Jackson RackStar Series Installation, Operation & Service Manual
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Jackson RackStar Series Installation, Operation & Service Manual

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INSTALLATION, OPERATION,
AND SERVICE MANUAL
®
RACKSTAR SERIES CONVEYOR DISHMACHINES
RackStar Manual • 07610-004-33-05-E

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Summary of Contents for Jackson RackStar Series

  • Page 1 INSTALLATION, OPERATION, AND SERVICE MANUAL ® RACKSTAR SERIES CONVEYOR DISHMACHINES RackStar Manual • 07610-004-33-05-E...
  • Page 2 ONE YEAR LIMITED PARTS AND LABOR WARRANTY For a period of one (1) year from date of original installation of a new Jackson Dishmachine (but in no event to exceed eighteen (18) months from date of shipment from Jackson’s factory), Jackson WWS, Inc. (Jackson) will repair or replace, at its discretion, any original part that proves defective in materials or workmanship at the time the Dishmachine was purchased;...
  • Page 3 MANUFACTURER'S LIMITED WARRANTY (CONT.) (APPLICABLE ONLY IN THE UNITED STATES AND CANADA) PRODUCT CHANGES: Jackson reserves the right to make changes in design and specification of any component of the Dishmachine as engineering or necessity requires. DISCLAIMER OF WARRANTIES: THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, THAT ARE NOT SET FORTH HEREIN, OR THAT EXTEND BEYOND THE DURATION HEREOF.
  • Page 4 REVISION HISTORY Revision Revision Made Applicable Details Letter Date ECNs 9-21-16 Initial release of manual. Corrected delime instructions. Corrected P/Ns for item #6 on pg. 42. Updated pg. 13 to change the pressure regulator from standard to optional. 10-25-16 Updated Miscellaneous Electrical Components page. Added a Door Assemblies page.
  • Page 5 NOMENCLATURE RackStar ® RackStar ® Electrically-heated rack conveyor machine, available in chemical-sanitizing and hot-water-sanitizing models. RackStar 44ER ® RackStar 66ER ® Electrically-heated, hot-water-sanitizing rack conveyor machine with Energy Recovery System. The manufacturer provides RackStar ® technical support for all of the dishmachines detailed RackStar ®...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS GUIDES Symbols ............................1 Abbreviations & Acronyms ......................1 SPECIFICATIONS Electric/Steam Dimensions ......................2 Energy Recovery Dimensions ....................6 Side-loader Dimensions......................10 Steam Booster Dimensions ......................11 Operating Parameters ......................12 Electrical Requirements ......................14 INSTALLATION Installation Instructions ......................19 Inspection........................19 Unpacking ........................19 Leveling..........................
  • Page 7 TABLE OF CONTENTS OPERATION Ware Preparation ......................27 Washing a Rack of Ware ....................27 Operational Inspection ....................27 Shutdown & Cleaning ....................28 Display Instructions ......................29 Delime Instructions ......................30 MAINTENANCE Preventative Maintenance ......................31 TROUBLESHOOTING Troubleshooting ........................32 Programming ..........................
  • Page 8 TABLE OF CONTENTS PARTS Side-loaders..........................65 Side-loader Drive Linkage ......................68 Steam Coil ........................69 Booster Heater (Electric) ......................70 Booster Heater Add-on Kit (Electric) ..................71 Frame ............................72 Doors ............................73 Energy Recovery System ......................74 Miscellaneous/Options ......................76 SCHEMATICS 208/230 V, 50/60 Hz, 3-Phase ....................

  • Page 9: Symbols

    GUIDES GUIDES SYMBOLS - Risk of Injury to Personnel WARNING - Risk of Damage to Equipment CAUTION - Risk of Electrical Shock - Caustic Chemicals - Reference Data Plate - Lockout Electrical Power - Important Note NOTICE  - Instructions Hyperlink ABBREVIATIONS &...

  • Page 10: Specifications

    44" ELECTRIC/STEAM DIMENSIONS SPECIFICATIONS 44" LEFT-TO-RIGHT LEGEND 22 1/2 A - Electrical Connection [572 mm] [305 mm] B - Main Water Inlet (1/2" NPT, 110 °F MIN (18 kW Booster), 140 °F MIN (12 kW Booster), or 180 °F MIN (No Booster or Supplied from Steam Booster))
  • Page 11 44" ELECTRIC/STEAM DIMENSIONS SPECIFICATIONS 44" RIGHT-TO-LEFT LEGEND 22 1/2 A - Electrical Connection [305 mm] [572 mm] B - Main Water Inlet (1/2" NPT, 110 °F MIN (18 kW Booster), 140 °F MIN (12 kW Booster), or 180 °F MIN (No Booster or Supplied from Steam Booster))
  • Page 12 66" ELECTRIC/STEAM DIMENSIONS SPECIFICATIONS 66" LEFT-TO-RIGHT LEGEND 39 3/4 [1009 mm] A - Electrical Connection 4 MIN B - Main Water Inlet [102 mm] (1/2" NPT, 110 °F MIN (18 kW Booster), [305 mm] 140 °F MIN (12 kW Booster), or 180 °F MIN (No Booster or Supplied from Steam Booster))
  • Page 13 66" ELECTRIC/STEAM DIMENSIONS SPECIFICATIONS 66" RIGHT-TO-LEFT LEGEND 39 3/4 [1009 mm] 4 MIN A - Electrical Connection [102 mm] B - Main Water Inlet [305 mm] (1/2" NPT, 110 °F MIN (18 kW Booster), 140 °F MIN (12 kW Booster), or 180 °F MIN (No Booster or Supplied from Steam Booster))

