Jackson Dishwasher AJ-100CS Installation Manual

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

DELIMING OPERATIONS

33

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. Adeliming solution should be available from your detergent supplier. Read and
follow all instructions on the label of the deliming solution.

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

Perform the following operations to delime the dishmachine:

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

2. Disconnect or turn off all chemical feeder pumps.

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

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

5. Turn the unit off and open the doors.

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

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

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

9. Drain and re-fill the machine.

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

Delime Switch

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

CURTAIN INSTALLATION DIAGRAMS

34

21"

12"

12"

21"

LSSL

RL

64

S

12" 12"

SS

12"12"

S

L R

SSL

12" 12"

21"

S

12"

L R

LS SL

21"

12"

12"

21"

12"

S

86-100

S

12"

21"

12"

12"

LSS

RL

12"

S

86-100

S

12" 12"12"

SS

RL

12"

S

S

12"12"

S

64

L R

SS

12" 12"

GAS MACHINES

XL

24.5" 24.5"

XL

24.5"

XL XL

24.5"

S

12"

21"

12"

12"

21"

LSSL

RL

12"

S

S

12"12"

S

L R

LS SL

21"

12"

12"

21"

UNHOODED SIDE LOADER

HOODED SIDE LOADER

UNHOODED SIDE LOADER

HOODED SIDE LOADER

ELECTRIC & STEAM MACHINES

Please refer to the chart for
placement of the curtains.

This accessory assists in the delivery of a full dish rack from the break down (scrapping) table to the dishmachine. It will con­vert the direction of travel 90°. Since the Side Loader is shipped mounted on the conveyor dishwasher there is no additional
installation required for this option. As it is operated mechanically by the dishwasher it does not require any plumbing or elec­trical connections.

This Side Loader does not require or add any additional electrical or mechanical devices to the unit which could create opera­tional or maintenance problems. As designed the drive mechanism is powered by the conveyor drive motor on the dishma­chine. An extension on the pawl bar provides the drive to push the racks into the unit.

PREPARATION: Before proceeding with the start-up of the unit, verify that the Side Loader pan strainer is installed.
WARE PREPARA TION:Proper preparation of ware will help ensure good results and less re-washes. If not done properly, ware

may not come out clean and the efficiency of the dishmachine will be reduced. It is important to remember that a dishmachine
is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether
of washing the ware. Scraps should be removed from ware prior to being loaded into a rack. Pre-rinsing and pre-soaking are
good ideas, especially for silverware and casserole dishes. Place cups and glasses upside down in racks so that they do not
hold water during the cycle. The dishmachine is meant not only to clean, but to sanitize as well, to destroy all of the bacteria
that could be harmful to human beings. In order to do this, ware must be properly prepared prior to being placed in the machine.

WASHING A RACK OF WARE: Once a rack is fully loaded it should be positioned against the front of the dish table. The rack
should then be moved into the Side Loader until it activates the actuator switch. Once the the machine is started, it should pull
the rack through the machine and push it out the unload end. Once a rack has started through, you may put another rack in.

OPERATIONALINSPECTION: Based upon usage, the pan strainer may become clogged with soil and debris as the workday
progresses. Operators should regularly inspect the pan strainer to ensure it has not become clogged. If the strainer does
become clogged, it will reduce the washing capability of the machine. Instruct operators to clean out the pan strainer at regu­lar intervals or as required by work load.

SHUTDOWN AND CLEANING: At the end of the workday, remove the pan strainer and clean as required. Wipe out the inside
of the Side Loader and then reinsert the strainer.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

SIDE LOADER INSTALLATION & OPERATION INSTRUCTIONS

35

CONCEALED DAMAGE OR MISSING P

ARTS:

IMPORTANT: FOR YOUR PROTECTION, PLEASE READ AND OBSERVE THE FOLLOWING:

This steam booster has been thoroughly inspected and carefully packed before leaving our warehouse.
Concealed loss or damage means loss or damage which does not become apparent until the booster has been unpacked. The

contents may be damaged in transit due to rough handling even though the carton may not show external damage.
If it is found that the shipment has concealed damage, PLEASE DO NOT RETURN IT TO JACKSON, but notify the carrier

(within 48 hours) asking them to send their agent to fill out an inspection report. Save the cartons so he may inspect them and
be sure to note in the report any black marks, creases, tears, crushed corners or any other marks indicating rough handling.
Also, notify your JACKSON dealer immediately.

If it is discovered that there are missing parts, please notify your JACKSON dealer immediately.

EQUIPMENT MOUNTING:

Your booster should come pre-assembled and will require that it be permanently mounted in place. The platform has pre­punched holes to allow for mounting to the installation floor. NOTE: The D226 Booster must be properly mounted and level
before being used. Once the platform is secure to the floor, attach the water and steam lines in accordance with local and
national codes.

PLUMBING:

NOTE: ALL CONNECTIONS MUST COMPLY WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL PLUMBING
CODES.

The plumber is responsible for ensuring that the water line is THOROUGHLY FLUSHED BEFORE connecting it to any manu-
al or solenoid valve. It is necessary to remove all foreign matter such as chips (resulting from cutting or threading pipes), pipe
joint compound or, if soldered fittings are used, bits of solder or cuttings from the lines. This debris, if not removed, may lodge
in the valves and render them inoperative.

The D226 Booster is designed to take incoming water from a minimum temperature of 110°F to approximately 180°F for use in
the final rinse of your Jackson dishmachine. In order to do this, water is supplied to the booster and is heated by tubes carry­ing 15-25 PSIG flow steam. Heat is transferred from the steam into the water, raising the temperature.

Install condensate drains in accordance with applicable codes.
The D226 Booster is designed to operate at a water flow rate of 20 ±5 PSI. The assembly comes with a water pressure reg-

ulator, which is preset at the factory. However, adjustment may be required so ensure that you verify the the flow pressure
before beginning operations. See the instructions regarding adjustment and maintenance of the water pressure regulator for
more information.

WARNING: The D226 Booster is designed to heat water to a minimum of 180°F and is extremely hot during operations.
Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur.

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

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

D226 STEAM BOOSTER INSTALLATION & OPERATION INSTRUCTIONS

36

ELECTRICAL:

WARNING: Electrical and grounding connections must comply with applicable portions of the National Electrical Code

ANSI / NFPA70 (latest edition) and/or other electrical codes.Disconnect electrical power supply and place a tag or lock
at the disconnect switch to indicate that you are working on the circuit.

To connect the incoming power, run the conduit for power wires through the open
hole in the back of the control box. Connect the power wires to the terminal block as
it is labeled (L1 and L2). Run the ground wire to the grounding lug marked “GND”.
Tight connections and conduit nuts and close the control box by putting the cover on
and securing with the 10-32 screws.

