AJ-44 Series Installation/Operation Service Manual Part 2 of 4

AJ-44 Series Installation/Operation Service Manual Part 2 of 4
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL (CONTINUED)
28. Re-install the lower wash arm support bracket to the pawl
bar support on the end of the tub opposite from where it was
removed.
29. Re-install the upper and lower rinse arms. Reinstall the
lower rinse arm support bracket.
30. Re-install the lower wash arm assembly, turning it 180°
and locking it in place with the locking screw.
31. Re-install the pawl bar. Ensure that the pawl bar is placed
so that when racks are placed in the unit, the pawl bar dogs
fold down.
Removing the hole cover weldment
32. Re-install the upper wash arm assembly. If you performed
all of the actions outlined in step 2, when you install it, it will be
directly over the lower wash arm assembly.
22. Separate the rinse plumbing from the rest of the incoming
plumbing by loosening the union. Ensure that the gasket on
the bottom of the rinse injector stays with the assembly as you
remove it.
33. Remove the heater box cover by unscrewing the four
screws holding it on.
Loosening the union on the incoming plumbing
Removing the heater box cover
23. Remove the remaining half of the union from the incoming
plumbing.
24. Remove the incoming water pressure regulator from the
incoming plumbing and replace with the union half that was
removed in step 23. Place the water pressure regulator on the
end that the union half was removed from.
1
2
3
25. Place the removed rinse plumbing assembly (with the gasket) in the hole left open from when you removed the hole
cover weldment in step 21. Tighten the two halves of the union
together.
26. Place the hole cover weldment (with its gasket) over the
hole from where the rinse plumbing assembly was originally
installed. Tighten down with the locknuts.
27. Re-install the rinse manifold (with its gasket) by connecting it to the rinse injector weldment at its new location.
Remove the locknut from the stud for the bracket down near
the rack rails and then secure the bracket to the machine
using the same lock nut.
Front of rack conveyor showing the conveyor
switches
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
38
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING THE AJ-44CE/CS DIRECTION OF TRAVEL (CONTINUED)
Conveyor Switch Chart:
Unit
Direction
Switch #1
Switch #2
Switch #3
Left to Right
Wash Switch
#1
Wash Switch
#2
Rinse Switch
Right to Left Rinse Switch
Wash Switch
#2
Wash Switch
#1
The chart above lists the conveyor switches and their functions, depending on the direction of travel for the machine. As
you can see, when you change the direction of the conveyor,
you must also alter the way the conveyor switches operate.
Incoming plumbing assembly for a Left to Right machine
(note hole cover weldment in lower right corner)
There is no need to remove the switches, only to change the
wiring inside the heater box.
Terminal board inside the heater box
34. Note: Before beginning any part of this maintenance evolution that deals with the wiring of the machine, ensure that it
is performed by qualified technicians only. Always refer to the
machine schematic, located inside the control box, for any
questions.
Incoming plumbing assembly for a Right to Left machine
(note hole cover weldment in upper left corner)
AFTER MAINTENANCE ACTIONS
Wash Switch #1 and the Rinse Switch need to have their wire
positions changed on the terminal board pictured above.
Locate the gray/yellow wire for Wash Switch #1 (do not confuse it with the gray/yellow wire for Wash Switch #2) and the
orange/yellow wire for the Rinse Switch. Exchange their positions on the terminal board.
1. Reconnect the incoming water and drain lines and
then restore power to the unit. Run the unit for at least 1/2
hour to ensure there are no leaks. Test the unit with an empty
rack to ensure that it pulls the rack all of the way through the
unit. If any problems arise you can contact your Jackson representative.
2. Replace the front dress panel once the unit is
ready for service again.
35. Verify that the plumbing has been reassembled correctly
and that the hole cover weldment has been replaced and none
of the gaskets are torn or pinched as this could lead to leaking
when the machine operates.
SPECIAL NOTES
1. There is a possibility that you may be required to
shorten or lengthen the conduit and wire lengths for the inlet
solenoid on the rinse plumbing once it is moved. This work
should be performed by qualified technicians who will do the
work according to applicable local, state and national codes.
Questions concerning this should be directed to your Jackson
representative.
35. Re-install the heater box cover.
SPECIAL PARTS
Gasket, Rinse Injector:
Mfg. No.: 05330-111-42-81
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
39
40
12"
21"
L
S
12"
S
66
L
21"
80
L
21"
L
21"
S
R
12"
21"
L
R
12"
S
S
L
12"
S
L
12"
L
21"
S
R
12"
12"
S
21"
L
21"
L
UNHOODED SIDE LOADER
21"
L
UNHOODED SIDE LOADER
R
12"
S
L
L
21"
L
L
21"
L
21"
L
21"
12"
S
12"
S
21"
L
S
R
12"
HOODED SIDE LOADER
12"
S
HOODED SIDE LOADER
21"
L
R
12"
S
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
L
21"
L
L
L
21"
L
OTHER
66
21"
XL
80
24.5"
S
R
12"
21"
L
80 COUNTRY BUFFET
12"
S
21" 21"
L
L
24.5" 12"
XL S
L
12"
XL S
24.5"
GAS MACHINES
44
21"
L
24.5"
R
21"
L
R
12"
XL S
Please refer to the chart for
placement of the curtains.
L
L
S
12"
L
21"
44
ELECTRIC & STEAM MACHINES
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CURTAIN INSTALLATION DIAGRAMS
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
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 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 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.
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.