  • Page 14: Energy Recovery Dimensions

    44" ENERGY RECOVERY DIMENSIONS SPECIFICATIONS 44" LEFT-TO-RIGHT LEGEND A - Electrical Connection B - Water Inlet (1/2" NPT, 110 °F MIN (27 kW Booster)) C - Drain Connection (1 1/2" NPT) D - Vent Connections (Including Dampers) E - Energy Recovery Water Inlet (1/2"...
  • Page 15 44" ENERGY RECOVERY DIMENSIONS SPECIFICATIONS 44" RIGHT-TO-LEFT LEGEND A - Electrical Connection B - Water Inlet (1/2" NPT, 110 °F MIN (27 kW Booster)) C - Drain Connection (1 1/2" NPT) D - Vent Connections (Including Dampers) E - Energy Recovery Water Inlet (1/2"...
  • Page 16 66" ENERGY RECOVERY DIMENSIONS SPECIFICATIONS 66" LEFT-TO-RIGHT LEGEND A - Electrical Connection B - Water Inlet (1/2" NPT, 110 °F MIN (27 kW Booster)) C - Drain Connection (1 1/2" NPT) D - Vent Connections (Including Dampers) E - Energy Recovery Water Inlet (1/2"...
  • Page 17 66" ENERGY RECOVERY DIMENSIONS SPECIFICATIONS 66" RIGHT-TO-LEFT LEGEND A - Electrical Connection B - Water Inlet (1/2" NPT, 110 °F MIN (27 kW Booster)) C - Drain Connection (1 1/2" NPT) D - Vent Connections (Including Dampers) E - Energy Recovery Water Inlet (1/2"...

  • Page 18: Side-Loader Dimensions

    SIDE-LOADER DIMENSIONS SPECIFICATIONS 23" R-L UNHOODED 23" L-R UNHOODED SIDE-LOADER SIDE-LOADER 30 5/16” 30 5/16” 29” 29” 16 3/8” 16 3/8” 23” 23” Dimension is 30" for the 30” Dimension is 30" for the 30” unhooded side-loader. unhooded side-loader. Adjustable Ventilation Adjustable Ventilation Duct Adapter Duct Adapter...

  • Page 19: Steam Booster Dimensions

    STEAM BOOSTER DIMENSIONS SPECIFICATIONS ” ” ” ” ” ” ” ” ” ” 22” 22”  ”  Click here for the Steam Booster manual. Main Electrical Connection (7/8" Hole) Steam Pressure Relief Outlet (1" NPT) Main Inlet Water Connection Steam Supply to Booster (1"...

  • Page 20: Operating Parameters

    OPERATING PARAMETERS SPECIFICATIONS RackStar RackStar RackStar RackStar RackStar RackStar Operating Capacity: 44ER 66ER Racks per Hour Dishes per Hour 5,575 5,575 5,575 5,575 5,575 5,575 Glasses per Hour 8,028 8,028 8,028 8,028 8,028 8,028 RackStar RackStar RackStar RackStar RackStar RackStar Tank Capacity (Gallons): 44ER 66ER...
  • Page 21 OPERATING PARAMETERS SPECIFICATIONS HOT-WATER SANITIZING RackStar RackStar RackStar RackStar RackStar RackStar 44ER 66ER Water Temperatures (°F): Pre-wash Temperature 110-140 110-140 110-140 Minimum Wash Temperature Incoming Rinse Temperature Minimum Incoming Water Temperature 12 kW Booster (40º Rise) 18 kW Booster (70º Rise) 27 kW Booster (ER Only) No Booster (from Steam...

  • Page 22: Electrical Requirements

    ELECTRICAL REQUIREMENTS SPECIFICATIONS ELECTRICAL All electrical ratings provided in this manual are for reference only. Always refer to the machine data plate to get the exact electrical information for this machine. All electrical REQUIREMENTS work performed on machines should be done in accordance with applicable local, state, territorial, and national codes.
  • Page 23 ELECTRICAL REQUIREMENTS SPECIFICATIONS Local codes may require more stringent protection than what is displayed here and on the data plate. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. Numbers in this manual are for reference and may change without notice. If using a third-party external booster, consult booster manufacturer for booster information.
  • Page 24 ELECTRICAL REQUIREMENTS SPECIFICATIONS Local codes may require more stringent protection than what is displayed here and on the data plate. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. Numbers in this manual are for reference and may change without notice. If using a third-party external booster, consult booster manufacturer for booster information.
  • Page 25 ELECTRICAL REQUIREMENTS SPECIFICATIONS Local codes may require more stringent protection than what is displayed here and on the data plate. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. Numbers in this manual are for reference and may change without notice. With single-point connection (option), Booster Heater shares a connection with machine.
  • Page 26 ELECTRICAL REQUIREMENTS SPECIFICATIONS Local codes may require more stringent protection than what is displayed here and on the data plate. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. Numbers in this manual are for reference and may change without notice. With single-point connection (option), Booster Heater shares a connection with machine.