OPERA

TION:

WARNING: The heat exchanger used in the D226 Booster system is a pres-

sure vessel with very precise operating parameters. Safety equipment such as
relief valves should never be tampered with or disabled. These devices are meant to
protect the equipment and the operator from harm, damage and death.

1. Ensure that water, steam and any condensate drains are connected to the booster.

2. Start the water flow first, open the condensate drains and then begin steam flow.

3. On the control box, press the power switch and put it in the ON position. The power light should illuminate.
The unit should run normally now.

WARNING: Do not shock the system by applying the steam before the water. This can cause damage to the booster.
The following explanation describes the operation of the D226 Booster.
NOTE: This explanation assumes that water and steam have been connected to the machine.

1. When the power switch (S1) is placed in the ON position, power is provided to both the power light (E1) and the thermostat
(TS1).

2. The thermostat (TS1) will close when the water falls below the minimum setpoint, energizing the steam solenoid light (E2)
and the steam solenoid (FS1).

3. The steam solenoid (FS1) will remain open, allowing steam into the booster, until the water temperature reaches the desired
temperature. At that point, the thermostat (TS1) will open, de-energizing the steam solenoid (FS1) and the steam solenoid light
(E2).

IMPORTANT: Please remember that all of the components in the control box are under line voltage (208-240 volts).

Under no circumstance is the control box cover to be removed or opened during normal operations!

SHUTDOWN (FOR SER

VICE ONLY):

WARNING: The D226 Booster is designed to heat water to a minimum of 180°F and is extremely hot during operations.

Advise personnel of the dangers associated with touching booster components as burns or severe injury can occur.

1. Turn the power switch to the OFF position. The power light should extinguish.

2. Secure steam flow to the unit.

3. Secure water flow.

4. Close the condensate drains as required by procedure and/or code.

5. Do not attempt to clean, wipe down or perform any maintenance on the booster until it has been given a generous amount
of time to cool down.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

D226 STEAM BOOSTER INSTALLATION & OPERATION INSTRUCTIONS (CONTINUED)

37

10

Terminal Block

D226 Conrtol Box

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

GAS CONVEYOR HOSE INSTALLATION

38

Due to the fact that each customer may have different requirements for the orientation of the gas booster heater relative to the
main dishmachine, the hose lengths that connect the two units must be customized during each installation. The appropriate
3/4” hosing, fittings and gaskets have been provided.

To prevent incorrect measurements of the hose, it is recommended to place one barbed hose fitting into the end of the uncut
length of hose coil and attach that fitting to an appropriate connection. Run the hose to the corresponding connection on the
other unit before cutting the hose. Use a barbed hose fitting that is screwed into the second connection on the other unit before
cutting the hose. Use a barbed hose fitting that is screwed onto the second connection to gauge the correct distance. Ensure
a smooth “flow” of hose without any sharp turns or kinks.

To aid in pushing the barbed hose fitting into the hose, place the fitting on a hard surface (i.e. the floor) with the barbed e nd of
the fitting pointing upward and push the hose down onto the fitting. Asmall amount of lubricant (i.e. petroleum jelly) may aid in
this process.

Barbed Hose Fitting

Connection

Attach the hose fitting to this
connection before making the
cut at the other end of the
hose.

Hose

Cut the hose at the location
where the hose is even
with the yellow plastic stop.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

GAS CONVEYOR HOSE INSTALLATION (CONTINUED)

39

TYPICAL RECIRCULATING WATER HOOK-UP

FOR ALL GAS HEATED CONVEYORS

HOOKUP WHEN GAS BOOSTER HEATER

IS LOCATED TO THE

RIGHT OF THE

DISHMACHINE

HOOKUP WHEN GAS BOOSTER HEATER

IS LOCATED TO THE

LEFT OF THE

DISHMACHINE

CONNECTION HOSES ARE CUT TO L ENGTH DURING INSTALLATION.

(ENOUGH HOSE IS PROVIDED TO L OCATE T HE GAS BO OT ER H EATER APPROXIMATELY 9 FEET

AWAY FROM THE DISHMACHINE. ADDITIONAL HO SE MUST BE OR DERED IF A GREATER DISTANCE

IS REQUIRED. DISTANCES GREATER THAN 20 F EET AWAY CAN AF FEC T TH E H EAT I N G PER F ORMANCE

OF THE UNIT)

* HOSES MARKED A IN THE ABOVE ILLUSTRATIONS CONNECT TO THE INLET WATER CONNECTION OF THE GAS BOOSTER HEATER

** HOSES MARKED B IN THE ABOVE ILLUSTRATIONS CONNECT TO THE OUTLET WATER CONNECTION OF THE GAS BOOSTER HEATER

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 (ELECTRICALLY-HEATED MODELS): To energize the unit, turn on the power at the service breaker. The volt-

age should have been previously verified as being correct. If not, the voltage will have to be verified.
POWER UP (STEAM-HEATED MODELS): 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. Ensure that the steam service is con­nected and that steam is flowing to the machine. Without steam, the water will not reach the required minimum temperatures
that the machine is designed to operate at.

POWER UP (GAS-HEATED MODELS):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. Ensure that the gas service is connected
and that gas is flowing to the machine. Without gas, the water will not reach the required minimum temperatures that the
machine is designed to operate at.

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.

Machines equipped with prewash sections should not be run without water in those sections. This can cause
damage to components.

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 PREPARA TION: 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 regularly 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.

NOTE: On units equipped with prewash sections (AJ-86 and AJ-100), operators should also take the time to inspect the pre­wash section strainers and clean them as required by workload.

SHUTDOWN AND CLEANING (ELECTRICALLY-HEATED MODELS): 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 equipped, 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.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

DISHMACHINE OPERATING INSTRUCTIONS

40

SHUTDOWN AND CLEANING (STEAM-HEATED MODELS): At the end of the workday, place the power switch in the OFF
position, secure the flow of steam to the machine and open the door(s). Open the drain valves and allow the machine to drain
completely. Remove the p awl bar assembly (clean as required). Remove the p an strainers and, if equipped, 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.

SHUTDOWN AND CLEANING (GAS-HEATED MODELS): At the end of the work day, shut down the gas booster in accor­dance with manufacturer’s instructions. Place the power switch in the OFF position, secure the flow to the machine 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 equipped, 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.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

DISHMACHINE OPERATION INSTRUCTIONS (CONTINUED)

41

Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate.
Using detergent in the proper amount can become, in time, a source of substantial savings. A qualified water treatment spe­cialist can tell you what is needed for maximum efficiency from your detergent, but you should still know some basics so you’ll
understand what they are talking about.

