Jackson Enodis AJ-54 Series Installation/Operation & Technical Manual Download Page 6

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SECTION

DESCRIPTION

PAGE

SPECIFICATION INFORMATION

Operating Characteristics

Electrical Requirements

D226 Steam Booster Parameters

AJ-54 Dimensions

AJ-76 (Left to Right) Dimensions

AJ-76 (Right to Left) Dimensions

AJ-90 (Left to Right) Dimensions

AJ-90 (Right to Left) Dimensions

Side Loader (Left to Right) Dimensions

Side Loader (Right to Left) Dimensions

Side Loader (Installed) Dimensions

D226 Steam Booster Dimensions

D226 Steam Booster Plumbing Line Drawings

Typical Electric and Gas Booster Dimensions

II.

INSTALLATION & OPERATION INSTRUCTIONS

Installation Instructions

Deliming Operations

Curtain Installation Diagram

Side Loader Installation & Operation Instructions

D226 Steam Booster Installation & Operation Instructions

Gas Conveyor Hose Installation

Dishmachine Operating Instructions

Detergent Control

Photoelectric Limit Switch Installation Instructions

Striker Plate Limit Switch Installation Instructions

Whisker Limit Switch Installation Instructions

III.

PREVENTATIVE MAINTENANCE

General Maintenance

D226 Maintenance

Drive Motor Gear Reducer Preventative Maintenance

IV.

TROUBLESHOOTING SECTION

Common Problems

D226 Common Problems

SERVICE PROCEDURES

Replacing the Pump Gasket & Seal

Rack Rail Stabilizer Kit

Rinse Solenoid Valve Repair Parts Kit

Vacuum Breaker Repair Parts Kit

Drive Motor & Gear Reducer Replacement

Replacing the Wash Heater

Replacing the Conveyor Motor

VI.

PARTS SECTION

AJ-54 Control Box Assembly

AJ-76/AJ-90 Control Box Assembly

Motor Overload Chart

Heater Assembly

Thermostats

Frame Weldments/Front Dress Panels

TABLE OF CONTENTS

Summary of Contents for Enodis AJ-54 Series

Page 1: ...LUDING SIDE LOADER D226 EXTERNAL STEAM BOOSTER Jackson MSC LLC P O Box 1060 Barbourville KY 40906 606 523 9795 Fax 606 523 9196 www jacksonmsc com AJ 54 RACK CONVEYOR DISHMACHINE SERIES April 19 2007 P N 7610 002 30 91 Revision E AJ 54CE AJ 54CGP AJ 54CS AJ 76CE AJ 76CGP AJ 76CS AJ 90CE AJ 90CS ...

Page 2: ...on if serial number has been removed or altered or if unit is used for purpose other than it was origi nally intended TRAVEL LIMITATIONS Jackson MSC limits warranty travel time to 2 two hours and mileage to 100 one hundred miles Jackson MSC will not pay for travel time and mileage that exceeds this or any fees such as those for air or boat travel without prior authorization WARRANTY REGISTRATION C...

Page 3: ... 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: ...ons Added 3 instruction sheets for limit switches Added instruction sheet for curtains Added AJ 54CGP AJ 76CGP models D 02 01 06 MAW 7600 Added gas exhaust fan hookup schematic updated electric exhaust fan schematic and updated dimension drawings E 03 22 06 MAW 7571 7330 7634 7558 7367 7428 7554 7462 7463 Added thermostat replacement kits Added vent cowl assembly for hooded side loader Replaced ri...

Page 5: ...C 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 Please have this manual with you when you call so that our staff can refer you if necessary to the prop er page Technical support is available from 8 00 a m to 5 00 p m EST Monday through Friday Technical suppor...

Page 6: ...n Operation Instructions 23 Gas Conveyor Hose Installation 25 Dishmachine Operating Instructions 27 Detergent Control 29 Photoelectric Limit Switch Installation Instructions 30 Striker Plate Limit Switch Installation Instructions 31 Whisker Limit Switch Installation Instructions 32 III PREVENTATIVE MAINTENANCE General Maintenance 34 D226 Maintenance 35 Drive Motor Gear Reducer Preventative Mainten...

Page 7: ...n Quench Assembly 92 Motor Assemblies 93 Prewash Wash Pump Weldments 94 Prewash Upper Wash Arm Assemblies 95 Lower Wash Arm Assembly 96 Curtains Tub Magnets 97 Final Rinse Assembly 98 Drive Assembly 99 Lubrication Chart for Drive Gear 101 Door Assemblies 102 Pawl Bar Miscellaneous Components 103 AJ 54 Pawl Bar Assembly 104 AJ 76 Pawl Bar Assemblies 105 AJ 90 Pawl bar Assemblies 106 AJ 54 Rack Rail...