OPERATIONAL INSPECTION: 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-44C Series Technical Manual 7610-001-76-22
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SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
D226 STEAM BOOSTER INSTALLATION & OPERATION INSTRUCTIONS
CONCEALED DAMAGE OR MISSING PARTS:
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 manual 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 regulator, 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-44C Series Technical Manual 7610-001-76-22
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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.
Terminal Block
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.
10
OPERATION:
WARNING: The heat exchanger used in the D226 Booster system is a pressure 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.
D226 Conrtol Box
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 SERVICE 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-44C Series Technical Manual 7610-001-76-22
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43
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
GAS CONVEYOR HOSE INSTALLATION
Barbed Hose Fitting
Connection
Attach the hose fitting to this
connection before making the
cut at the other end of the
hose.
Cut the hose at the location
where the hose is even
with the yellow plastic stop.
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. 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 end of
the fitting pointing upward and push the hose down onto the fitting. A small amount of lubricant (i.e. petroleum jelly) may aid in
this process.
AJ-44C Series Technical Manual 7610-001-76-22
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AJ-44C Series Technical Manual 7610-001-76-22
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45
* HOSES MARKED A IN THE ABOVE ILLUSTRATIONS CONNECT TO THE
** HOSES MARKED B IN THE ABOVE ILLUSTRATIONS CONNECT TO THE
OUTLET WATER CONNECTION OF THE GAS BOOSTER HEATER
INLET WATER CONNECTION OF THE GAS BOOSTER HEATER
(ENOUGH HOSE IS PROVIDED TO LOCATE THE GAS BOOTER HEATER APPROXIMATELY 9 FEET
AWAY FROM THE DISHMACHINE. ADDITIONAL HOSE MUST BE ORDERED IF A GREATER DISTANCE
IS REQUIRED. DISTANCES GREATER THAN 20 FEET AWAY CAN AFFECT THE HEATING PERFORMANCE
OF THE UNIT)
CONNECTION HOSES ARE CUT TO LENGTH DURING INSTALLATION.
HOOKUP WHEN GAS BOOSTER HEATER
IS LOCATED TO THE RIGHT OF THE
DISHMACHINE
TYPICAL RECIRCULATING WATER HOOK-UP
FOR ALL GAS HEATED CONVEYORS
HOOKUP WHEN GAS BOOSTER HEATER
IS LOCATED TO THE LEFT OF THE
DISHMACHINE
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
GAS CONVEYOR HOSE INSTALLATION (CONTINUED)
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
DISHMACHINE OPERATING INSTRUCTIONS
PREPARATION: Before proceeding with the start-up of the unit, verify the following:
1. Close door(s) on dishmachine.
2. Close the drain valve(s).
POWER UP (ELECTRICALLY-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.
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 PREPARATION: Refer to the section entitled “PREPARATION” at the top of this page and follow the instructions there. Afterwards, check that all of the chemical levels are correct and/or that there is plenty of detergent available for the
expected workload.
WASHING A RACK OF WARE: To wash a rack, simply slide a rack of soiled ware into the load end of the machine. Once the
the machine is started, it should pull the rack through the machine and push it out the unload end. Once a rack has started
through, you may put another rack in.
OPERATIONAL INSPECTION: Based upon usage, the pan strainers may become clogged with soil and debris as the workday progresses. Operators should 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-66 and AJ-80), 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-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
46
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. 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.
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-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
47
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING DUAL SANITIZATION MODE
If the machine has a dataplate like the one shown, which indicates both Hot Water Sanitizing and Chemical Sanitizing
operation parameters (the area within dashed box), it is possible to change the sanitizing mode after the machine has left
the original manufacturer's facility. This change can only be
performed by an authorized Jackson service technician. If the
machine does not have a dataplate like the one shown, the
sanitization mode CAN NOT be changed.
An
XXXXXXXXX
MODEL: AJ-44CE
Company
XXX XXXX X
SERIAL #
60 HZ 3 PHASE 3 WIRE
WASH MOTOR
DRIVE MOTOR
WASH HEATER LOAD
TOTAL AMP LOAD
Follow the instructions below to change the mode of sanitization. Failure to follow these instructions can result in a violation of applicable regulatory codes.
2.0 HP
1/4 HP
15 KW
208 V
230 V
460 V
5.6 A
1.1 A
41.7 A
48.4 A
5.6 A
1.1 A
37.7 A
44.4 A
2.8 A
0.6 A
18.8 A
22.2 A
HOT WATER
SANITIZING
6.9 FPM
160° F MIN.
180° F MIN.
20 ±5 PSI
DRIVE MECHANISM MAXIMUM SPEED ADJUSTMENT:
Note: This adjustment is only required when changing from
hot water sanitizing to chemical sanitizing mode.
CHEMICAL
SANITIZING
CONVEYOR SPEED
WASH TANK TEMPERATURE
FINAL RINSE TEMPERATURE
FLOW PRESSURE
6.5 FPM
140° F MIN.
140° F MIN.
20 ±5 PSI
NOTE: SEE INSTRUCTION IN MANUAL FOR MODIFYING MODE OF
SANITIZATION.
Locate the maximum speed adjustment mechanism at the top
of the conveyor drive mechanism (Figure 1). Figure 2 shows
an enlarged view of the maximum speed adjustment mechanism. Loosen the Bottom Jam Nut approximately one turn
counterclockwise. Move the Top Jam Nut down on the
threaded shaft by turning it approximately 1/2 turn counterclockwise. Tighten the Adjustment Nut by turning it clockwise.
Retighten the Bottom Jam Nut against the Top Jam Nut.