First, you must understand that hard water greatly effects the performance of the dishmachine. Water hardness is the amount
of dissolved calcium and magnesium in the water supply. The more dissolved solids in the water, the greater the water hard­ness. Hard water works against detergent, thereby causing the amount of detergent required for washing to increase. As you
use more detergent, your costs for operating the dishmachine will increase and the results will decrease. The solids in hard
water also may build-up as a scale on wash and rinse heaters, decreasing their ability to heat water. Water temperature is
important in removing soil and sanitizing dishes. If the water cannot get hot enough, your results may not be satisfactory. This
is why Jackson recommends that if you have installed the machine in an area with hard water, that you also install some type
of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine.

Second, hard water may have you adding drying agents to your operating cycle to prevent spotting, when the real problem is
deposited solids on your ware. As the water evaporates off of the ware, the solids will be left behind to form the spotting and
no amount of drying agent will prevent this. Again, using treated water will undoubtedly reduce the occurrences of this prob­lem.

Third, treated water may not be suitable for use in other areas of your operation. For instance, coffee made with soft water may
have an acid or bitter flavor. It may only be feasible to install a small treatment unit for the water going into the dishmachine
itself. Discuss this option with your qualified water treatment specialist.

Even after the water hardness problems have been solved, there still must be proper training of dishmachine operators in how
much detergent is to be used per cycle. Talk with your water treatment specialist and detergent vendor and come up with a
complete training program for operators. Using too much detergent has as detrimental effects as using too little. The proper
amount of detergent must be used for job. It is important to remember that certain menu items may require extra detergent by
their nature and personnel need to be made aware of this. Experience in using the dishmachine under a variety of conditions,
along with good training in the operation of the machine, can go a long way in ensuring your dishmachine operates as effi­ciently as possible.

Certain dishmachine models require that chemicals be provided for proper operation and sanitization. Some models even
require the installation of third-party chemical feeders to introduce those chemicals to the machine. Jackson does not recom­mend or endorse any brand name of chemicals or chemical dispensing equipment. Contact your local chemical distributor for
questions concerning these subjects.

Some dishmachines come equipped with integral solid detergent dispensers. These dispensers are designed to accommodate
detergents in a certain sized container. If you have such a unit, remember to explain this to your chemical distributor upon first
contacting them.

As explained before, water temperature is an important factor in ensuring that your dishmachine functions properly. The data
plate located on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank
and the rinse tank, depending on what model of dishmachine you have installed. These temperatures may also be followed by
temperatures that Jackson recommends to ensure the highest performance from you dishmachine. However, if the minimum
requirements are not met, the chances are your dishes will not be clean or sanitized. Remember, a dish can look clean, but it
may not be sanitized. Instruct your dishmachine operators to observe the required temperatures and to report when they fall
below the minimum allowed. Aloss of temperature can indicate a much larger problem such as a failed heater or it could also
indicate that the hot water heater for your operation is not up to capacity and a larger one may need to be installed.

There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it
and that it operates at peak efficiency for many years. Discuss your concerns with your local chemical distributor and water
treatment specialist before there is a problem.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

DETERGENT CONTROL

42

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS

43

TABLE LIMIT SWITCH THROUGH ROD HOLES

TABLE

SWITCH RODS

STRIKE PLATE

STRIKE PLATE BOLTS

MOUNTING BOLTS

TABLE BOTTOM

3.00

2.00

Ø0.75

Ø0.25

1.50

TABLE BOTTOM

1.875

INSTALL AT FAR END OF TABLE

1/3 RACK WIDTH

Installation Instructions:

1. Wiring: The switch is wired common and nor­mally open because of the hinge design. By
interrupting the line in series with the door
switches, the dishmachine ceases to operate.
Refer to the machine schematic for details on
how to wire the switch.

2. Parts of the table switch are mounted in the
dishtable, at the end of the table and under the
table. See the drawing(s) for the relationship of
the switch to the table.

3. Move the limit switch as far down on the two
slots as possible and see that the limit switch is
straight on the base plate. This might require
adjustment of the nut on the connector for the
limit switch.

4. Then adjust the inside and the outside con­nector nuts for the connector box so that it lines
up even with the limit switch and the base plate.

5. Tighten down the nuts for the seal so that
they are tight.

6. If you have any difficulty you might have to adjust the
connectors to the seal, screwing in or screwing out
until the installation is straight on the table and the limit
switch is actuated correctly by the rack.

Unless noted, all dimensions are in
inches.

44

SECTION 3:

PREVENTATIVE MAINTENANCE

The dishmachines covered in this manual are designed to operate with a minimum of interaction with the operator. However,
this does not mean that some items will not wear out in time. Jackson highly recommends that any maintenance and repairs
not specifically discussed in this manual should be performed by QUALIFIED SERVICE PERSONNELONLY. Performing main­tenance on your dishmachine may void your warranty if it is still in effect, so if you have a question or concern, do not hesitate
to contact Jackson.

There are many things that operators can do to prevent catastrophic damage to the dishmachine. One of the major causes of
component failure has to do with prescrapping procedures. Adishmachine is not a garbage disposal; any large pieces of mate­rial that are put into the machine shall remain in the machine until they are either broken up (after spreading out on your ware!)
or physically removed. Strainers are installed to help catch debris, but they do no good of they are clogged. Have operators
regularly inspect the pan strainers to ensure (1) that they are free of soil and debris and (2) they are laying flat in the tub.

When cleaning out strainers, do NOT beat them on waste cans. The strainers are made of metal and can be forgiving; but once
severe damage is done, it is next to impossible for the strainer to work in the way it was designed to. Wipe out strainers with
a rag and rinse under a faucet if necessary. For stubborn debris, a toothpick should be able to dislodge any obstructions from
the perforations. Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub.

You may wish to also refer to the page entitled “Detergent Control” in order to learn more about how your water hardness will
effect the performance of your machine. Hard water makes dishmachines work harder and decreases efficiency.

Again, it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larg­er problems or even cause harm to the operator. If a problem is discovered; secure the dishmachine using proper shut down
procedures as listed in this manual and contact Jackson.

Some problems, however, may having nothing to do with the machine itself and no amount of preventative maintanence is
going to help. Acommon problem has to do with temperatures being too low. Verify that the water temperatures coming to your
dishmachine match the requirements listed on the machine data plate. There can be a variety of reasons why your water tem­perature could be too low and you should discuss it with Jackson to determine what can be done.

By following the operating and cleaning instructions in this manual, you should get the most efficient results from your machine.
As a reminder, here are some steps to take to ensure that you are using the dishmachine the way it was designed to work:

1. Ensure that the water temperatures match those listed on the machine data plate.

2. Ensure that all strainers are in place before operating the machine.

3. Ensure that all wash and/or rinse arms are secure in the machine before operating.

4. Ensure that drains are closed/sealed before operating.

5. Remove as much soil from dishes by hand as possible before loading into racks.

6. Do not overfill racks.

7. Ensure that glasses are placed upside down in the rack.

8. Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations.