Page 8: ...Phase 132 460 575 600 Volt 60 Hz 3 Phase 133 AJ 76CS AJ 90CS 208 230 Volt 60 Hz 1 Phase 134 208 230 Volt 60 Hz 3 Phase 135 460 575 600 Volt 60 Hz 3 Phase 136 AJ 54CGP 208 230 Volt 60 Hz 1 Phase 137 208 230 Volt 60 Hz 3 Phase 138 460 Volt 60 Hz 3 Phase 139 AJ 76CGP 208 230 Volt 60 Hz 1 Phase 140 208 230 Volt 60 Hz 3 Phase 141 460 Volt 60 Hz 3 Phase 142 Exhaust Fan Hook Up Schematics 143 D226 Steam ...

Page 9: ...1 SECTION 1 SPECIFICATION INFORMATION ...

Page 10: ...AJ 76 AJ 90 110 140 F WASH MINIMUM 160 F RINSE MINIMUM 180 F FLOW PRESSURE PSI 20 5 FLOWRATE GPM AJ 54 76 90CE CS CGP 4 7 STEAM COIL TANK HEAT CS CSL MODELS ONLY STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG lbs hr AJ 54 76 90CS CSL 60 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 WASH MOTOR HP 2 POWER RINSE MOTOR HP 2 PREWASH MOTOR HP AJ 76 MODELS 1 AJ 90 MODE...

Page 11: ... VOLTS PH HZ AMPS CIRCUIT 208 1 60 11 A 15 AMP 230 1 60 11 A 15 AMP 208 3 60 7 A 15 AMP 230 3 60 7 A 15 AMP 460 3 60 4 A 15 AMP 575 3 60 4 A 15 AMP 600 3 60 4 A 15 AMP AJ 76CE MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 113 A 150 AMP 230 1 60 104 A 150 AMP 208 3 60 66 A 90 AMP 230 3 60 61 A 80 AMP 460 3 60 31 A 40 AMP 575 3 60 25 A 35 AMP 600 3 60 26 A 35 AMP AJ 76CGP MODELS ...

Page 12: ... electrical and water requirements The material provided on this page is for reference only and may be subject to change without notice D226 STEAM BOOSTER ELECTRICAL REQUIREMENTS VOLTAGE V 208 230 FREQUENCY HZ 60 PHASE SINGLE WATER REQUIREMENTS INCOMING WATER TEMPERATURE MINIMUM 110 F FLOW PRESSURE PSI 20 5 STEAM REQUIREMENTS INCOMING STEAM PRESSURE PSIG 15 25 HEAT EXCHANGER SPECIFICATIONS TUBESID...

Page 13: ...View 84 75 1 2 60 1 4 62 1 2 34 29 8 10 7 5 22 10 4 6 6 1 2 4 54 70 X Table to Table Overall A B G B A D E F C 25 Opening 1 21 Opening 25 12 1 34 Right Side 21 6 1 2 5 B A C 8 4 1 2 8 4 62 10 1 2 21 Opening 70 4 wide x 16 long cutout in Vent Cowl Splash Shield Shipped with Cover Plate Floor Sink Or Drain With 3 Minimum Drain Line 12 1 2 25 54 Table to Table Table Turndown Flange 3 4 Max 3 4 21 Rac...

Page 14: ... inlet 140 F water max C Drain connection 1 1 2 NPT F Vent collar 4 wide x 16 long x 7 high Optional E Vent cowl standard G Incoming low pressure steam connection 3 4 FPT gate valve supplied Optional H Condensate return connection 3 4 FPT return to boiler feeder or open drain J Cold water thermostat plumbing connection 3 4 NPT Optional Steam tank heat option only Note All vertical dimensions are 1...

Page 15: ... 3 4 J H D J A H C 34 8 1 2 10 3 8 1 25 Opening 6 1 8 12 21 Opening 25 4 1 2 B J A H 67 1 2 7 8 84 Drive Unit w Doors Open A Machine water inlet 3 4 NPT 180 F Hi temp minimum flow requirements 4 7 GPM 279 GPH B 3 4 NPT prewash water inlet 140 F water max C Drain connection 1 1 2 NPT F Vent collar 4 wide x 16 long x 7 high Optional E Vent cowl standard G Incoming low pressure steam connection 3 4 F...