  • Page 27: Installation

    INSTRUCTIONS INSTALLATION INSPECTION Before installing the machine, check packaging and machine for damage. Damaged packaging is an indication there is possible damage to the product. If there is any type of damage to both the packaging and the machine, DO NOT THROW AWAY THE PACKAGING.

  • Page 28: Drain Line Connection

    INSTRUCTIONS INSTALLATION PLUMBING If water hardness tests at greater than 3 GPG, install the Scaltrol Water Treatment system (see the Plumbing Options page) into the water line before the machine’s incoming water connection point. If water hardness tests at lower than 3 GPG, install the water supply A water hardness test line directly to the machine’s incoming water connection point.

  • Page 29: Steam Line Connection

    INSTRUCTIONS INSTALLATION STEAM LINE The steam machines come with lines to connect the source steam. Connect all steam lines to the machine as all applicable codes provide. See machine data plate for CONNECTION information concerning steam flow pressure.  Click here for the Steam Booster manual.

  • Page 30: Motor Rotation

    INSTRUCTIONS INSTALLATION MOTOR On 3-Phase machines only, correct pump motor rotation must be verified before the machine is operated. Failure to do so can result in damage to the machine and ROTATION components. 1. Follow the "Power Up" section. 2. Remove the front panel of the machine. CAUTION CAUTION! On 3-Phase machines...

  • Page 31: Chemical Feeder Equipment

    INSTRUCTIONS INSTALLATION CHEMICAL FEEDER This machine does not come with an integral chemical supply/feeder system. For the machine to operate correctly, connect it to a third-party chemical dispenser (see EQUIPMENT Connection Points section) that meets the requirements of NSF Standard 29. Contact a chemical supplier about connecting a dispenser to the machine.

  • Page 32: External Device Wiring

    INSTRUCTIONS INSTALLATION CONNECTION POINTS L-R unit shown. Rinse-aid and sanitizer tube connections shown to the right. S: Sanitizer (1/8" NPT) R: Rinse-aid (1/8" NPT) L-R unit shown. View of machine to the right is a top view with the panel removed. DETERGENT DISPENSER CONNECTION LIVE WHEN WASH...

  • Page 33: Curtain Installation

    CURTAIN INSTALLATION INSTALLATION The machine has decals marking the curtain locations inside the machine, starting at the load end and ending at the unload end. The illustrations below indicate the curtain size to be placed on the curtain hooks provided. If any curtain components are missing, they must be obtained and installed before operation.

  • Page 34: Operation

    OPERATING INSTRUCTIONS OPERATION PREPARATION Before operating the machine, verify the following: • Strainers are installed. • Drain valve is closed. • Actuator switches move with relative freedom and do not bind. • Curtains are installed correctly. POWER UP To place the machine in standby, press the Power Button on the display. 1.

  • Page 35: First Rack

    OPERATING INSTRUCTIONS OPERATION FIRST RACK The first rack of ware placed in the machine will typically reduce the temperature of the wash tank and might need to be run through again. This process might be necessary any time the machine has not been operated for an extended period of time, although this is dependent on the type of ware being used, its temperature, and the ambient temperature of the kitchen area.

  • Page 36: Shutdown & Cleaning

    OPERATING INSTRUCTIONS OPERATION SHUTDOWN & 1. Turn machine off by pressing the Power Button. 2. Open access door and allow steam/heat to escape. CLEANING 3. Turn drain handle to “OPEN” and allow tub to drain. WARNING! Wash tank water will be hot. WARNING 4.

  • Page 37: Display Instructions

    OPERATING INSTRUCTIONS OPERATION SHUTDOWN & 8. Spray or wipe out interior of machine. CLEANING 9. Ensure the strainers, curtains, and wash and rinse arms are clean and securely in place. 10. Use stainless steel polish to clean and protect outside of machine. DISPLAY Rinse Modes INSTRUCTIONS...

  • Page 38: Delime Instructions

    OPERATING INSTRUCTIONS OPERATION DISPLAY Operational Messages INSTRUCTIONS DISPLAY CONDITION One of the doors is not fully closed or one of the switches is not being "Check doors" triggered. "Filling" The wash tank is filling with water. "Heating" The machine is heating the water in the wash tank. "Delime"...