9. Clean out the machine at the end of every workday as per the instructions in the manual.

10. Always contact Jackson whenever a serious problem arises.

11. Follow all safety procedures, whether listed in this manual or put forth by local, state or national codes/regulations.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 3: PREVENTATIVE MAINTENANCE

PREVENTATIVE MAINTENANCE

45

WARNING: Maintenance should only be performed by authorized service personnel in order to ensure safe and

effective workmanship, while minimizing danger to operating personnel. The D226 Steam Booster is designed
to operate at temperatures capable of causing burns to personnel. Always allow the unit to cool down to an accept­able temperature prior to performing any maintenance.

Very little maintenance is required to be performed on the D226 Booster. So long as the steam and water used with the unit
have the proper filtration and are operated at the correct temperature and pressures, then you should expect many years of
reliable service out of your system.

MAINTENANCE OF THE W

ATER PRESSURE REGULATOR:

Incoming water pressure can be regulated by adjusting the water pressure regulator on the system. In order to adjust pressure,
loosen the top nut on the regulator. This will allow you to turn the adjusting screw. Turn the adjusting screw clockwise to
increase pressure and counter-clockwise to decrease. Pressure can be read on the pressure gauge located on the water out­let side of the heat exchanger. Once the desired pressure is achieved, tighten the top nut to ensure that the adjustment can­not be accidently changed.

The water pressure regulator has an internal strainer that can be removed through the bottom hexagonal plug. This may need
to be periodically checked depending on the water quality. It is important that the water supply to the water pressure regulator
be secured prior to trying to clean the strainer.

MAINTENANCE OF THE RELIEF V

ALVES, SAFETY VALVES AND THERMOSTAT:

These components are shipped from the factory preset and should not be tampered with. None of these components are con­sidered adjustable and no attempt should be made to do so. If a component does not appear to be working properly, then it
should be replaced immediately by an authorized service representative.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

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SECTION 3: PREVENTATIVE MAINTENANCE

D226 MAINTENANCE

46

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SECTION 3: PREVENTATIVE MAINTENANCE

47

LUBRICATION CHART FOR DRIVE GEAR

Note: The maintenance procedures detailed here are manufacturer’s instructions for the WINSMITH brand of gear reducer
that is installed on the rack conveyors covered in this manual.

Ambient Temperature -30 - 15°F 16 - 50°F 51 - 95°F 51 - 95°F 96 - 131°F 96 - 131°F
Final Stage Worm Speed

1

up to 2000 FPM up to 2000 FPM up to 450 FPM above 450 FPM up to 450 FPM above 450 FPM

ISO Viscosity Grade 220 460 680 460 680 460

1

AGMA Lubricant No. 5S #7 Compounded #8 Compounded #7 Compounded 8S 7S
Mobil SHC 630 600W Super Extra Hecla Super 600W Super SHC 636 SHC 634

Cylinder Cylinder
American Lubricants SHC-90W AGMA #7 Gear Oil AGMA #8 Gear Oil AGMA #7 Gear Oil N/A N/A
Castrol Tribol 800/220 Tribol 1105-7C Tribol 1105-8C Tribol 1105-7C Tribol 800/680 Tribol 800/460
Chevron Tegra 220 Cylinder Oil W460 Cylinder Oil W680 Cylinder Oil W460 Tegra 680 Tegra 460
Conoco Syncon R & O Inca Oil 460 Inca Oil 680 Inca Oil 460 N/A Syncon R & O

220 460

Exxon (Esso) Teresstic SHP220 Spartan EP 460 Spartan EP 680 Spartan EP 460 Teresstic SHP680 Teresstic SHP

460
Fiske Brothers SPO-MG SPO-277 SPO-288 SPO-277 N/A N/A
Shell Omala RL 220 Valvata J 460 Valvata J 680 Valvata J 460 Omala RL 680 Omala RL 460
Texaco Pinnacle 220 Vanguard 460 Vanguard 680 Vanguard 460 Pinnacle 680 Pinnacle 460

(1) The sliding velocity in feet per minute (FPM) for standard ratios is determined by multiplying the speed of the worm in RPM by
the factor from the table below. For selecting proper lubricant, use the speed of the worm in the final stage (input RPM divided by
the first stage ratio).

Note: The maintenance procedures detailed here are manufacturer’s instructions for the WINSMITH brand of gear reducer that
is installed on the rack conveyors covered in this manual.

Lubrication & Maintenance:
Factory filling - WINSMITH speed reducers are oil filled at the factory to the proper level for the standard mounting position that you

will find it in on the unit. The oil level should be checked and adjusted (if necessary) prior to operation, using the oil level plug provided
and while the unit is oriented in its operating position.

Ambient temperature - If the operating ambient temperature is other than 51 - 95°F, then refer to the lubrication chart and refill the unit
with the correct grade based on actual ambient temperature and operating speed. See “Oil changing” below for additional information.

Oil changing - When changing the oil for any reason, it should be remembered that oils of various types may not be compatible.
Therefore, when changing to a different oil, it is recommended that the housing be completely drained and thoroughly flushed with a
light flushing oil prior to refilling with the appropriate lubricant. The oil level should be rechecked after a short period of operation and
adjusted, if necessary. When changing double reduction models, each housing should be drained and filled independently, even though
there may be a common level.

Initial oil change: The new oil in a speed reducer should be changed at the end of 250 hours of operation. This is equivalent

to 30 days of peration for 8 hours per day; 15 days of operation for 16 hours per day, or 10 days of operation for 24 hours per day.

Subsequent oil changes: Under normal conditions, after the initial oil change, the oil should be changed after every 2500
hours of operation, or every 6 months, whichever occurs first. Under severe conditions (rapid temperature changes, moist, dirty or cor­rosive environment) it may be necessary to mchange oil at intervals of one to three months. Periodic examination of oil samples taken
from the unit will help establish the appropriate interval.

Synthetic oils: Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable, have a much
longer life, and operate over a wider temperature range. These oils are appropriate for any application but are especially useful when
units are subjected to low start-up temperatures or high operating temperatures. However , continuous operation above 225°F may cause
damage to seals or other components. It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation
to remove metal particles that accumulate during break-in. Subsequent oil changes should be made after 5000 hours operation if units
are operating in a clean environment. This can be extended to 10,000 hours if using new reformulated Mobil SHC lubricants (orange in
color) and the lubricant remains free of contamination over this period. See comments under “Subsequent oil changes” for discussion
of severe ambient conditions.

Long term storage or infrequent operation: If a speed reducer is to stand idle for an extended period of time, either prior to
installation or during use, it is recommended that the unit be filled completely with oil to protect interior parts from rust and corrosion due
to internal condensation. Be sure to drain the oil to the proper level before placing the speed reducer in service.