Commercial
Dishwasher
597G
US Patent Number(s):
6,012,567
Canadian Patent Number(s):
2,205,331
Made in the USA
Jackson MSC Inc.
P. O. Box 1060
Barbourville, KY. 40906
(606) 523-9795
09905-021-70-81 E
Please note the parameters for both modes of sanitization. If your data
plate has this information, it is convertible from one mode to another.
Adjustment Nut
Top Jam Nut
Bottom Jam Nut
Figure 2
Figure 1: Drive Mechanism
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 05-03-2007
48
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
CHANGING DUAL SANITIZATION MODE (CONTINUED)
THERMOSTAT ADJUSTMENT: Remove the front dress
panel from the machine to expose the heater/thermostat box.
Remove the cover from the heater/thermostat box. Locate the
wash tank regulating thermostat (see diagram).
IDENTIFICATION OF SANITIZING MODE: Apply the correct
temperature gauge label to the face of the temperature
gauges. In the chemical sanitizing mode, the temperature
gauge labels must specify 140ºF minimum wash temperature
and 140ºF minimum rinse temperature. In the hot water sanitizing mode, the temperature gauge labels must specify
160ºF minimum wash temperature and 180ºF minimum rinse
temperature.
Apply the correct sanitizing mode label in a visible location on
the side of the control box.
NOTICE:
THIS MACHINE IS
CURRENTLY IN
HOT WATER SANITIZING
MODE!
Front Dress Panel
09905-003-33-15
Orange background
NOTICE:
THIS MACHINE IS
CURRENTLY IN
CHEMICAL SANITIZING
MODE!
09905-003-33-14
Yellow background
INSTALL SANITIZER DISPENSER: For machines in the
chemical sanitizing mode, a NSF Standard 29 approved
chemical dispenser must be installed to dispense sanitizer
into the final rinse line. Follow instructions included with the
chemical dispenser. The system selected must be able to provide detergent and sanitizer in the required concentrations.
The minimum chlorine concentration for proper sanitization is
50 PPM. Furthermore, the selected feeder needs to be able to
operate against a head of 25 PSI and deliver 7.38 ml of a 10%
chlorine sanitizer per minute.
Wash Thermostat
The wash tank regulating thermostat will maintain the correct
wash water temperature. NSF requirements specify that the
wash water during operation be 140ºF minimum in the chemical sanitizing mode and 160ºF minimum in the hot water sanitizing mode. Adjust the thermostat to achieve the required
minimum temperatures during operation. Turn the adjustment
screw clockwise to increase the temperature set point, counterclockwise to decrease the temperature set point.
FINAL CHECK: Verify that the incoming water matches the
flow pressure and temperature requirements listed on the
machine data plate. Verify that minimum wash and rinse temperatures are maintained during operation.
Replace heater/thermostat box cover and front dress panel.
Control Box Gauge Location
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: 04-30-2007
49
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
DETERGENT CONTROL
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. A loss 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-44C Series Technical Manual 7610-001-76-22
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50
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
STRIKER PLATE LIMIT SWITCH INSTALLATION INSTRUCTIONS
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.
1/3 RACK WIDTH
INSTALL AT FAR END OF TABLE
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.
TABLE LIMIT SWITCH THROUGH ROD HOLES
TABLE
SWITCH RODS
STRIKE PLATE
STRIKE PLATE BOLTS
3.00
MOUNTING BOLTS
2.00
TABLE BOTTOM
Ø0.75
1.875
Ø0.25
1.50
Unless noted, all dimensions are in
inches.
TABLE BOTTOM
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 3:
PREVENTATIVE MAINTENANCE
52
SECTION 3: PREVENTATIVE MAINTENANCE
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 PERSONNEL ONLY. 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. A dishmachine 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 if 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. A common 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-44C Series Technical Manual 7610-001-76-22
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53
SECTION 3: PREVENTATIVE MAINTENANCE
D226 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
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 WATER 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 VALVES, 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-44C Series Technical Manual 7610-001-76-22
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54
SECTION 3: PREVENTATIVE MAINTENANCE
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
Final Stage Worm Speed1
ISO Viscosity Grade
AGMA Lubricant No.
-30 - 15°F
up to 2000 FPM
220
5S
16 - 50°F
up to 2000 FPM
460
#7 Compounded
51 - 95°F
up to 450 FPM
680
#8 Compounded
51 - 95°F
above 450 FPM
460
#7 Compounded
96 - 131°F
up to 450 FPM
680
8S
96 - 131°F
above 450 FPM
4601
7S
Mobil
SHC 630
600W Super
Cylinder
Extra Hecla Super
600W Super
Cylinder
SHC 636
SHC 634
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
220
Inca Oil 460
Inca Oil 680
Inca Oil 460
N/A
Syncon R & O
460
Exxon (Esso)
Teresstic SHP220
Spartan EP 460
Spartan EP 680
Spartan EP 460
Teresstic SHP 680
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).
AJ-44C Series Technical Manual 7610-001-76-22
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55
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. 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-44C Series Technical Manual 7610-001-76-22
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56
SECTION 4:
TROUBLESHOOTING SECTION
57
SECTION 4: TROUBLESHOOTING
COMMON PROBLEMS
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: 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.
AJ-44C Series Technical Manual 7610-001-76-22
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58
SECTION 4: TROUBLESHOOTING
COMMON PROBLEMS
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
Heater Contactor
Heater Nuts
Terminal Block
16
35
16
50
In/lbs
In/lbs
In/lbs
In/lbs
AJ-44C Series Technical Manual 7610-001-76-22
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59
SECTION 4: TROUBLESHOOTING
D226 COMMON PROBLEMS
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.