  • Page 39: Maintenance

    PREVENTATIVE MAINTENANCE MAINTENANCE PREVENTATIVE The manufacturer highly recommends that any maintenance and repairs not specifically discussed in this manual be performed only by QUALIFIED SERVICE PERSONNEL. Performing MAINTENANCE maintenance on your dishmachine may void your warranty, lead to larger problems, or even cause harm to the operator.

  • Page 40: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING WARNING! Inspection, testing, and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. WARNING OBSERVATION POSSIBLE CAUSE...
  • Page 41 TROUBLESHOOTING TROUBLESHOOTING WARNING! Inspection, testing, and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. WARNING OBSERVATION POSSIBLE CAUSE...

  • Page 42: Programming

    PROGRAMMING TROUBLESHOOTING PROGRAM To access Program Selection Mode, the machine should be on and preferably not in operation (accessing this mode during operation will interrupt the process). SELECTION MODE The programming buttons (Up-arrow, Down-arrow, and Select) are hidden on the display and are shown below outlined with red dots.
  • Page 43 PROGRAMMING TROUBLESHOOTING SETUP MODE To access Setup Mode, the machine should be on and preferably not in operation (accessing this mode during operation will interrupt the process). 1. Press and hold the Up-arrow and Down-arrow Buttons until “Setup” starts flashing (2 - 3 seconds). S E T U P 2.

  • Page 44: Fault Codes

    FAULT CODES TROUBLESHOOTING DISPLAY SHOWS POSSIBLE CAUSES REMEDY "F4 Service needed," 1. Incoming power not properly connected. 1. Check connections to heater. "Check incoming power" 2. L3 is missing (3-phase units only). 2. Verify that L3 is present and connected properly. 1.
  • Page 45 FAULT CODES TROUBLESHOOTING RESISTANCE-TO-TEMPERATURE VALUES R (kΩ) °F 11.58 69.8 10.37 75.2 9.30 80.6 7.78 89.6 3.05 140.0 2.54 150.8 2.18 159.8 1.58 179.6 1.45 185.0 1.33 190.4 1.16 199.4 0.96 212.0 07610-004-33-05-E...

  • Page 46: Parts

    CONTROL BOX PARTS ITEM DESCRIPTION PART NUMBER Terminal Block, 3-pole 05940-011-48-27 Fuse Holder 05920-011-72-89 Fuse, 1 A (208/230 V) (Not Shown) 05920-002-67-23 Fuse, 1/2 A (380/460 V) (Not Shown) 05920-011-72-88 Terminal Board 05940-002-78-97 I/O Module 06401-004-76-12 Relay 05945-111-72-51 Timer, Universal Digital Multi-timer* 05945-004-22-78 Overload See Motor Overloads page.

  • Page 47: Display

    DISPLAY PARTS Complete Display Assembly 05700-004-31-50 ITEM DESCRIPTION PART NUMBER Nut, Thumb, 6-32 Nylon 05310-002-83-12 Board, Populated Circuit 05945-004-46-18 Spacer, Display Board 05999-004-19-75 Membrane Switch and Panel Assembly 05700-004-59-65 Communication Cable 05700-004-33-64 Cover, Display Board (Not Shown) 05700-004-35-60 07610-004-33-05-E...

  • Page 48: Miscellaneous Electrical Components

    MISCELLANEOUS ELECTRICAL COMPONENTS PARTS Parts are not shown to scale with relation to each other. ITEM DESCRIPTION PART NUMBER Actuator Switch 05930-111-68-44 Float Switch 06680-121-70-71 Float Switch Cover 05700-004-71-80 Probe Fitting, Brass 05310-924-02-05 Thermistor Probe 06685-004-34-58 Fuse, 200 mA Slow-acting 05999-004-44-33 Fuse, 1 A Fast-acting 05999-004-47-87...

  • Page 49: Wash Heater & Shroud

    WASH HEATER & SHROUD PARTS ITEM DESCRIPTION PART NUMBER Lower Heater Shroud 05700-003-74-21 Upper Heater Shroud 05700-003-74-24 Gasket, Suction Casting 05330-003-75-89 Gasket, Pump Suction 05330-003-75-87 Gasket, Heater 05330-200-02-70 Heater Box Rails 05700-003-74-72 Wash Pump Suction 05700-003-77-63 Washer, 1/4-20 05311-174-01-00 Locknut, 1/4-20 Hex with Nylon Insert 05310-374-01-00 Nut, Hex 5/16-18 05310-275-01-00...

  • Page 50: Wash Heaters

    WASH HEATERS PARTS VOLTAGE PHASE PART NUMBER CONTACTOR 04540-121-68-45 05945-111-68-38 04540-121-68-46 05945-111-68-38 04540-121-68-45 05945-002-24-70 04540-121-68-46 05945-002-24-70 04540-121-68-47 05945-002-24-70 04540-002-39-93 05945-002-24-70 NOTICE When replacing wash heaters, it is highly recommended to change the gasket as well. Once installed, gaskets become compressed and are subject to extreme temperature changes. Replacing the gasket with the heater might prevent future leaks.