Grease fittings: Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash.
These fittings must be lubricated every 3 - 6 months depending on operating conditions. bearing greases must be compatible with the
type of gear lubricant being used (i.e. mineral, synthetic, food grade, etc.). For mineral oils, use a high quality lithium base NLGOI #2
bearing grease. For synthetic oils, use a synthetic bearing grease such as Mobil Synthetic Universal gease, Mobilith SHC 100 or a
sutable equivalent. For food grade lubricants, use Chevron FM grease, NGLI 2, or equivalent.

Low input speeds (under 1600 RPM): When input speeds are less than 1600 RPM, grease fittings will be required to lubri­cate any bearings not partially covered by the normal oil level.

Oil temperature: Speed reducers in normal operation can generate temperatures up to 200°F depending on the type of reduc­er and the severity of the application 9loading, duration of service, ambient temperatures). Excessive oil temperatures may be the result
of several factors including overloading, overfilling, underfilling or inadequate cooling.

Nominal Ratio

Size 5 7.5 10 15 20 25 30 40 50 60 80 100

920 0.347 0.263 0.225 0.216 0.202 0.191 0.215 0.200 0.188 0.182 0.164 0.161
Lubricant selections are provided by the lubricant manufacturer based on AGMA recommeded viscosity grades. Viscosity grades are

based on Lubrication Standard ANSI/AGMA 9005-D94.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

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48

DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE

49

SECTION 4:

TROUBLESHOOTING SECTION

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COMMON PROBLEMS

50

WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service per-

sonnel. 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 reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker.

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 ±5 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 ±5 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.

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SECTION 4: TROUBLESHOOTING

COMMON PROBLEMS

51

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.

6. Inadequate rinse.

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.

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

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 4: TROUBLESHOOTING

D226 TROUBLESHOOTING SECTION

52

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 reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker.

Problem: Power light does not illuminate.

1. Power not connected to the unit through the control box. Open the control box cover and verify that incoming power lines
are connected and light.

2. Service breaker tripped or open. Verify that the breaker is closed.

3. Power switch connections could be loose. Ensure that the connections are of sound quality.

4. Power switch is faulty. Replace the power switch.

5. Power light is faulty. Replace the light.

Problem: Water pressure is too low.

1. Water pressure regulator is out of adjustment. Follow the instructions provided in the maintenance section and adjust so that
the flow pressure is 20 ±5 PSI.

2. Water pressure regulator internal strainer is clogged. Clean in accordance with the instructions provided in the maintenance
section.

3. Water pressure regulator is faulty. Replace the regulator.

4. Water pressure gauge is faulty or the cut off from the system. Verify that the test cock valve under the gauge is open to allow
for the sensing of line pressure. Replace gauge if necessary.

5. Heat exchanger is clogged. Replace the heat exchanger.

Problem: Solenoid valve is not opening/shutting.

1. Power not connected to the unit through the control box. Open the control box cover and verify that incoming power lines
are connected and light.

2. Service breaker tripped or open. Verify that the breaker is closed.

3. Power switch connections could be loose. Ensure that the connections are of sound quality.

4. Power switch is faulty. Replace the power switch.

5. Thermostat is faulty. Replace the thermostat.

6. Solenoid wires are loose or broken. Verify that the electrical connections are of sound quality.

7. Faulty solenoid coil. Replace the solenoid.

Problem: Outlet water temperature too low.

1. Power not connected to the unit through the control box. Open the control box cover and verify that incoming power lines
are connected and light.

2. Service breaker tripped or open. Verify that the breaker is closed.

3. Power switch connections could be loose. Ensure that the connections are of sound quality.

4. Power switch is faulty. Replace the power switch.

5. Thermostat is faulty. Replace the thermostat.

6. Solenoid wires are loose or broken. Verify that the electrical connections are of sound quality.

7. Faulty solenoid coil. Replace the solenoid.

8. Steam flow pressure is too low for the unit. Verify that the steam flow is 15-25 PSIG.

9. Water flow pressure is too high. Follow the instructions provided in the maintenance section and adjust so that the flow pres­sure is 20 ±5 PSI.

10. Heat exchanger is clogged. Replace the heat exchanger.

11. Insufficient volume of steam to unit. Check the line size and flow pressure.

53

SECTION 5:

PARTS SECTION

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SECTION 5: PARTS SECTION

54

AJ-64 CONTROL BOX ASSEMBLY

1

2

3, 4, 5

6a

6b

4, 7, 10, 11, 12

8

4, 9, 10

14c

14b

14a

15
16a

17

16b

18

20, 21

22, 23

24, 25, 26

26, 27

26, 28

29

32

31

30

13, 26

19, 26

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SECTION 5: PARTS SECTION

55

AJ-64 CONTROL BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Electrical Box Weldment 05700-041-88-50
2 1 Decal, L1-L2-L3 09905-101-12-66
3 1 Terminal Block 05940-011-48-27
4 6 Lockwasher, #10 05311-273-02-00
5 2 Screw, 10-32 x 3/4” Long Phillips Trusshead 05305-011-62-17
6a 1 Light, Amber (Wash Heater Overload) (Not used on steam or gas models) 05945-111-44-44
6b 1 Light, Amber (Rinse Heater Overload) (Not used on steam or gas models) 05945-111-44-44
7 1 Wire Lug, 2 AWG to 14 AWG 05940-200-76-00
8 1 Light, Red (Power) 05945-111-44-45
9 1 Din Rail 05700-021-72-75
10 3 Screw, 10-32 x 1/2” Long Phillips Trusshead 05305-011-39-36
11 1 Washer, Flat, 1/4” 05311-174-01-00
12 1 Decal, Ground 09905-011-86-86
13 1 Terminal Board 05940-002-78-97
14a 1 Drive Motor Contactor 05945-111-68-38
14b 1 Wash Pump Motor Contactor 05945-111-68-38
14c 1 Recirculating Rinse Pump Motor Contactor 05945-111-68-38
15 1 Circuit Breaker (208 & 230 volt models only) 05925-011-68-34
16a 1 Recirculating Rinse Pump Motor Overload (See motor overloads chart) N/A
16b 1 Wash Pump Motor Overload (See motor overloads chart) N/A
17 1 Switch, ON/FILL & OFF/DRAIN 05930-011-49-55
18 1 Drive Motor Overload (See motor overloads chart) N/A
19 1 Terminal Board 05940-021-89-41
20 2 Heater Contactor (Not available on steam or gas models) 05945-002-24-70
21 2 Screw, 10-32 x 3/8” Long Phillips Trusshead 05305-173-12-00
22 1 Transformer 05950-011-68-35
23 4 Locknut, 10-24 with Nylon Insert 05310-373-01-00
24 1 Fuse Holder (460 volt models only) 05920-011-72-89
25 1 Fuse (460 volt models only) 05920-011-72-88
26 12 Screw, 6-32 x 3/8” Long Phillipshead 05305-171-02-00
27 4 Control Relay, 2 Pole 05945-111-35-19
28 1 Relay, 3 Pole 05945-111-72-51
29 1 Rinse Thermometer 06685-111-68-49