AJ-44C Series Technical Manual 7610-001-76-22
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60
SECTION 5:
PARTS SECTION
61
SECTION 5: PARTS SECTION
AJ-44 CONTROL BOX ASSEMBLY
11
1
2
12
4, 8, 9, 10
4, 5
13
14
10
15
16
19
17
20
17
4, 18, 29
22, 23, 24
25, 26
21, 22
21, 22
21, 22
22, 27
7
6
3
22, 28
AJ-44C Series Technical Manual 7610-001-76-22
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SECTION 5: PARTS SECTION
AJ-44 CONTROL BOX ASSEMBLY (CONTINUED)
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
QTY
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
12
1
1
1
1
4
1
1
3
2
DESCRIPTION
Electrical Box Weldment
Terminal Block, 3 Pole
Thermometer, 96” Lead
Star Washer, External Tooth, 10-24
Screw, 10-32 x 3/4” Long Phillips Trusshead
Decal, Gauge
Thermometer, 48” Lead
Wire Lug, 2 AWG to 14 AWG
Decal, Ground
Screw, 10-32 x 1/2” Long Phillips Trusshead
Decal, L1-L2-L3
Light, Amber
Light, Red
Din Rail
Circuit Breaker (200-380 Volt, 60 Hz Models Only)
Circuit Breaker (CGP Models Only)
Switch, ON/FILL - OFF/DRAIN
Motor Contactor
Heater Contactor
Overload
Overload
Control Relay
Screw, 6-32 x 3/8” Long Round Phillipshead
Fuse (380 Volt-460 Volt, (all 60 Hz) Models Only)
Fuse, 600 Volt Models Only
Fuse Holder for (23) Above
Transformer
200 Volt Model
208-220-230-460 Volt Models
208-220-230-460 Volt CGP Models
380-415 Volt Models
600 Volt Model
Locknut, 10-24 with Nylon Insert
Terminal Board
Terminal Board
Screw, 10-32 x 3/8” Long Phillips Trusshead
Control Relay (CGP Models Only (Not Shown)
MISCELLANEOUS PARTS NOT SHOWN:
Grommet, 1/2” OD x 3/8” ID
Bushing, Heyco SB100
Plug, Heyco 2700 G-875
Control Box Cover
Control Box Cover Hinge Weldment
Control Hinge Rod
Washer, Flat, S/S, 1/4” ID
Cotter Pin
MANUAL/DELIME Switch (located on rear of control box)
MANUAL/DELIME Switch Decal (located on rear of control box)
Copper Conductors Only Decal
Control Box Leg
Bolt, 1/4”-20 x 2-1/2” Long Hex Head
Locknut, 1/4”-20 with Nylon Insert
Component Mounting Plate (located inside the control box)
Conduit Bracket
AJ-44C Series Technical Manual 7610-001-76-22
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63
Mfg. No.
05700-041-88-43
05940-011-48-27
06685-111-68-49
05311-273-02-00
05305-011-62-17
09905-021-72-29
06685-111-68-48
05940-200-76-00
09905-011-86-86
05305-011-39-36
09905-101-12-66
05945-111-44-44
05945-111-44-45
05700-021-72-75
5925-011-68-34
5925-111-64-18
05930-301-46-00
05945-111-68-38
05700-011-71-44
See Chart
See Chart
05945-111-35-19
05305-171-02-00
5920-011-72-88
5920-002-75-95
5920-011-72-89
05950-002-41-47
05950-011-68-35
05950-002-46-10
05950-011-75-59
05950-002-23-77
05310-373-01-00
05940-002-78-97
05940-021-89-41
05305-173-12-00
05945-111-72-51
05325-011-46-73
05975-210-09-00
05975-011-47-81
05700-031-66-88
05700-021-68-57
05700-011-68-58
05311-174-01-00
05315-011-68-56
05930-301-22-18
09905-011-74-61
09905-011-47-35
05700-011-71-47
05306-011-83-52
05310-374-01-00
05700-031-67-03
05700-021-70-88
SECTION 5: PARTS SECTION
AJ-66 & AJ-80 CONTROL BOX ASSEMBLY
1
2
6
3
7, 12
8
9
15
14
16
17
14
18
19
14
20
24, 25
22
23
23
11
23
5
21
10
13
10
4
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
64
SECTION 5: PARTS SECTION
AJ-66 & AJ-80 CONTROL BOX ASSEMBLY (CONTINUED)
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
QTY
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
23
24
25
3
1
1
1
2
26
DESCRIPTION
Electrical Box Weldment
Decal, L1-L2-L3
Terminal Block
Terminal Board
Decal, Gauge
Light, Amber
Wire Lug, 2 AWG to 14 AWG
Light, Red
Din Rail
Thermometer, 96” Lead
Thermometer, 48” Lead
Decal, Ground
Terminal Board
Motor Contactor
Circuit Breaker (200/208/230/360 Volt, 60 Hz Models Only)
Circuit Breaker (CGP Models Only)
Overload
Switch, ON/FILL & OFF/DRAIN
Overload
Overload
Heater Contactor (for non-steam units)
Relay
Transformer (200 Volt Models Only)
Transformer (208/220/230/460 Models Only)
208-220-230-460 Volt CGP Models
Transformer (380/415 Volt Models Only)
Transformer (600 Volt Models Only)
Control Relay
Fuse Holder (380 (60 Hz)/460/600 Volt Models Only)
Fuse (380 (60 Hz)/460 Volt Models Only)
Fuse (600 Volt Models Only)
Control Relay (CGP Models (Not Shown)
MISCELLANEOUS PARTS NOT SHOWN:
Manual/Delime Switch
Manual/Delime Switch Decal
Decal, High Limit Warning Light
Transformer, 150V, 60 Cycle
Control Box Cover
Control Box Leg
Conduit Bracket
Mfg. No.
