Jackson AJ-100CE Installation/Operation & Technical Manual
Rack conveyor dishmachine series
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INSTALLATION/OPERATION &
AJ-64CE
AJ-64CS
September 29, 2007
P/N 7610-002-30-93 (Revision F)
TECHNICAL MANUAL
FOR JACKSON MODELS:
AND ASSOCIATED OPTION PACKAGES INCLUDING:
D226 EXTERNAL STEAM BOOSTER
AJ-64 RACK CONVEYOR DISHMACHINE SERIES
AJ-86CE
AJ-86CGP
AJ-86CS
SIDE LOADER
AJ-100CE
AJ-100CGP
AJ-100CS
Jackson MSC LLC.
P.O. Box 1060
Barbourville, KY. 40906
(606) 523-9795
Fax: (606) 523-9196
www.jacksonmsc.com
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Summary of Contents for Jackson AJ-100CE
- Page 1 INSTALLATION/OPERATION & TECHNICAL MANUAL AJ-64CE AJ-64CS AND ASSOCIATED OPTION PACKAGES INCLUDING: September 29, 2007 P/N 7610-002-30-93 (Revision F) AJ-64 RACK CONVEYOR DISHMACHINE SERIES FOR JACKSON MODELS: AJ-86CE AJ-86CGP AJ-86CS SIDE LOADER D226 EXTERNAL STEAM BOOSTER AJ-100CE AJ-100CGP AJ-100CS Jackson MSC LLC.
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Page 2: Manufacturers Warranty
The warranty registration card supplied with the machine must be returned to Jackson MSC within 30 days to validate the warranty. REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the factory, which ever occurs first. - Page 3 STOP! PARE! ARRET! CALL 1-888-800-5672 TO REGISTER THIS PRODUCT! FAILURE TO DO SO WILL VOID THE WARRANTY! LLAME AL 1-888-800-5672 PARA REGISTRAR ESTE PRODUCTO! AL NO HACERLO LA GARANTIA SERA ANULADA! S.V.P . APPELER 1-888-800-5672 POUR ENREGISTRER CE PRODUIT, LA GARANTIE SERA ANNULEE POUR TOUT PRODUIT NON- ENREGISTREE...
- Page 4 REVISION MADE REVISION DATE 04-06-05 02-02-06 05-02-06 PG. 116 04-19-07 5 thru 22, 104 09-29-2007 APPLICABLE Updated drawings for limit switch actuators. Changed AJ-86 drain 6999, 7193 plumbing copper lengths. Added rack rail stabilizer kit. Replaced 7217, 7064 heater 04540-121-76-93 with 04540-002-29-82. Updated installa- 7212, 7259 tion instructions.
- Page 5 Installation Date: Service Rep. Name: Phone No.: AJ-64CS Jackson MSC LLC. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer to this manual before making a call to our technical support staff.
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Page 6: Table Of Contents
SECTION DESCRIPTION SPECIFICATION INFORMATION Operating Characteristics Electrical Requirements D226 Steam Booster Parameters AJ-64 Electric - Left to Right AJ-64 Electric - Right to Left AJ-64 Gas - Left to Right AJ-64 Gas - Right to Left AJ-64 Steam - Left to Right AJ-64 Steam - Right to Left AJ-86 Electric - Left to Right AJ-86 Electric - Right to Left... -
Page 7: Parts Section
PARTS SECTION AJ-64 Control Box Assembly AJ-86/AJ-100 Control Box Assembly Motor Overload Chart Heater Box Assembly Heater Assembly Frame Weldments/Front Dress Panels Prewash Plumbing Assembly Incoming Plumbing Assembly Rinse Header Plumbing Assembly (CGP Models) External Electric Booster Option Incoming Plumbing External Electric Booster Option Outlet Plumbing WPRK Plumbing Option 3/4”... -
Page 8: Electrical Schematics
208-230 Volt, 60 Hz, 3 Phase Secondary Side 460-575-600 Volt, 60 Hz, 3 Phase Primary Side 460-575-600 Volt, 60 Hz, 3 Phase Secondary Side AJ-86CE & AJ-100CE 208-230 Volt, 60 Hz, 1 Phase Primary Side 208-230 Volt, 60 Hz, 1 Phase Secondary Side... -
Page 9: Section 1: Specification Information
SECTION 1: SPECIFICATION INFORMATION... -
Page 10: Operating Characteristics
SECTION 1: SPECIFICATION INFORMATION RACKS PER HOUR: AJ-64-86-100CE/CS/CGP DISHES OR GLASSES PER HOUR: AJ-64-86-100CE/CS/CGP PREWASH TANK CAPACITY (GALLONS): AJ-86CE/CS/CGP AJ-100CE/CS/CGP WASH TANK CAPACITY (GALLONS): AJ-64-86-100CE/CS/CGP POWER RINSE TANK CAPACITY (GALLONS): AJ-86CE/CS/CGP AJ-100CE/CS/CGP PREWASH PUMP CAPACITY (GPM): AJ-86CE/CS/CGP AJ-100CE/CS/CGP WASH PUMP CAPACITY... -
Page 11: Electrical Requirements
SECTION 1: SPECIFICATION INFORMATION AJ-64CE MODELS TYPICAL TOTAL ELECTRICAL VOLTS AMPS CIRCUIT 139 A 175 AMP 128 A 175 AMP 82 A 110 AMP 76 A 100 AMP 38 A 50 AMP AJ-64CS MODELS TYPICAL TOTAL ELECTRICAL VOLTS AMPS CIRCUIT 19 A 25 AMP 19 A... -
Page 12: D226 Steam Booster Parameters
SECTION 1: SPECIFICATION INFORMATION ELECTRICAL REQUIREMENTS (CONTINUED)/D226 STEAM BOOSTER PARAMETERS AJ-100CE MODELS TYPICAL TOTAL ELECTRICAL VOLTS AMPS CIRCUIT 148 A 200 AMP 136 A 175 AMP 88 A 110 AMP 81 A 110 AMP 41 A 60 AMP AJ-100CGP MODELS... -
