20 PSI.

2. Incoming water solenoid is clogged. Verify that debris is not entrapped in valve. If so, remove debris.

Problem: Pawl bar moves with no load, but does not move when loaded.

1. Clutch on drive assembly is out of adjustment. Adjust as required.

Problem: Pawl bar does not move.

1. Failed or broken overload spring. Replace spring if necessary.

2. No power to the drive motor/failed drive motor. Verify power and wiring connections to the motor. If necessary, replace the motor.

3. Pawl bar not properly installed. Verify that the pawl bar is installed correctly.

Problem: Racks go through the machine, but results are poor.

1. Verify that detergent is being dispensed into the machine at the appropriate quantities for the water volume. If not, get detergent to appropriate level and review results of washing ware.

2. Clogged strainers/scrap basket. Clean out strainers and scrap basket and replace.

3. Ware not being properly prescrapped. Review paragraph entitled ‘Ware Preparation” in Operating Instructions.

4. Wash or rinse arms missing end plugs or caps. Verify and replace as required.

5. Low tank heat (see previous page).

6. Inadequate rinse (see previous page).

7. Incorrect voltage coming to the machine. Verify that the voltage matches that on the machine data plate.

8. Wash pump cavitation due to low water level. Verify that the drains are shut and that the water level is correct.

TROUBLESHOOTING SECTION

Problem: Spotting of silverware, glasses and dishes.

1. Incorrect final rinse temperature. Verify that the rinse water temperature matches that which is listed on the machine data plate.

2. Clogged wash and/or rinse nozzles and arms. Remove the arms and verify that they and their nozzles are from debris.

3. Excessively hard water. Install a water softener to reduce hardness.

4. Loss of water pressure due to clogged/obstructed wash pump. Turn the power off to the machine at the source. Drain the wash tank of water and verify that the pump intake is free from debris.

5. Improper scrapping procedures. Review the paragraph entitled “Ware Preparation” in Operating Instructions.

6. incorrect detergent/chemcial concentrations. Verify that the detergent/chemical concentrations are correct for the associated water volume.

TORQUE SETTINGS

When replacing components either in the control box or the heater box area, the manufacturer has suggestions on how much to torque the screws and nuts used in securing items to the machine. Refer to the table below for the torque specifictions:

ITEMS

TORQUE SPEC

Relays 16 In/lbs Heater Contactor 35 In/lbs Heater Nuts 16 In/lbs Terminal Block 50 In/lbs

TROUBLESHOOTING SECTION (CONTINUED)

DIMENSIONS

Single-Tank Rack

Conveyor Dishwashers

AJ-44 Vision Series

SINGLE PHASE CONTROL BOX ASSEMBLY

4, 5

4, 8, 9, 10

4, 18, 26

19, 20

19, 21

22, 23

19, 24

19, 25

MISCELLANEOUS PARTS NOT SHOWN: Grommet, 1/2” OD x 3/8” ID 5325-011-46-73

Bushing, Heyco SB100 5975-210-09-00 Plug, Heyco 2700 G-875 5975-011-47-81 Control Box Cover 5700-031-89-42 Control Box Cover Hinge Weldment 5700-021-68-57 Control Hinge Rod 5700-011-68-58 Washer, Flat, S/S, 1/4” ID 5311-174-01-00 Cotter Pin 5315-011-68-56 MANUAL/DELIME Switch (located on rear of control box) 5930-301-22-18 MANUAL/DELIME Switch Decal (located on rear of control box) 9905-011-74-61 Copper Conductors Only Decal 9905-011-47-35 Control Box Leg 5700-011-71-47 Bolt, 1/4”-20 x 2-1/2” Long Hex Head 5306-011-83-52 Locknut, 1/4”-20 with Nylon Insert 5310-374-01-00 Component Mounting Plate (located inside the control box) 5700-031-67-03

SINGLE PHASE CONTROL BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Electrical Box Weldment 5700-041-88-43 2 1 Terminal Block, 3 Pole 5940-011-48-27 3 1 Thermometer, 96" Lead 6685-111-68-49 4 6 Starwasher, External Tooth, 10-24 5311-273-02-00 5 6 Screw, 10-32 x 3/4" Long Phillip Trusshead 5305-011-62-17 6 1 Decal, Gauge 9905-021-72-29 7 1 Thermometer, 48" Lead 6685-111-68-48 8 1 Wire Lug, 2 AWG to 14 AWG 5940-200-76-00

THREE PHASE CONTROL BOX ASSEMBLY

4, 5

4, 8, 9, 10

4, 18, 29

21, 22

30, 22

22, 23, 24

25, 26

22, 27

22, 28

MISCELLANEOUS PARTS NOT SHOWN: Grommet, 1/2” OD x 3/8” ID 5325-011-46-73

THREE PHASE CONTROL BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Electrical Box Weldment 5700-041-88-43 2 1 Terminal Block, 3 Pole 5940-011-48-27 3 1 Thermometer, 96" Lead 6685-111-68-49 4 6 Starwasher, External Tooth, 10-24 5311-273-02-00 5 6 Screw, 10-32 x 3/4" Long Phillip Trusshead 5305-011-62-17 6 1 Decal, Gauge (208-230 Volt Models Only) 9905-021-72-29 6 1 Decal, Gauge (460 Volt Models Only) 9905-021-72-83 7 1 Thermometer, 48" Lead 6685-111-68-48 8 1 Wire Lug, 2 AWG to 14 AWG 5940-200-76-00