05700-041-88-50
09905-101-12-66
05940-011-48-27
05940-021-89-41
09905-021-72-30
05945-111-44-44
05940-200-76-00
05945-111-44-45
05700-021-72-75
06685-111-68-49
06685-111-68-48
09905-011-86-86
05940-002-78-97
05945-111-68-38
5925-011-68-34
5925-111-64-18
See Chart
05930-301-46-00
See Chart
See Chart
05945-002-24-70
05945-111-72-51
05950-002-41-47
05950-011-68-35
05950-002-46-10
05950-011-75-59
05950-002-23-77
05945-111-35-19
5920-011-72-89
5920-011-72-88
5920-002-75-95
05945-111-72-51
05930-301-22-18
09905-011-74-61
09905-002-49-48
05950-011-68-35
05700-031-66-88
05700-011-71-47
05700-021-70-88
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
65
SECTION 5: PARTS SECTION
MOTOR OVERLOAD CHART
Model
Volts
Hz
Phase
AJ-44’S
208
220
230
380
415
440
50
50
50
50
50
50
3
3
3
3
3
3
208
230
60
60
1
1
200
208
230
380
460
600
60
60
60
60
60
60
3
3
3
3
3
3
05945-002-66-00
05945-111-68-39
05945-111-68-39
05945-111-69-12
05945-111-68-39
05945-111-69-12
200
208
220
230
380
415
440
50
50
50
50
50
50
50
3
3
3
3
3
3
3
05945-011-84-59
05945-011-84-59
05945-011-84-59
05945-011-84-59
05945-002-71-09
05945-111-69-12
05945-111-69-12
208
230
60
60
1
1
200
208
230
380
460
600
60
60
60
60
60
60
3
3
3
3
3
3
05945-002-66-00
05945-111-68-39
05945-111-68-39
05945-111-69-12
05945-111-68-39
05945-111-69-12
05945-002-66-02
05945-111-68-41
05945-111-68-41
05945-002-24-70
05945-111-68-41
05945-111-81-33
05945-002-65-99
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-68-40
05945-111-81-33
200
208
220
230
380
415
440
50
50
50
50
50
50
50
3
3
3
3
3
3
3
05945-011-84-59
05945-011-84-59
05945-011-84-59
05945-011-84-59
05945-002-71-09
05945-111-69-12
05945-111-69-12
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-81-33
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-81-33
208
230
60
60
1
1
200
208
230
380
460
600
60
60
60
60
60
60
3
3
3
3
3
3
AJ-66’S
AJ-80’S
Drive Motor
Prewash Motor
05945-011-84-59
05945-011-84-59
05945-011-84-59
05945-002-71-09
05945-111-69-12
05945-111-69-12
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
05945-002-65-98
05945-002-24-70
05945-002-24-70
05945-002-24-70
05945-002-24-70
05945-002-24-70
05945-002-24-70
N/A
N/A
N/A
N/A
N/A
N/A
05945-002-66-00
05945-111-68-39
05945-111-68-39
05945-111-69-12
05945-111-68-39
05945-111-69-12
N/A
N/A
05945-002-65-99
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-68-40
05945-111-81-33
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
66
Wash Motor
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-81-33
N/A
N/A
05945-002-65-99
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-68-40
05945-111-81-33
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-81-33
N/A
N/A
N/A
N/A
05945-002-65-99
05945-111-68-40
05945-111-68-40
05945-111-81-33
05945-111-68-40
05945-111-81-33
SECTION 5: PARTS SECTION
HEATER ASSEMBLY
See Heater Chart Below
5/16”-18 Hex Nut
Heater Gasket
05330-200-02-70
5/16” Lockwasher
Heater Replacement Kit Chart
Model
Volts
Phase
KW
Part Number
All*
208
230
200
208
220
230
380
415
440
460
600
1
1
3
3
3
3
3
3
3
3
3
15
15
15
15
15
15
15
15
15
15
15
06401-003-10-21
06401-003-10-22
06401-003-10-21
06401-003-10-21
06401-003-10-22
06401-003-10-22
06401-003-10-28
06401-003-10-28
06401-003-10-29
06401-003-10-31
06401-003-10-33
Replacement Kit Note:
All heater kits come with the
heater, the gasket, lockwashers
and locknuts.
* - AJ-44CGP, AJ-44CS, AJ-44CSL, AJ-66CGP, AJ-66CS, AJ-66CSL, AJ-80CS and AJ-80CSL models do not use electric
heaters in the wash 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 154 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 154 in-lbs.
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
67
SECTION 5: PARTS SECTION
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 (3 phase only). 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-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
68
SECTION 5: PARTS SECTION
HEATER ASSEMBLY (CONTINUED)/THERMOSTATS/DRESS PANELS
THERMOSTATS
The thermostat range is from 140°F to 240°F with a maximum bulb exposure temperature of 300°F.
Calibration:
Wash Thermostat:
Set Point: 165°F (Adjustable range)
Hi-LImit Thermostat:
Fixed set point: 210°F (Non-adjustable)
The hi-limit thermostat is used to protect the heater element in the event of a run away regulating thermostat or a dry fire situation. It is set for 210°F +0°F or -10°F with a fixed set point. This part is not adjustable.