Page 13: Electric - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-64 ELECTRIC - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 14: Electric - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-64 ELECTRIC - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 15: Gas - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-64 GAS - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 16: Gas - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-64 GAS - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 17: Steam - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-64 STEAM - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 18: Steam - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-64 STEAM - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 19: Electric - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-86 ELECTRIC - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 20: Electric - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-86 ELECTRIC - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 21: Gas - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-86 GAS - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 22: Gas - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-86 GAS - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 23: Steam - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-86 STEAM - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 24: Steam - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-86 STEAM - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 25: Aj-100 Electric - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-100 ELECTRIC - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 26: Aj-100 Electric - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-100 ELECTRIC - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 27: Aj-100 Gas - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-100 GAS - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 28: Aj-100 Gas - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-100 GAS - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 29: Aj-100 Steam - Left To Right
SECTION 1: SPECIFICATION INFORMATION AJ-100 STEAM - LEFT TO RIGHT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 30: Aj-100 Steam - Right To Left
SECTION 1: SPECIFICATION INFORMATION AJ-100 STEAM - RIGHT TO LEFT AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: 09-29-2007... -
Page 31: Side Loader (Left To Right) Dimensions
SECTION 1: SPECIFICATION INFORMATION SIDE LOADER (LEFT TO RIGHT) DIMENSIONS 4 1/2” DISHWASHER MINIMUM CONVEYOR DISHMACHINE 14 1/2” * - 15” for 30” Model ** - 30” for 30” Model 1/2” MINIMUM WALL OF SIDE LOADER 25” 5” 12 1/2”... -
Page 32: Side Loader (Right To Left) Dimensions
MINIMUM WALL OF SIDE LOADER 5” DISHMACHINE AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: N/A 25” DISHWASHER 12 1/2” CONVEYOR 14 1/2” 29” * - 15” for 30” Model ** - 30” for 30” Model 4 1/2” MINIMUM... -
Page 33: Model Dimensions
SECTION 1: SPECIFICATION INFORMATION 23” SIDE LOADER DIMENSIONS DIMENSIONS MODEL AJ-64 95” AJ-86 117” AJ-100 131” 30” SIDE LOADER DIMENSIONS MODEL DIMENSIONS AJ-64 102” AJ-86 124” AJ-100 138” NOTE: ALL DIMENSIONS ARE TYPICAL. 10” 4” 34” 23” or 30” Depending on the width of the sideoloader. -
Page 34: D226 Steam Booster Dimensions
SECTION 1: SPECIFICATION INFORMATION 11” 14” NOTE: All dimensions are in inches and are for reference only. 16” AJ-64 Conveyor Series Technical Manual 7610-003-30-93 D226 STEAM BOOSTER DIMENSIONS 43” 24” 16” 13” Issued: 05-02-2006 Revised: N/A 4” 11” 16” 6”... -
Page 35: D226 Steam Booster Plumbing Line Drawings
SECTION 1: SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS Steam Booster Piping - Double Tank Machine AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: N/A... -
Page 36: Typical Electric And Gas Booster Dimensions
SECTION 1: SPECIFICATION INFORMATION TYPICAL ELECTRIC AND GAS BOOSTER DIMENSIONS Electric Booster Dimensions (Typical) 30 / " (775 mm) 30-1/2” 24” 24" (610 mm) / " NPT Coupling for Temperature/Pressure 18” Relief Valve Electical connection from side or below SIDE VIEW 20-3/4”... -
Page 37: Installation/Operation Instructions
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS... -
Page 38: Installation Instructions
However, rough handling by carriers or others may result in damage to the unit while in transit. If such a situ- ation occurs, do not return the unit to Jackson; instead, contact the carrier and ask them to send a representative to the site to inspect the damage to the unit and to complete an inspection report. - Page 39 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS STEAM LINE CONNECTIONS: Some machines covered in this manual are designed to use low pressure steam as a source of heat for wash tank water. The machines come with lines by which outside source steam needs to be connected. Connect all incoming steam lines in accordance with the steam booster manufacturer’s instructions.