  • Page 51: Pump Suction

    PUMP SUCTION PARTS Pump Suction Assembly 05700-003-83-98 RackStar 66 Pre-wash Pump Suction Assembly 05700-004-34-24 ITEM DESCRIPTION PART NUMBER Gasket, Suction Casting 05330-003-75-89 Gasket, Pump Suction 05330-003-75-87 Pre-wash Pump Suction Weldment 05700-003-82-27 Strainer, Pre-wash Pump 05700-003-81-28 07610-004-33-05-E...

  • Page 52: Plumbing

    PLUMBING PARTS Complete Inlet Plumbing Assembly, L-R 05700-004-59-86 Complete Inlet Plumbing Assembly, R-L 05700-004-59-79 ITEM DESCRIPTION PART NUMBER Manifold, Tank Fill 05700-004-38-64 Elbow, 90-degree 1/2" Street Brass 04730-206-08-00 Solenoid Valve, 1/2" 04810-003-71-55 Nipple, 1/2" Close Brass 04730-207-15-00 Tee, 1/2" Brass 04730-211-27-00 Vacuum Breaker, 1/2"...
  • Page 53 PLUMBING PARTS Complete Rinse Plumbing Assembly, L-R 05700-004-48-52 Complete Rinse Plumbing Assembly, R-L 05700-004-48-45 ITEM DESCRIPTION PART NUMBER Rinse Injector, L-R 05700-003-76-82 Rinse Injector, R-L 05700-003-76-83 Elbow, 90-degree 1/2" Street Brass 04730-206-08-00 Elbow, 1/2" Brass 04730-011-42-96 Nipple, 1/2" Close Brass 04730-207-15-00 Tee, 1/2"...

  • Page 54: Pre-Wash Fill Plumbing

    PRE-WASH FILL PLUMBING PARTS Complete Pre-wash Fill Plumbing Assembly 05700-004-59-80 ITEM DESCRIPTION PART NUMBER Elbow, 90-degree 1/2" Street Brass 04730-206-08-00 Manifold, Tank Fill 05700-004-38-64 Vacuum Breaker, 1/2" Brass 04820-003-06-13 Nipple, 1/2" Close Brass 04730-207-15-00 Solenoid Valve, 1/2" 04810-003-71-55 Tee, 1/2" x 1/2" x 1/4" 04730-002-22-56 Plug, 1/4"...

  • Page 55: Energy Recovery Plumbing

    ENERGY RECOVERY PLUMBING PARTS Complete ER Fill Plumbing Assembly, L-R* 05700-004-41-53 Complete ER Fill Plumbing Assembly, R-L* 05700-004-41-54 ITEM DESCRIPTION PART NUMBER Manifold, Tank Fill 05700-004-38-64 Elbow, 90-degree 1/2" Street Brass 04730-206-08-00 Solenoid Valve, 1/2" 04810-003-71-55 Nipple, 1/2" Close Brass 04730-207-15-00 Tee, 1/2"...
  • Page 56 ENERGY RECOVERY PLUMBING PARTS Complete ER Inlet Plumbing Assembly, L-R (with bracket) 05700-004-41-62 (without bracket) 05700-004-41-64 Complete ER Inlet Plumbing Assembly, R-L (with bracket) 05700-004-41-63 (without bracket) 05700-004-41-64 ITEM DESCRIPTION PART NUMBER Elbow, 90-degree 1/2" Street Brass 04730-206-08-00 Valve, 1/2" 04810-003-71-55 Washer, 1/4-20 05311-174-01-00...
  • Page 57 ENERGY RECOVERY PLUMBING PARTS Complete ER Rinse Plumbing Assembly, L-R 05700-004-41-65 Complete ER Rinse Plumbing Assembly, R-L 05700-004-41-66 ITEM DESCRIPTION PART NUMBER Nipple, 1/2" Close Brass 04730-207-15-00 Tee, 1/2" Brass 04730-211-27-00 Nipple, 1/2 Brass, 2" Long 04730-207-19-00 Vacuum Breaker, 1/2" Brass 04820-003-06-13 Elbow, 90-degree 1/2"...

  • Page 58: Wash System

    WASH SYSTEM PARTS Mechanical Pump Seal 05330-002-34-22 07610-004-33-05-E...
  • Page 59 WASH SYSTEM PARTS ITEM DESCRIPTION PART NUMBER Pump & Motor Assembly See Table Below Gasket, Pump Suction 05330-003-75-87 Gasket, Pump Discharge 05330-003-75-88 Hose Clamp, Range 2 9/16" to 3 1/2" 04730-003-15-40 Hose, Wash Pump Discharge 05700-003-77-62 Lower Wash Manifold, L-R 05700-004-27-39 Lower Wash Manifold, R-L 05700-004-30-27...