The wash tank regulating thermostat will maintain the correct wash water temperature to meet NSF requirements. These specify that the wash be no lower than 140°F on chemical sanitizing models and no lower than 160°F on hot water sanitizing
machines.
To order the thermostats and corresponding decals:
Kit, Thermostat Wash Regulating (CE/CEL Models)
Kit, Thermostat Wash Regulating (CS/CSL Models)
Thermostat, High Limit Control
06401-003-18-20
06401-003-18-21
05930-011-49-43
HEATER BOX COMPONENTS
Heater Box Weldment
Heater Box Cover
Terminal Board
05700-031-66-81
05700-031-66-82
05940-002-78-97
FRONT DRESS PANELS
Model
Left to Right Part Number
Right to Left Part Number
AJ-44’s
AJ-44CGP
AJ-66’s
AJ-66CGP
AJ-80’s
05700-031-72-22
05700-002-52-77
05700-031-71-85
05700-002-51-22
05700-031-74-06
05700-031-72-22
05700-002-52-77
05700-031-72-42
05700-002-57-84
05700-031-77-10
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
69
SECTION 5: PARTS SECTION
PREWASH PLUMBING ASSEMBLY
Vacuum Breaker, 3/4”
04820-002-53-77
Valve, Solenoid, 3/4”
04810-100-53-00
Elbow, 90°, 3/4” Brass
04730-206-04-34
Nipple, 3/4”, Brass, Close
04730-207-34-00
Nipple, 3/4” x 6” Long
05700-001-26-74
A new gasket can be
ordered using part number 05330-111-42-81.
Fill Line Injector Replacement Kit
06401-003-09-93
Y-Strainer, 3/4” NPT,
Brass
04730-717-02-06
Nipple, 3/4”, Brass, Close
04730-207-34-00
Elbow, 90°, 3/4” Brass
04730-206-04-34
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
70
Replacement Kit Note:
The kit for the fill line injector comes
with the injector weldment, a new
gasket and the mounting hardware.
SECTION 5: PARTS SECTION
WASH SECTION INCOMING PLUMBING ASSEMBLY
3
8
7
13, 14
2
15
Left to right direction shown
17
8
1
6
8
7
Tube Length Chart
Item
Length (Inches)
10
12
15
18
3/4”
3/4”
3/4”
3/4”
x
x
x
x
3-7/16”
2-5/8”
3”
2-13/16”
Replacment Kits Notes:
The rinse and fill injector
replacement kits come with
the injectors, gasket and
mounting hardware. The
rinse injector kit (item 1)
also has the (3) required
brass plugs.
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
QTY
1
1
3
2
3
1
2
2
4
2
1
1
1
1
1
1
1
2
1
2
1
1
1
2
4
20
19
4
6
9
10
21
12
16
22
18 5, 16 11 18
22
DESCRIPTION
Rinse Injector Replacement Kit
Gasket
Plug, Brass, 1/8” NPT
Vacuum Breaker, 3/4” NPT
Elbow, Street, 3/4” NPT
Plug
Union, Brass, 3/4”
Solenoid Valve, 3/4”
Nipple, Close, Brass, 3/4” NPT
Fitting, 3/4” Male to Slip Copper
Tube, Copper
Fill Injector Replacement Kit
Gasket
Tube, Copper
Gauge, Pressure, 0-100 PSI
Valve, Ball, Test Cock, 1/4” NPT
Tube, Copper
Tee, 3/4” x 3/4” x 1/2”
Elbow, Brass, 90°, 3/4” Copper
Tube, Copper
Regulator, Pressure, 3/4” NPT, Brass
Nipple, Brass, 6” Long
Tee, 3/4”, CU x CU x CU
Fitting, Adapter, 1/2” to 1/4”
9
Mfg. No.
06401-003-11-88
05330-111-42-81
04730-209-07-37
04820-002-53-77
04730-206-04-34
04730-209-01-00
04730-212-05-00
04810-100-53-00
04730-207-34-00
04730-401-11-01
See Chart
06401-003-09-93
05330-111-42-81
See Chart
06685-111-88-34
04810-011-72-67
See Chart
04730-411-03-01
04730-406-42-01
See Chart
06685-011-58-22
05700-001-26-74
04730-411-46-01
04730-401-41-01
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
71
SECTION 5: PARTS SECTION
EXTERNAL ELECTRIC BOOSTER INCOMING PLUMBING ASSEMBLIES
Plumbing with Water Hammer Arrestor
1
2
10
3
8
9
11
Tube Length Chart
Item # Length (Inches)
7
9
8
9
3/4” x 3-7/16”
4
5
6
Plumbing without Water Hammer Arrestor
6
3
4
1
7
6
5
ITEM
1
2
3
4
5
6
7
8
9
10
11
QTY
-
DESCRIPTION
Y-Strainer, 3/4” NPT, Brass
Arrestor, Water Hammer, 1/2” NPT
Regulator, Pressure, 3/4” NPT, Brass
Nipple, 3/4” NPT x 2” Long, Brass
Elbow, Brass, 90°, 3/4”
Nipple, 3/4” NPT, Close, Brass
Coupling, 3/4” FNPT x 3/4” FNPT, Brass
Adapter, 3/4” Male
Tube, Copper
Adapter, 1/2” NPT x Male
Tee, Copper, 3/4” x 3/4” x 1/2”
Mfg. No.