Page 16: ...al E Vent cowl standard G Incoming low pressure steam connection 3 4 FPT gate valve supplied Optional H Condensate return connection 3 4 FPT return to boiler feeder or open drain J Cold water thermostat plumbing connection 3 4 NPT Optional Steam tank heat option only Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet Recommended Table Fabrication Rack Rail Height Above D...

Page 17: ...er max C Drain connection 1 1 2 NPT F Vent collar 4 wide x 16 long x 7 high Optional E Vent cowl standard G Incoming low pressure steam connection 3 4 FPT gate valve supplied Optional H Condensate return connection 3 4 FPT return to boiler feeder or open drain J Cold water thermostat plumbing connection 3 4 NPT Optional Steam tank heat option only Note All vertical dimensions are 1 2 from floor du...

Page 18: ...TH 8 4 1 2 MINIMUM 25 DISHWASHER 5 12 1 2 14 1 2 29 1 1 2 TABLE ROLL 20 3 4 OPENING 1 A A 1 2 MINIMUM 1 2 DISHTABLE USE SILICONE BETWEEN TABLE AND LIP OF SIDE LOADER TO PREVENT LEAK AGE WALL OF SIDE LOADER SECTION A A CENTER LINE DISHMACHINE SPLASH SHIELD VENT CONNECTION OPENING 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE CONVEYOR DISHMACHINE 15 for 30 Model 30 for 30 Model ...

Page 19: ...HMACHINE LENGTH 4 1 2 MINIMUM 12 1 2 25 DISHWASHER 5 1 1 2 TABLE ROLL 20 3 4 OPENING 1 1 2 MINIMUM DISHTABLE 1 2 WALL OF SIDE LOADER USE SILICONE BETWEEN TABLE AND LIP OF SIDE LOADER TO PRE VENT LEAKAGE SECTION A A CONVEYOR DISHMACHINE CENTER LINE DISHMACHINE VENT CONNECTION OPENING SPLASH SHIELD A A 1 1 2 DRAIN CONNECTED TO DISHMACHINE DRAIN LINE 15 for 30 Model 30 for 30 Model ...

Page 20: ...STALLATION DIMENSIONS 12 Refer to chart above 34 23 or 30 10 4 23 SIDE LOADER DIMENSIONS 30 SIDE LOADER DIMENSIONS MODEL AJ 54 AJ 76 AJ 90 MODEL AJ 54 AJ 76 AJ 90 DIMENSIONS 85 107 121 DIMENSIONS 92 114 128 Left to Right installation shown for reference NOTE ALL DIMENSIONS ARE TYPICAL Depending on the width of the side loader ...

Page 21: ...ies Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER DIMENSIONS 13 16 6 16 16 13 11 NOTE All dimensions are in inches and are for reference only 43 11 14 4 24 11 16 16 13 6 16 ...

Page 22: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS 14 Steam Booster Piping Single Tank Machine ...

Page 23: ...ow 3 4 NPT Nipple 2 1 4 3 1 4 7 7 8 200 mm 18 457 mm 6 152 mm 6 152 mm 3 1 4 83 mm 36 914 mm PMG 200 RIGHT SIDE VIEW Water Outlet Water Inlet Gas Inlet Alternate Flue Location TPRV 4 102 mm Vent Adapter Water Outlet Water Inlet Gas Inlet Water Outlet Electrical Electrical Water Inlet Gas Inlet 36 914 mm PMG 200 LEFT SIDE VIEW Water Outlet Water Inlet Gas Inlet Alternate TPRV Location Electric Boos...

Page 24: ...16 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS ...

Page 25: ... from the water line that may potentially get trapped in the valves or cause an obstruction Any valves that are fouled as a result of foreign matter left in the water line and any expenses resulting from this fouling are not the responsibility of the manufacturer Water hardness should be a maximum of 6 grains per gallon Harder water should be treated prior to using the machine Iron in the water su...

Page 26: ...machine operating requirements machine voltage total amperage load and serial number To install the incoming power lines open the control box Install conduit into the pre punched holes in the back of the control box Route power wires and connect to power block and grounding lug Install the service wires L1 L2 and L3 3 phase only to the appropriate terminals as they are marked on the terminal block...

Page 27: ...ning detergent concerns please refer to the page entitled Detergent Control The 1 8 brass plugs on the incoming plumbing rinse injector may be removed to install rinse aid injection fittings All wires for the chemical injectors should be routed through one of the extra openings in the back of the control box Terminals in the control box marked CVS provide a constant voltage signal whenever the dri...