Decal, Rinse 180°F 09905-002-97-62

30 1 Wash Thermometer 06685-111-87-13

Decal, Wash 150°F 09905-002-97-61

31 1 Power Rinse Thermometer 06685-111-87-13

Decal, Power Rinse 160°F 09905-003-01-31

32 1 Decal, Gauge 09905-021-82-65

Items not shown:

Grommet, 1/2” OD x 3/8” ID 05325-011-46-73
Bushing, Heyco SB100 05975-210-09-00
Plug, Heyco 2700 G-875 05975-011-47-81
Control Box Cover 05700-031-66-88
Control Box Cover Hinge Weldment 05700-021-68-57
Control Hinge Rod 05700-011-68-58
MANUAL/DELIME Switch (Located on rear of contol box) 05930-301-22-18
MANUAL/DELIME Decal 09905-011-74-61
Copper Conductors Only Decal 09905-011-47-35
Control Box Leg 05700-011-71-47

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SECTION 5: PARTS SECTION

56

AJ-86 & AJ-100 CONTROL BOX ASSEMBLY

1

2

6b

4, 7, 10, 11, 12

3, 4, 5

6a

8
16b

14d

14c

14b

14a

15

18

17

16a

18

20, 21

22, 23

24, 25, 26

29a

29b

13, 26

30a

30b

26, 28

26, 27

19, 26

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SECTION 5: PARTS SECTION

57

AJ-86 & AJ-100 CONTROL BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Electrical Box Weldment 05700-041-88-50
2 1 Decal, L1-L2-L3 09905-101-12-66
3 1 Terminal Block 05940-011-48-27
4 6 Lockwasher, #10 05311-273-02-00
5 2 Screw, 10-32 x 3/4” Long Phillips Trusshead 05305-011-62-17
6a 1 Light, Amber (Wash Heater Overload) (Not used on steam or gas models) 05945-111-44-44
6b 1 Light, Amber (Rinse Heater Overload) (Not used on steam or gas models) 05945-111-44-44
7 1 Wire Lug, 2 AWG to 14 AWG 05940-200-76-00
8 1 Light, Red (Power) 05945-111-44-45
9 1 Din Rail 05700-021-94-96
10 3 Screw, 10-32 x 1/2” Long Phillips Trusshead 05305-011-39-36
11 1 Washer, Flat, 1/4” 05311-174-01-00
12 1 Decal, Ground 09905-011-86-86
13 1 Terminal Board 05940-002-78-97
14a 1 Drive Motor Contactor 05945-111-68-38
14b 1 Wash Pump Motor Contactor 05945-111-68-38
14c 1 Recirculating Rinse Pump Motor Contactor 05945-111-68-38
14d 1 Prewash Pump Motor Contactor 05945-111-68-38
15 1 Circuit Breaker (208 & 230 volt models only) 05925-011-68-34
16a 1 Recirculating Rinse Pump Motor Overload (See motor overloads chart) N/A
16b 1 Wash Pump Motor Overload (See motor overloads chart) N/A
17 1 Switch, ON/FILL & OFF/DRAIN 05930-011-49-55
18 1 Drive Motor Overload (See motor overloads chart) N/A
19 1 Terminal Board 05940-021-89-41
20 2 Heater Contactor (Not available on seam models) 05945-002-24-70
21 2 Screw, 10-32 x 3/8” Long Phillips Trusshead 05305-173-12-00
22 1 Transformer 05950-011-68-35
23 4 Locknut, 10-24 with Nylon Insert 05310-373-01-00
24 1 Fuse Holder (460 volt models only) 05920-011-72-89
25 1 Fuse (460 volt models only) 05920-011-72-88
26 12 Screw, 6-32 x 3/8” Long Phillipshead 05305-171-02-00
27 7 Control Relay, 2 Pole (5 for Gas models, 1 not shown) 05945-111-35-19
28 3 Relay, 3 Pole (Gas models only) 05945-111-72-51
29a 1 Rinse Thermometer, 96” (L-R & R-Lmodels) 06685-111-68-49

Decal, Rinse 180°F 09905-002-97-62
29b 1 Power Rinse Thermometer, 96” (L-R models) 06685-111-68-49
29b 1 Power Rinse Thermometer, 120” (R-Lmodels) 06685-111-87-13

Decal, Power Rinse 160°F 09905-003-01-31
30a 1 Wash Thermometer, 120” (L-R models) 06685-111-87-13
30a 1 Wash Thermometer, 96” (R-L models) 06685-111-68-49

Decal, Wash 150°F 09905-002-97-61
30b 1 Prewash Thermometer, 120” (L-R & R-Lmodels) 06685-111-87-13
31 1 Power Rinse Thermometer 06685-111-87-13

Decal, Power Rinse 160°F 09905-003-01-31
32 1 Decal, Gauge 09905-021-82-65

Items not shown:

Grommet, 1/2” OD x 3/8” ID 05325-011-46-73
Bushing, Heyco SB100 05975-210-09-00
Plug, Heyco 2700 G-875 05975-011-47-81
Control Box Cover 05700-031-66-88
Control Box Cover Hinge Weldment 05700-021-68-57
Control Hinge Rod 05700-011-68-58
MANUAL/DELIME Switch (Located on rear of contol box) 05930-301-22-18
MANUAL/DELIME Decal 09905-011-74-61
Copper Conductors Only Decal 09905-011-47-35
Control Box Leg 05700-011-71-47

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SECTION 5: PARTS SECTION

58

MOTOR OVERLOADS

AJ-64 SERIES MOTOR OVERLOAD CHART:

208-230V/60 HZ/1 PHASE 208-230V/60 HZ/3 PHASE 460V/60 HZ/3 PHASE
Drive Motor Not Applicable 05945-111-68-39 05945-111-69-12
PreWash Motor Not Applicable Not Applicable Not Applicable
Wash Motor Not Applicable 05945-111-68-40 05945-111-68-41
Power Rinse Motor Not Applicable 05945-111-68-40 05945-111-68-41

AJ-86 SERIES MOTOR OVERLOAD CHART:

208-230V/60 HZ/1 PHASE

208-230V/60 HZ/3 PHASE 460V/60 HZ/3 PHASE
Drive Motor Not Applicable 05945-111-68-39 05945-111-69-12
PreWash Motor Not Applicable 05945-111-68-41 05945-111-69-13
Wash Motor Not Applicable 05945-111-68-40 05945-111-68-41
Power Rinse Motor Not Applicable 05945-111-68-40 05945-111-68-41

AJ-100 SERIES MOTOR OVERLOAD CHART:

208-230V/60 HZ/1 PHASE

208-230V/60 HZ/3 PHASE 460V/60 HZ/3 PHASE
Drive Motor Not Applicable 05945-111-68-39 05945-111-69-12
PreWash Motor Not Applicable 05945-111-68-40 05945-111-68-41
Wash Motor Not Applicable 05945-111-68-40 05945-111-68-41
Power Rinse Motor Not Applicable 05945-111-68-40 05945-111-68-41

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SECTION 5: PARTS SECTION

59

ITEM QTY DESCRIPTION Mfg. No.