  • Page 60: Pre-Wash System

    PRE-WASH SYSTEM PARTS Mechanical Pump Seal 05330-002-34-22 07610-004-33-05-E...
  • Page 61 PRE-WASH SYSTEM PARTS ITEM DESCRIPTION PART NUMBER Gasket, Pump Suction 05330-003-75-87 Hose Clamp 04730-003-15-40 Hose, Wash Pump Discharge 05700-003-77-62 Manifold, Pre-wash System 05700-004-31-60 O-ring, Silicone, 0.103 Dia., 2 1/2" x 2 11/16" OD 05330-003-73-71 Tube, Manifold Riser 05700-003-81-53 Casting, Pre-wash Manifold 09515-003-77-22 O-ring, Silicone, 0.139 Dia., 2 1/4"...

  • Page 62: Rinse System

    RINSE SYSTEM PARTS 07610-004-33-05-E...
  • Page 63 RINSE SYSTEM PARTS ITEM DESCRIPTION PART NUMBER Upper Rinse Arm 05700-003-76-02 Nozzle, Upper Rinse Arm 04730-003-76-07 O-ring, Silicon, 0.103 Dia., 11/16" x 7/8" OD 05330-003-77-82 Rinse Manifold 05700-003-76-79 Rinse Manifold, HH 05700-004-49-62 Fitting, 1/2" Male Swivel Brass 04730-004-19-62 47" Hose (Specify Length When Ordering) 04720-004-19-81 47"...

  • Page 64: Plumbing Options

    PLUMBING OPTIONS PARTS WATER HAMMER ARRESTOR OPTION Water Hammer Arrestor Complete Assembly Water Arrestor, 1/2” 05700-002-64-67 06685-100-05-00 Water Hammer Arrestor Repair Kit (Plunger & O-ring) 06401-003-06-23 Tee, 1/2” x 1/2” x 1/2” 04730-211-27-00 Nipple, 1/2” NPT, Brass 04730-207-15-00 PRESSURE REGULATING VALVE OPTION* Water Pressure Regulator, 1/2”...

  • Page 65: Pawl Bar

    PAWL BAR PARTS Complete Pawl Bar Assembly 05700-004-17-75 ITEM DESCRIPTION PART NUMBER Locknut, 1/4-20 Hex with Nylon Insert 05310-374-01-00 Washer, 1/4-20 05311-174-01-00 Washer, Flat, 0.406 ID x 0.750 OD 05311-004-29-35 Rack Catch, Left 05700-004-29-32 Rack Catch, Right 05700-004-29-33 Bolt, Shoulder, 3/8" x 1/4", 1/4-20 05306-004-29-34 Pawl Bar Weldment 05700-004-17-74...

  • Page 66: Rack Rails

    RACK RAILS PARTS RackStar 66 07610-004-33-05-E...
  • Page 67 RACK RAILS PARTS ITEM DESCRIPTION PART NUMBER Front Rack Rail 05700-004-26-87 Paddle Switch 05700-004-26-89 Screw, 1/4-20 x 5/8" Hex 05305-274-24-00 Glide Block 05700-004-11-75 Rear Rack Rail 05700-004-22-95 Screw, 1/4-20 x 7/8" Hex 05305-274-05-00 Rack Rail, Pre-wash 05700-004-47-04 Screw, 1/4-20 x 1" Hex 05305-274-27-00 Paddle Switch, Pre-wash, L-R 05700-004-34-03...

  • Page 68: Drive Assembly

    DRIVE ASSEMBLY PARTS Drive Assembly 05700-004-29-95 (doesn't include Item #17) 07610-004-33-05-E...
  • Page 69 DRIVE ASSEMBLY PARTS ITEM DESCRIPTION PART NUMBER Drive Casting, Top 09515-004-17-06 Gasket, Drive Casting 05330-004-20-31 Screw, 1/4-20 x 1 1/2" Hex 05305-004-55-76 Drive Casting, Bottom 09515-004-17-03 Drive Shaft 05700-004-29-79 Gasket, Drain Seat 05700-002-04-42 Screw, 10-32 x 1 3/4" 05306-003-92-52 Drive Shaft Cover 05700-004-29-46 Clutch-Drive, 3/4"...

  • Page 70: Ventilation Cowl

    VENTILATION COWL PARTS ITEM DESCRIPTION PART NUMBER Ventilation Cowl 05700-004-34-01 Ventilation Scoop 05700-004-29-68 Ventilation Duct Adapter 05700-003-75-73 Damper, Ventilation Scoop 05700-003-74-76 Curtain Hook 05700-003-17-98 07610-004-33-05-E...

  • Page 71: Ventilation Cowl For Unhooded Side-Loader

    VENTILATION COWL FOR UNHOODED SIDE-LOADER PARTS To attach the curtain and rod to the Ventilation Cowl, ensure that the curtain is oriented as depicted and follow the steps below: This illustration 1. Insert the rod into the hole at the rear of the depicts the Ventilation Cowl.

  • Page 72: Motor Overloads

    MOTOR OVERLOADS PARTS WASH MOTORS: Overloads are specified for 3-phase units only. For GE brand MT03* series overloads, the process for setting is as follows: • Determine the Full Load Amps (FLA) for the wash motor. • Set the overload at the closest setting without going over for the FLA of the motor. •...