04730-717-02-06
06685-100-05-00
06685-011-58-22
04730-207-46-00
04730-206-13-00
04730-207-34-00
04730-011-87-95
04730-401-11-01
See Chart
04730-401-07-01
04730-411-03-01
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
72
SECTION 5: PARTS SECTION
EXTERNAL ELECTRIC BOOSTER OPTION OUTLET PLUMBING
Elbow, 3/4” Copper to Copper (Female)
04730-406-16-01
Tube, Copper, 3/4” x 5-7/8” Long
Elbow, 3/4”, 90°, Street, Copper to Copper
04730-406-40-01
Tube, Copper, 3/4” x 49-1/2” Long
Adapter, 3/4”, Brass
04730-401-11-01
Nipple, 3/4” NPT x 2” Long, Brass
04730-207-46-00
Elbow, 3/4” Copper to Copper (Female)
04730-406-16-01
Tube, Copper, 3/4” x 24” Long
Union, 3/4” NPT, Brass
04730-212-05-00
Elbow, Brass, 90°, 3/4”
04730-206-13-00
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
73
SECTION 5: PARTS SECTION
WATER HAMMER ARRESTOR OPTION/WATER PRESSURE REGULATOR KIT OPTION
WATER HAMMER ARRESTOR OPTION
Water Arrestor, 1/2” NPT
06685-100-05-00
Tee, 3/4” x 3/4” x 1/2”
04730-211-06-00
Nipple, 3/4” NPT,
Close, Brass
04730-207-34-00
WATER PRESSURE REGULATOR WITH ARRESTOR KIT OPTION
Water Arrestor, 1/2” NPT
06685-100-05-00
Bushing, 3/4” x 1/2”
04730-002-01-34
Regulator, Pressure, 3/4”
06685-011-58-22
Tee, Brass, 3/4” x 3/4” x 3/4”
04730-211-01-34
Nipple, Close, 3/4”
04730-207-34-00
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
74
SECTION 5: PARTS SECTION
RINSE SOLENOID VALVE & VACUUM BREAKER REPAIR PARTS KITS
Screw
Data Plate
Cap Screw
Coil & Housing
Data Plate
Valve Bonnet
Spring
06401-003-07-40
Spring position is moved
for clarity.
Goes below the plunger.
Cap
Plunger
06401-003-07-40
O-Ring
06401-003-07-42
Cap Retainer
Diaphragm
Retainer
O-Ring
Diaphragm
06401-003-07-42
Plunger
Components of
Repair Kit
04820-001-60-57
Screen
Retainer
Body
Mesh Screen
Valve Body
Complete Vacuum Breaker Assembly, 3/4” NPT
04820-002-53-77
Complete 110 Volt Solenoid Valve Assembly, 3/4”
04810-100-53-00
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.
Coil & Housing only, 3/4”
06401-003-07-43
Possible Problems:
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.
1. Pilot port extension #1 clogged. Clean hole.
2. Hole #2 Clogged. Pass heated straight pin through hole.
1
2
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
75
SECTION 5: PARTS SECTION
STEAM UNIT WASH TANK COIL ASSEMBLY
Coil Weldment
05700-002-84-03
Stand “D” Weldment
05700-002-74-85
Stand “B” Weldment
05700-002-74-83
Coil Nut
05310-011-17-85
Stand “C” Weldment
05700-002-74-84
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.
Flat Washer
05700-001-17-87
Coil Gasket
05700-001-17-86
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
76
SECTION 5: PARTS SECTION
STEAM PLUMBING (LEFT TO RIGHT)
4
1
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
2
3
5
3
QTY
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
10
STEAM INLET PLUMBING
3
9
6
DESCRIPTION
Reducer, 3/4” NPT to 1/2” NPT, Black Iron
Union, 3/4” NPT, Black Iron
Nipple, Close, 3/4” NPT, Black Iron
Valve, Steam Solenoid, 3/4” NPT, 120V
Elbow, 90°, 3/4” FNPT, Black Iron
Elbow, Street, 90°, 3/4” NPT, Black Iron
Y-Strainer, 3/4” NPT, Black Iron
Valve, Gate, Steam, 3/4” NPT
Plug, 3/8” NPT, Black Iron
Nipple, 3/4” NPT x 32” Long
Reducer, 3/4” NPT to 1/2” NPT, Black Iron
Elbow, 90°, 3/4” FNPT, Black Iron
Elbow, Street, 3/4” NPT, Black Iron
Union, 3/4” NPT, Black Iron
Nipple, Close, 3/4” NPT, Black Iron
Steam Trap, 3/4” NPT
Pipe, 3/4” NPT x 10” Long, Black Iron
STEAM OUTLET PLUMBING
16
11
15
14
8
Mfg. No.
04730-911-02-34
04730-912-01-00
04730-907-01-00
04820-011-87-39
04730-906-10-34
04730-011-87-37
04730-217-01-32
04820-100-19-00
04730-909-02-34
04730-002-21-27
04730-911-02-34
04730-906-10-34
04730-011-87-37
04730-912-01-00
04730-907-01-00
06680-500-02-77
04730-907-06-34
13
12
17
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
77
SECTION 5: PARTS SECTION
STEAM PLUMBING (RIGHT TO LEFT)
STEAM INLET PLUMBING
5
8
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
QTY
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
4
3
10
7
9
3
6
DESCRIPTION
Reducer, 3/4” NPT to 1/2” NPT, Black Iron
Union, 3/4” NPT, Black Iron
Nipple, Close, 3/4” NPT, Black Iron
Valve, Steam Solenoid, 3/4” NPT, 120V
Elbow, 90°, 3/4” FNPT, Black Iron
Elbow, Street, 90°, 3/4” NPT, Black Iron
Y-Strainer, 3/4” NPT, Black Iron
Valve, Gate, Steam, 3/4” NPT
Plug, 3/8” NPT, Black Iron
Nipple, 3/4” NPT x 10” Long
Reducer, 3/4” NPT to 1/2” NPT, Black Iron
Elbow, 90°, 3/4” FNPT, Black Iron
Elbow, Street, 3/4” NPT, Black Iron
Union, 3/4” NPT, Black Iron
Nipple, Close, 3/4” NPT, Black Iron
Steam Trap, 3/4” NPT
Pipe, 3/4” NPT x 10” Long, Black Iron
2
1
Mfg. No.