- Page 40 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS ELECTRIC HEAT: The thermostats for the machines covered in this manual are factory set. They should not be adjusted except by an authorized service agent. CHEMICAL FEEDER EQUIPMENT: Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting.
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Page 41: Deliming Operations
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS DELIMING OPERATIONS: In order to maintain the dishmachine at its optimum performance level, it will be required to remove lime and corrosion deposits on a frequent basis. A deliming solution should be available from your detergent supplier. Read and follow all instructions on the label of the deliming solution. -
Page 42: Curtain Installation Diagram
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS CURTAIN INSTALLATION DIAGRAMS Please refer to the chart for placement of the curtains. AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: N/A... -
Page 43: Side Loader Installation & Operation Instructions
This accessory assists in the delivery of a full dish rack from the break down (scrapping) table to the dishmachine. It will con- vert 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. -
Page 44: D226 Steam Booster Installation & Operation Instructions
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 carry- ing 15-25 PSIG flow steam. - Page 45 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS D226 STEAM BOOSTER INSTALLATION & OPERATION INSTRUCTIONS (CONTINUED) ELECTRICAL: WARNING: Electrical and grounding connections must comply with applicable portions of the National Electrical Code ANSI / NFPA 70 (latest edition) and/or other electrical codes.Disconnect electrical power supply and place a tag or lock at the disconnect switch to indicate that you are working on the circuit.
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Page 46: Gas Conveyor Hose Installation
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS Attach the hose fitting to this connection before making the Connection cut at the other end of the hose. 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. - Page 47 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS GAS CONVEYOR HOSE INSTALLATION (CONTINUED) AJ-64 Conveyor Series Technical Manual 7610-003-30-93 Issued: 05-02-2006 Revised: N/A...
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Page 48: Dishmachine Operating Instructions
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS PREPARATION: Before proceeding with the start-up of the unit, verify the following: 1. Close door(s) on dishmachine. 2. Close the drain valve(s). POWER UP (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. - Page 49 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS DISHMACHINE OPERATION INSTRUCTIONS (CONTINUED) 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.
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Page 50: Detergent Control
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. -
Page 51: Striker Plate Limit Switch Installation Instructions
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS Installation Instructions: 1. Wiring: The switch is wired common and nor- mally 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. -
Page 52: Section 3: Preventative Maintenance
SECTION 3: PREVENTATIVE MAINTENANCE... - Page 53 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 PERSONNEL ONLY.
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Page 54: D226 Maintenance
SECTION 3: PREVENTATIVE MAINTENANCE 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 accept- able temperature prior to performing any maintenance. -
Page 55: Lubrication Chart For Drive Gear
SECTION 3: PREVENTATIVE MAINTENANCE 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 Final Stage Worm Speed up to 2000 FPM ISO Viscosity Grade AGMA Lubricant No. -
Page 56: Drive Motor Gear Reducer Preventative Maintenance
SECTION 3: PREVENTATIVE MAINTENANCE DRIVE MOTOR GEAR REDUCER PREVENTATIVE MAINTENANCE 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. -
Page 57: Section 4: Troubleshooting Section
SECTION 4: TROUBLESHOOTING SECTION... -
Page 58: Drive Assembly
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. -
Page 59: Torque Settings
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. -
Page 60: D226 Common Problems
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.
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