1 1 Heater Box Cover 05700-031-81-61
2 1 Kit, Thermostat, Wash Regulating (Electrically Heated) 06401-003-18-20
2 1 Kit, Thermostat, Wash Regulating (Steam Heated) 06401-003-18-21
3 1 Thermostat, High Limit 05930-011-49-43
4 1 Terminal Board 05940-002-78-97
5 1 Fitting, 1/4”, Imperial Brass 05310-924-02-05
6 1 Heater Box Weldment 05700-002-41-18

HEATER BOX ASSEMBLY

1

See Heater Assembly Page

6

5

3

2

4

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SECTION 5: PARTS SECTION

60

HEATER ASSEMBLY

Heater Chart

Model Volts Phase KW Part Number

All* 208 1 10 06401-003-12-94

230 1 10 06401-003-12-95
208 3 10 06401-003-12-94
230 3 10 06401-003-12-95
460 3 10 06401-003-12-96

Heater Chart

Model KW 208V Models 230V Models 460V Models
All* 15 04540-121-68-45 04540-121-68-46 04540-121-68-47
* - “CS” & “CGP” models do not use electric heaters in the wash tank or power rinse tank.
SERVICE NOTE: When replacing the tub heaters, it is HIGHLY recommended that you also change out the gasket as well.

Once installed, gaskets become compressed and are subjected to extreme temperature changes. Replacing the gasket with a
new one when replacing the heater may prevent future leaks.

SERVICE NOTE: The nuts used to secure the heater to the tub should be torqued to 16 in-lbs. After tightening, the unit should
be allowed to heat up and operate normally for approximately 30 minutes. Secure power to the machine and check the nuts
once more to ensure that they are torqued to 16 in-lbs.

See Heater Chart Below

Heater Gasket
05330-011-47-79

5/16” Lockwasher

05311-275-01-00

5/16”-18 Hex Nut
05310-275-01-00

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

61

HEATER ASSEMBLY (CONTINUED)

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° F.(preferably about 130°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 connections.
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 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.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

62

FRAME WELDMENTS/DRESS PANELS

FRAME WELDMENTS

Model Left to Right Part Number Right to Left Part Number
AJ-64’s 05700-002-73-00 05700-002-73-00

AJ-86’s 05700-041-83-65 05700-041-83-65
AJ-86CGP 05700-041-83-65 05700-041-83-65
AJ-100’s 05700-041-91-00 05700-041-91-00
AJ-100CGP 05700-041-91-00 05700-041-91-00

Bullet Feet (4 per model) - order using part number 05340-011-71-74.

FRONT DRESS PANELS

Model Left to Right Part Number Right to Left Part Number
AJ-64’s 05700-002-40-41 05700-002-40-41

AJ-86’s 05700-031-83-68 05700-041-86-60
AJ-86CGP 05700-002-89-68 05700-041-86-60
AJ-100’s 05700-041-94-89 05700-041-91-06
AJ-100CGP 05700-041-94-89 05700-041-91-06

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

63

PREWASH PLUMBING ASSEMBLY

Y-Strainer, 3/4” NPT,

Brass

04730-717-02-06

Nipple, 3/4”, Brass, Close

04730-207-34-00

Valve, Solenoid, 3/4”

04810-100-53-00

Nipple, 3/4”, Brass, Close

04730-207-34-00

Vacuum Breaker, 3/4”

04820-002-53-77

Elbow, 90°, 3/4” Brass

04730-206-04-34

Elbow, 90°, 3/4” Brass

04730-206-04-34

Nipple, 3/4” x 6” Long
05700-001-26-74

Fill Line Injector

05700-011-67-99

A new gasket can be
ordered using part num­ber 05330-111-42-81.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

64

INCOMING PLUMBING ASSEMBLY (ELECTRIC & GAS HEATED MODELS)

1

2

3

7

7

4

4

7

4

5

5

5

5

6

6

6

6

6

6

8

8

8

9

9

9

9

10

10

11

12

12

13

13, 14

14, 15, 16

17

17

18

19

19a

20

21

22

22

2

For the CGP models, an

elbow replaces the regulator.

For the CGP models,

an elbow replaces the

regulator.

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

65

INCOMING PLUMBING ASSEMBLY(CONTINUED)

ITEM QTY DESCRIPTION Mfg. No.

1 1 Injector, Rinse Weldment (L-R all units) 05700-021-67-98
1 1 Injector, Rinse Weldment (R-L CGP units only) 05700-002-57-87
2 2 Fill Line, Injector 05700-011-67-99
3 3 Plug, 1/8” NPT, Brass 04730-209-07-37
4 3 Vacuum Breaker, 3/4” NPT, Brass 04820-002-53-77
5 5 Elbow, 3/4” NPT, Street, Brass 04730-206-04-34
6 6 Nipple, 3/4” NPT, Close, Brass 04730-207-34-00
7 3 Valve, Solenoid, 3/4” NPT, 110 Volt 04810-100-53-00
8 3 Union, 3/4” NPT, Brass 04730-212-05-00
9 4 Adapter, 3/4” Male 04730-401-11-01
10 2 Tee, Copper, 3/4” CU x CU x CU 04730-411-46-01
11 1 Tube, Copper, 3/4” x 3” Long 05700-000-54-85
12 2 Nipple, 3/4” NPT, Brass, 6” Long 05700-001-26-74
13 2 Tee, Copper, 3/4” x 3/4” x 1/2” 04730-411-03-01
14 2 Adapter, Threaded, 1/4” 04730-401-41-01
15 1 Valve, Ball, Test Cock, 1/4” NPT 04810-011-72-67
16 1 Gauge, 0-100 PSI 06685-111-88-34

1 Decal, 15-25 PSI 09905-002-97-74
17 2 Tube, 3/4” x 2-13/16” Long 05700-011-72-72
18 1 Plug, 1/4” 04730-209-01-00
19 1 Regulator, Pressure, 3/4” NPT (Not used on CGP models) 06685-011-58-22
19a 1 Elbow, 3/4” 90° Brass (Used on CGP models only) 04730-206-13-00
20 1 Tube, 3/4” x 9” Long 05700-000-75-61
21 1 Tube, 3/4” x 16-1/4” Long 05700-011-31-48
22 2 Tube, 3/4” x 5-1/2” Long 05700-002-61-46

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

66

RINSE HEADER PLUMBING ASSEMBLY (CGP MODELS)

Complete Plumbing Assembly
05700-002-51-16

Incoming Piping Assembly

05700-002-51-15

Incoming Plumbing Support Bracket

05700-002-50-70

Nipple, 3/4” Close Brass

04730-207-34-00

Solenoid Valve, 3/4” 110V
04810-100-53-00

Valve, 3/4” Pressure Reducing
04820-002-51-53

Y-Strainer, 3/4” Brass

04730-717-02-06

Inlet Plumbing Mounting Bracket
2 per
05700-002-51-41

Clamp, Pipe

2 per

05700-000-35-06

Elbow, 3/4” NPT 90° Brass
04730-206-13-00

Nipple, 3/4” Close Brass
04730-207-34-00

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

67

EXTERNAL ELECTRIC BOOSTER INCOMING PLUMBING ASSEMBLIES

ITEM QTY DESCRIPTION Mfg. No.