  • Page 73: Side-Loaders

    SIDE-LOADERS PARTS This illustration depicts a 23" Left-to-Right Unhooded Side-loader. Differences in parts for the 23" Right-to-Left and both directions of the 30" Side-loaders are reflected in the parts list. *Order lengths of hose or conduit by mea- NOTICE suring the lengths in the field and adding an additional 1' to ensure any custom-cut lengths are accounted for.
  • Page 74 SIDE-LOADERS PARTS This illustration depicts a 23" Left-to-Right Unhooded Side-loader. Differences in parts for the 23" Right-to-Left and both directions of the 30" Side-loaders are reflected in the parts list. *Order lengths of hose or conduit by mea- NOTICE suring the lengths in the field and adding an additional 1' to ensure any custom-cut lengths are accounted for.
  • Page 75 SIDE-LOADERS PARTS ITEM DESCRIPTION PART NUMBER Tub Weldment, 23" Side-loader L-R 05700-004-37-44 Tub Weldment, 23" Side-loader R-L 05700-004-38-03 Tub Weldment, 30" Side-loader L-R 05700-003-88-46 Tub Weldment, 30" Side-loader R-L 05700-003-88-39 Support Leg 05700-021-87-59 Adjustable Foot 05340-108-01-03 Locknut, 1/4-20 Hex with Nylon Insert 05310-374-01-00 Leg Socket 05700-002-56-14...

  • Page 76: Side-Loader Drive Linkage

    SIDE-LOADER DRIVE LINKAGE PARTS ITEM DESCRIPTION PART NUMBER Pawl Bar, Side-loader 05700-021-86-88 Drive Linkage, Side-loader 05700-004-37-81 Pawl Dog with Wing 05700-021-86-79 Locknut, 3/8-16 with Nylon Insert 05310-011-72-55 Bolt, 3/8-16 x 1 3/4" Hex 05306-011-36-94 Spacer, Pawl Bar Dog 05700-011-71-45 Screw, 1/4-20 x 1" Hex 05305-274-27-00 Locknut, 1/4-20 Hex with Nylon Insert 05310-374-01-00...

  • Page 77: Steam Coil

    STEAM COIL PARTS Complete Steam Coil Assembly, L-R 05700-004-44-82 Complete Steam Coil Assembly, R-L 05700-004-46-30 Complete Steam Inlet Plumbing Assembly 05700-004-46-32 ITEM DESCRIPTION PART NUMBER Steam Coil 05700-004-36-15 Reducer, 3/4" to 1/2" Black Iron 04730-911-02-34 Union, 3/4" Black Iron 04730-912-01-00 Nipple, 3/4"...

  • Page 78: Booster Heater (Electric)

    BOOSTER HEATER* (ELECTRIC) PARTS The hose from the Final Rinse Plumbing connects here. For Booster Heater service parts not listed here, see the Hatco Booster Manual.  Call Hatco at 800-558-0607 with service support questions. The hose from the Main Inlet Plumbing connects here.

  • Page 79: Booster Heater Add-On Kit (Electric)

    BOOSTER HEATER ADD-ON KIT (ELECTRIC) PARTS Find the machine's applicable electrical configuration and the booster type (70-degree, 40-degree, or ER) in the table below and use the associated part number to order.  Click here for install instructions. BOOSTER HEATER KIT PART NUMBER 12 kW (40 °F Rise) 208 V, 3-Phase 05700-004-48-38...

  • Page 80: Frame

    FRAME PARTS RackStar 66 ITEM DESCRIPTION PART NUMBER Hood Dress Panel 05700-004-18-39 Left Dress Panel, L-R 05700-004-30-60 Right Dress Panel, R-L 05700-004-31-93 Display See "Display Assembly" page. Front Dress Panel, RackStar 44 05700-004-30-44 Adjustable Foot 05340-011-71-74 Right Dress Panel, L-R 05700-004-30-59 Left Dress Panel, R-L 05700-004-31-92...

  • Page 81: Doors

    DOORS PARTS ITEM DESCRIPTION PART NUMBER Left Door Assembly 05700-004-79-72 Left Door Assembly, HH 05700-004-81-13 Right Door Assembly 05700-004-80-04 Right Door Assembly, HH 05700-004-81-12 Bearing, Flanged Sleeve 03120-004-39-92 Door Seal 09330-004-17-41 Screw, 10-32 x 1/2" 05305-011-44-51 Door Assembly, Pre-wash, L-R 05700-004-75-90 Door Assembly, Pre-wash, R-L 05700-004-75-93...