9 1 Decal, Ground 9905-011-86-86 10 1 Screw, 10-32 x 1/2" Long Phillips Trusshead 5305-011-39-36 11 1 Decal, L1-L2-L3 9905-101-12-66 12 1 Light, Amber 5945-111-44-44 13 1 Light, Red 5945-111-44-45 14 1 Din Rail 5700-021-72-75 15 1 Circuit Breaker (208/ 230 Volt Models Only) 5925-011- 68-34 16 1 Switch, ON/FILL - OFF/DRAIN 5930-011-49-55 17 2 Motor Contactor 5945-111-68-38 18 1 Heater Contactor 5945-002-24-70 19 1 Overload (5.5 - 7.5 RTIM)(208-230 Volt Models Only) 5945-111-68-40 19 1 Overload (460 Volt Models Only) 5945-111-69-12 20 1 Overload (1.0 - 1.5 RTIG)(208-230 Volt Models Only) 5945-111-68-39 20 1 Overload (2.5 -4 RTIK )(460 Volt Models Only) 5945-111-68-41 21 3 Control Relay 5945-111-35-19 22 12 Screw, 6-32 x 3/8" Long 5305-002-25-91 23 1 Fuse (460 Volt Models Only) 5920-011-72-88 24 1 Fuse Holder (460 Volt Models Only) 5920-011-72-89 25 1 Transformer 5950-011-68-35 26 4 Locknut, 10-24 with Nylon Insert 5310-373-01-00 27 1 Terminal Board 5940-021-70-70 28 1 Terminal Board 5940-021-89-41 29 2 Screw, 10-32 x 3/8" Long Phillips Trusshead 5305-173-12-00 30 1 Relay 5945-111-72-51

HEATER BOX ASSEMBLY

1, 2

3, 4, 5

10, 11

The wash tank heater system is electrically connected in the circuit so that they are dependent upon the dishwasher being properly filled with and maintaining a safe water level, two thermostats (mounted in the heater box behind the dress panel), float switch (mounted in the wash tank), and the heater relay (mounted in control box) with the heater being activated by the thermostats.

Once the dishwasher has been filled to the correct level, the heater should operate automatically. Should the tank heat be too high, too low or no indication of temperatures at all, the following checkout should be made.

Note: The following checkout should be made by either a qualified service person or electrician.

A.- Checkout of the heater system

1.- If the temperature is too high, adjust thermostat using instructions on the page entitled “Thermostats”.

2.- If temperature is too low, adjust thermostat as above, then: a.- Turn off power to machine by placing customer’s circuit breaker in the “OFF” position. Turn off machine circuit

breaker located on right side of control box.

b.- Remove cover from control box on top of dishwasher. c.- Make sure water temperature is below 140 degrees F.(preferably about 130 degrees F.). d.- Turn on both circuit breakers. Observe heater relay (R1) while the power switch is turned “ON” and “OFF”. If relay

contacts move in and out, the heater relay is operating correctly: if not proceed to ”C”.

B.- If heater relay (R1) closes:

1.- Check power supply at incoming terminal board L1, L2 & L3. It should be the same voltage as indicated on the

machine data plate.

2.- Check power at connections on heater relay (R1). The voltage should agree with the voltage on the machine data

plate. If not, check wires for breaks or bad connections.

3.- Check power at terminals of heater which should agree with the data plate. If not check wires for breaks or bad con-

nections.

4.- Temperatures should rise as explained in “C-1”, and amperage may be checked according to those instructions.

Replace any defective elements.

C.- If heater relay (R1) does not close.

1.- There is an insulated movable insulated movable bar on relay across the top. With an insulated probe, depress this

bar and observe the thermometer: the temperature should rise noticeably in a minute or two. If it moves slowly, it would indicate that the element is faulty. If it moves constantly higher at a good rate, elements should be good.

Note: A check with an amp probe at heater relay (R1) terminals should be made to verify the amp draw on each leg. This should be appropriate for the voltage and phase indicated on the data plate.

HEATER BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 See Page Entilted "Wash Heaters" N/A 2 1 Heater Gasket 5330-200-02-70 3 6 Washer, Flat, 5/16" 5311-175-01-00 4 6 Lockwasher, 5/16" 5311-275-01-00 5 6 Nut, 5/16"-18 5310-275-01-00 6 1 Thermostat, Wash Regulating 5930-121-67-72 7 1 Thermostat, High Limit Control 5930-121-71-36 8 1 Float Switch (Wash Tank) 6680-121-70-71

9 1 Heater Box Weldment 5700-031-66-81 10 3 Reed Switch (All Models) 5930-111-68-44 11 3 Reed Switch Bracket (All Models) 5700-021-85-15

HEATER PROTECTION & AUTOMATIC FILL

This control is activated when the power switch is turned “ON”. The primary function is to automatically energize the wash tank heat circuit. It will also cutoff the wash tank heat circuit should the water be accidently drained from the machine with the power switch still “ON”. The power switch should always be turned-off before draining the unit.

This water level control consists of two (2) floats that operate when the power switch is turned on and works in conjunction with the thermostats and heater relays.

When the power switch is turned “ON” water starts to enter the dishmachine. When it reaches the proper level the normally open contacts in the water level float switch close activating the heating circuit for tank heat.

If the water level below the correct level while power is still on, the float switch will sense the lack of water and de-activate the heater.

HEATER BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Terminal Board 5940-021-70-70 2 2 Locknut, 6-32 with Nylon Insert 5310-373-03-00 3 1 Thermostat Bracket 5700-011-73-72

+ 39 hidden pages

Jackson / Dalton Dishwasher AJ-44CE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

SPECIFICATIONS

INSTALLATION INSTRUCTIONS

OPERATING INSTRUCTIONS

AJ-44 SEQUENCE OF OPERATION

FIELD MODIFICATION OF AJ-44 DIRECTION

TROUBLESHOOTING SECTION

DIMENSIONS

SINGLE PHASE CONTROL BOX ASSEMBLY

THREE PHASE CONTROL BOX ASSEMBLY

HEATER BOX ASSEMBLY