04730-911-02-34
04730-912-01-00
04730-907-01-00
04820-011-87-39
04730-906-10-34
04730-011-87-37
04730-217-01-32
04820-100-19-00
04730-909-02-34
04730-907-06-34
04730-911-02-34
04730-906-10-34
04730-011-87-37
04730-912-01-00
04730-907-01-00
06680-500-02-77
04730-907-06-34
STEAM OUTLET PLUMBING
13
14
17
16
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
78
SECTION 5: PARTS SECTION
GAS COIL ASSEMBLY (CGP MODELS)
Gas Coil Weldment
05700-002-44-23
Connection point for:
Hose, Recirculating Discharge
(See “Hose Connections” page )
Connects with:
3/4” 90° Elbow Brass
04730-206-13-00
3/4” Close Brass Nipple
04730-207-34-00
Connection point for:
Hose, Wash Coil Assembly
(See “Hose Connections” page )
Connects with:
3/4” 90° Elbow Brass
04730-206-13-00
3/4” Close Brass Nipple
04730-207-34-00
Coil Box Weldment
05700-002-50-94
Gas Coil Box Cover
Replacement Kit
06401-003-10-37
Other items used but not shown.
ITEM
1
2
3
4
5
6
QTY
1
1
1
1
1
2
DESCRIPTION
Thermostat, High Limit
Terminal Board
Thermostat Bracket
Decal, Thermostat Regulating
Thermostat, Wash Regulating
Fitting, 1/4”, Imperial Brass
Mfg. No.
05930-011-49-43
05940-002-78-97
05700-011-81-64
09905-011-84-31
06401-140-00-32
05310-924-02-05
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
79
SECTION 5: PARTS SECTION
TANK, RINSE BOOSTER (CGP MODELS ONLY)
1
4
7
6
8
6
7
BOTTOM ANGLED VIEW
6
2
7
1
TOP ANGLED VIEW
ITEM
1
2
3
4
5
6
7
8
QTY
2
1
1
1
1
1
3
1
DESCRIPTION
Plumbing Assembly, Inlet/Discharge, Rinse Tank
Tube, Dispersion Weldment
Tank, GP Rinse
Bracket, Upper Rinse Tank
Bracket, Lower Rinse Tank
Nipple, 3/4” NPT x 4” Long
Elbow, 3/4” NPT, 90° Brass
Nipple, 3/4” NPT x Closed Brass
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
80
Mfg. No.
05700-002-51-24
05700-002-46-16
05700-002-45-05
05700-002-67-13
05700-002-67-14
04730-207-05-00
04730-206-13-00
04730-207-34-00
SECTION 5: PARTS SECTION
RECIRCULATING PUMP ASSEMBLY (CGP MODELS ONLY)
Elbow, 3/4” 90° Brass
2 per
04730-206-13-00
Pump, Recirculating with Adapters
05700-002-51-28
Nipple, 3/4” Close Brass
2 per
04730-207-34-00
Used on AJ-44CGP, AJ-66CGP, AJ-80CGP units right to
left units and the AJ-44CGP left to right unit.
Used only on AJ-66CGP/AJ-80CGP left to right units.
Mounting Bracket
05700-002-25-74
Mounting Bracket
05700-002-23-61
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
81
SECTION 5: PARTS SECTION
HOSE CONNECTIONS (CGP MODELS ONLY)
D
A
A
C
B
F
B
Recirculating Pump Assembly
Gas Coil Weldment
Rinse Booster Tank
E
C
D
Rinse Header Plumbing Assembly
HOSE ASSEMBLIES
Wash/Fill Plumbing Assembly
AJ-44CGP (L-R & R-L)
AJ-66CGP (L-R )
AJ-66CGP (R-L)
*Each hose assembly includes 2, 3/4” Pushlock Fittings (part number 04730-011-94-00).
A - Hose, Recirculating Discharge
(8 1/2”) 05700-002-52-74
(18”) 05700-002-51-38
(8 1/2”) 05700-002-52-74
B - Hose, Recirculating Pump Suction
(18 1/2”) 05700-002-52-75
(26”) 05700-002-51-37
(18 1/2”) 05700-002-52-75
C - Hose, Wash Coil Assembly
(34”) 05700-002-52-76
(36”) 05700-002-51-39
(50”) 05700-002-57-58
D - Hose, Recirculating Discharge
(L-R 48”) 05700-003-03-95 (60”) 05700-003-03-97
(R-L 60”) 05700-003-03-97
(60”) 05700-003-03-97
E - Hose connection to existing gas booster outlet fitting.
F - Hose connection to existing gas booster inlet fitting.
Gas Booster Connection Kit 05700-002-51-73 includes:
18 Feet of 3/4” Hose
4 - 3/4” Push Lock Fittings
AJ-44C Series Technical Manual 7610-001-76-22
Issued: 03-21-2006 Revised: N/A
82
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