1 - Y-Strainer, 3/4” NPT, Brass 04730-717-02-06
2 - Arrestor, Water Hammer, 1/2” NPT 06685-100-05-00
3 - Regulator, Pressure, 3/4” NPT, Brass 06685-011-58-22
4 - Nipple, 3/4” NPT x 2” Long, Brass 04730-207-46-00
5 - Elbow, Brass, 90°, 3/4” 04730-206-13-00
6 - Nipple, 3/4” NPT, Close, Brass 04730-207-34-00
7 - Coupling, 3/4” FNPT x 3/4” FNPT, Brass 04730-011-87-95
8 - Adapter, 3/4” Male 04730-401-11-01
9 - Tube, Copper, 3/4” x 3-7/16” Long 05700-011-72-70
10 - Adapter, 1/2” NPT x Male 04730-401-07-01
11 - Tee, Copper, 3/4” x 3/4” x 1/2” 04730-411-03-01

1

8

9

11

9

8

2

10

3

4

5

6

7

1

3

4

7

5

6

Plumbing with Water Hammer Arrestor

Plumbing without Water Hammer Arrestor

6

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

68

EXTERNAL ELECTRIC BOOSTER OPTION OUTLET PLUMBING

Elbow, Brass, 90°, 3/4”

04730-206-13-00

Nipple, 3/4” NPT x 2” Long, Brass

04730-207-46-00

Union, 3/4” NPT, Brass

04730-212-05-00

Adapter, 3/4”, Brass

04730-401-11-01

Tube, Copper, 3/4” x 24” Long

05700-021-76-53

Elbow, 3/4” Copper to Copper (Female)

04730-406-16-01

Tube, Copper, 3/4” x 49-1/2” Long

05700-031-87-98

Elbow, 3/4” Copper to Copper (Female)

04730-406-16-01

Elbow, 3/4”, 90°, Street, Copper to Copper

04730-406-40-01

Tube, Copper, 3/4” x 5-7/8” Long
05700-011-87-96

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

69

WATER HAMMER ARRESTOR OPTION/WATER PRESSURE REGULATOR KIT OPTION

Nipple, 3/4” NPT,

Close, Brass

04730-207-34-00

Water Arrestor, 1/2” NPT
06685-100-05-00

Tee, 3/4” x 3/4” x 1/2”
04730-211-06-00

Water Arrestor, 1/2” NPT
06685-100-05-00

Bushing, 3/4” x 1/2”
04730-002-01-34

Tee, Brass, 3/4” x 3/4” x 3/4”
04730-211-01-34

Nipple, Close, 3/4”

04730-207-34-00

Regulator, Pressure, 3/4”

06685-011-58-22

WATER PRESSURE REGULATOR WITH ARRESTOR KIT OPTION

WATER HAMMER ARRESTOR OPTION

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

70

RINSE SOLENOID VALVE & VACUUM BREAKER REPAIR PARTS KITS

Complete 110 Volt Solenoid Valve Assembly, 3/4”

04810-100-53-00

Coil & Housing only, 3/4”

04810-200-01-18

Possible Problems:

1. Pilot port extension #1 clogged. Clean hole.

2. Hole #2 Clogged. Pass heated straight pin through hole.

DISASSEMBLY - These valves may be taken apart by
unscrewing the bonnet and the enclosing tube assembly from
the valve body assembly. After unscrewing, carefully lift off the
bonnet and enclosing tube assembly. Don’t drop the plunger.
The o-ring seal and diaphragm cartridge can now be lifted out.
Be careful not to damage the machined faces while the valve
is apart.

TO REASSEMBLE - Place the diaphragm cartridge in the
body with the pilot port extension UP. Hold the plunger with
the synthetic seat against the pilot port. Make sure the o-ring
is in place, then lower the bonnet and enclosing tube assem­bly over the plunger. Screw the bonnet assembly snugly down
on the body assembly.

Screw

Data Plate

Coil & Housing

Valve Bonnet

Spring
06401-003-07-40

Plunger
06401-003-07-40

Spring position is moved
for clarity.
Goes below the plunger.

O-Ring
06401-003-07-42

Diaphragm

Retainer

Diaphragm
06401-003-07-42

Screen

Retainer

Mesh Screen

Valve Body

Components of

Repair Kit

06401-003-06-24

Cap Screw

Data Plate

Cap

O-Ring

Plunger

Body

Cap Retainer

1

2

Complete Vacuum Breaker Assembly, 3/4” NPT

04820-002-53-77

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

71

WASH TANK COIL ASSEMBLY

WASH TANK COIL ASSEMBLY

(LEFT TO RIGHT) (05700-041-88-31)

Coil Weldment
05700-031-88-30

Stand “A” Weldment
05700-002-74-82

Stand “C” Weldment

05700-002-74-84

Coil Nut

05310-011-17-85

Flat Washer

05700-001-17-87

Coil Gasket
05700-001-17-86

SERVICE NOTE: Jackson HIGHLY recom­mends that the Coil Gaskets be replaced
any time the Coil Weldment is replaced or
removed for an extended period of time.

WASH TANK COIL ASSEMBLY

(RIGHT TO LEFT) (05700-002-81-44)

Coil Weldment

05700-031-88-30

Stand “a” Weldment

05700-002-74-82

Coil Gasket
05700-001-17-86

Coil Nut

05310-011-17-85

Flat Washer

05700-001-17-87

Stand “A” Weldment
05700-002-74-82

AJ-64 Conveyor Series Technical Manual 7610-003-30-93

Issued: 05-02-2006 Revised: N/A

SECTION 5: PARTS SECTION

72

STEAM INLET PLUMBING ASSEMBLY (LEFT TO RIGHT MODELS)

1

2

3

4

5

15

14

8

10

10

9

8

10

11

12
10

13

11
12

13

12

10

12

11

7

11

10 6

9

12

16

9