  • Page 82: Energy Recovery System

    ENERGY RECOVERY SYSTEM PARTS Complete Energy Recovery System Assembly L-R - 05700-004-39-68 R-L - 05700-004-40-13 L-R HH - 05700-004-68-92 R-L HH - 05700-004-69-04 07610-004-33-05-E...
  • Page 83 ENERGY RECOVERY SYSTEM PARTS ITEM DESCRIPTION PART NUMBER Vent Cowl, L-R 05700-004-36-36 Vent Cowl, L-R HH 05700-004-68-91 Vent Cowl, R-L 05700-004-40-16 Vent Cowl, R-L HH 05700-004-69-03 Mounting Plate 05700-004-36-32 Washer, 1/4-20 05311-174-01-00 Locknut, 1/4-20 Hex with Nylon Insert 05310-374-01-00 Coil, Heat Exchanger 04420-004-40-73 Side Cover, Left 05700-004-41-17...

  • Page 84: Miscellaneous/Options

    MISCELLANEOUS/OPTIONS PARTS Miscellaneous Parts Curtain Bracket, Middle Curtain Bracket, End 05700-004-32-75 05700-004-21-24 Strainer, Pre-wash Strainer, Wash Tank 05700-004-37-61 05700-004-29-02 Pre-wash Connecting Rod 05700-004-56-16 Options Striker Table Limit Whisker Table Limit Switch Option Switch Option 05700-002-88-07 05700-002-06-83   07610-004-33-05-E...

  • Page 85: Schematics

    208/230 V, 50/60 HZ, 3-PHASE SCHEMATICS Connection Diagram for IO Module Input Assignments Programming I1 Wash T2 T1 header I2 Cycle I3 Float I4 Rinse I5 Door/Chemicals VDC OUT Temperature Analog input AC signals DC RTN Sensor inputs L1   L2/N VDC OUT LOGIC INPUT DC RTN AC power input 24 VDC OUT / RS‐232 Relay Assignments K1 Power BLK (DC RTN) K2 Booster heater  K3 Wash heater RED (+24 ...

  • Page 86: 460 V, 50/60 Hz, 3-Phase

    460 V, 50/60 HZ, 3-PHASE SCHEMATICS Connection Diagram for IO Module PN 05945‐004‐36‐34 ALL CONNECTIONS MAY NOT BE USED ON CERTAN MODELS T3 (Booster) RED/BLU T4 (spare) T2 (Rinse Injector) GRY/BLU Input Assignments Programming I1 Wash header I2 Cycle T1 (Wash) RED/WHT I3 Float I4 Rinse I5 Chemicals +24 VDC Temperature Analog input Pressure sensor AC signals DC RTN L1  L2/N Sensor inputs ~+4.5 VDC OUT Piezo switch LOGIC INPUT AC power in DC RTN 24 VDC OUT / RS‐232 Relay Assignments K1 Power BLK (DC RTN)

  • Page 87: 600 V, 50/60 Hz, 3-Phase

    600 V, 50/60 HZ, 3-PHASE SCHEMATICS Connection Diagram for IO Module PN 05945‐004‐36‐34 ALL CONNECTIONS MAY NOT BE USED ON CERTAN MODELS T3 (Booster) RED/BLU T4 (spare) Input Assignments T2 (Rinse Injector) GRY/BLU Programming I1 Wash header I2 Cycle T1 (Wash) RED/WHT I3 Float I4 Rinse I5 Chemicals +24 VDC Pressure sensor Temperature Analog input AC signals L1  L2/N DC RTN Sensor inputs ~+4.5 VDC OUT Piezo switch LOGIC INPUT AC power in DC RTN 24 VDC OUT / RS‐232 Relay Assignments K1 Power BLK (DC RTN)

  • Page 88: Steam

    STEAM SCHEMATICS Connection Diagram for IO Module PN 05945‐004‐36‐34 ALL CONNECTIONS MAY NOT BE USED ON CERTAN MODELS T3 (Booster) RED/BLU T4 (spare) Input Assignments T2 (Rinse Injector) GRY/BLU Programming I1 Wash header I2 Cycle T1 (Wash) RED/WHT I3 Float I4 Rinse I5 Chemicals +24 VDC Pressure sensor Temperature Analog input AC signals DC RTN L1  L2/N Sensor inputs ~+4.5 VDC OUT Piezo switch LOGIC INPUT AC power in DC RTN 24 VDC OUT / RS‐232 Relay Assignments K1 Power BLK (DC RTN) K2 Booster heater ...

  • Page 89: Side-Loader

    SIDE-LOADER SCHEMATICS 07610-004-33-05-E...

  • Page 90: Addendum

    DISPLAY TEMPLATE ADDENDUM This page can be copied and the display templates cut-out. Lay the cut-out over the display and use the Up-arrow, Down- arrow, and Select Buttons to locate the hidden programming buttons. 07610-004-33-05-E...
  • Page 92 Jackson WWS, Inc. • 6209 N. US Hwy 25E • Gray, KY 40734 USA 1.888.800.5672 • www.jacksonwws.com RackStar Manual • 07610-004-33-05-E...

This manual is also suitable for:

Rackstar 44Rackstar 66Rackstar 44erRackstar 66erRackstar 44sRackstar 66s

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