Page 28: ...isconnect or turn off all chemical feeder pumps 3 Close all doors after adding the deliming solution 4 Run the machine for the recommended period of time 5 Turn the unit off and open the doors 6 Wait five minutes then inspect the inside of the machine If the machine is not delimed run another time cycle as per the deliming solution s instructions 7 When clean drain and re fill the machine 8 Run in...

Page 29: ...L L S S R L 21 21 12 12 21 L L S S L R L 76 12 S 90 S 12 L R S S L L 12 12 21 21 90 S 12 76 L R S S L 12 12 21 21 12 12 24 5 L S S XL R L 54 GAS MACHINES XL 24 5 24 5 XL 24 5 XL S 12 L R L S S L L 21 12 12 21 21 21 21 12 12 21 L L S S L R L HOODED SIDE LOADER UNHOODED SIDE LOADER UNHOODED SIDE LOADER HOODED SIDE LOADER ELECTRIC STEAM MACHINES Please refer to the chart for placement of the curtains...

Page 30: ...sing 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 W...

Page 31: ... 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 f...

Page 32: ...n 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 F...

Page 33: ...nection 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 ...

Page 34: ...O THE LEFT OF THE DISHMACHINE CONNECTION HOSES ARE CUT TO LENGTH DURING INSTALLATION 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 HOSES MARKED A IN THE ABOVE ILLUSTRATIONS CONNECT TO THE INLET ...

Page 35: ...lly 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 secti...

Page 36: ...EANING GAS HEATED MODELS At the end of the work day shut down the gas booster in accor dance 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 of...

Page 37: ...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...

Page 38: ...he outside of the dishtable using the 1 4 20 hardware supplied The cable entering the switch body should be pointing upwards so that the switch sensitivity adjust ment screw is downwards for adjusting from the underside of the table 4 Wiring instructions a White wire from the conveyor control panel to red black wire from proximity switch b Door switch wire from the conveyor control panel to the bl...

Page 39: ... the switch 2 Parts of the table switch are mounted in the dishtable at the end of the table and under the table See the drawing s for the relationship of the switch to the table 3 Move the limit switch as far down on the two slots as possible and see that the limit switch is straight on the base plate This might require adjustment of the nut on the connector for the limit switch 4 Then adjust the...

Page 40: ...STALLATION INSTRUCTIONS 32 Installation Instructions 1 Wiring Refer to the machine schematic 2 Mounting Mount the switch as indicated in the drawing s above Mounting Bracket Limit Switch and Lever 3 7 8 Typ Spacing Dish Table Wall Side View 12 Typ Spacing Limit Switch and Lever Wall Dish Table Top View Switch Mounting Bracket Limit Switch Lever ...

Page 41: ...33 SECTION 3 PREVENTATIVE MAINTENANCE ...

Page 42: ...work harder and decreases efficiency Again it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larg er 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 machi...

Page 43: ... 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 out let side of the heat exchanger Once the desired pressure is achieved tighten the top nut to ensure that the adjustment can not be accidently changed The water pressure regulator has an internal strainer that can be removed through the bottom...

Page 44: ...wever 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 usin...

Page 45: ...37 SECTION 4 TROUBLESHOOTING SECTION ...

Page 46: ...ressure 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 operatin...

Page 47: ...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 ob...

Page 48: ...lace 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...

Page 49: ...41 SECTION 5 SERVICE PROCEDURES ...

Page 50: ...er 5 Large flathead screwdriver TIME REQUIRED It is estimated that it will take 1 person one and a half hours to perform this task not including all of the items indicated in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance procedure Become familiar with the parts and what actions need to be taken This will save time in the l...

Page 51: ...rwise carefully examine the gasket for tears and other damage If it is accept able set to the side If you are not going to replace the seal go to step 16 8 Using a large screwdriver flathead preferred but a phillip shead will work just as well and the 7 16 socket loosen and then remove the bolt holding the impeller to motor shaft Refer to the picture below 9 With the bolt and washer removed grasp ...

Page 52: ...s place a rag or paper towel between your fingers and the seal Gently slide the shaft seal over the shaft and push it down against the mounting plate seal Place the spring and cap over the shaft 15 Place the woodruff key back into the groove of the motor shaft and re install the impeller being careful to align the woodruff key with the slot in the impeller Replace the bolt and washer then tighten ...

Page 53: ...ON 5 SERVICE PROCEDURES 45 RACK RAIL STABILIZER KIT First remove three bolts locknuts and flat washers at middle hood tub junction Next remove door splash shield Then install new door splash shield using the three bolts locknuts and flat washers Rack Rail Stabilizer 05700 011 34 63 ...

Page 54: ...ED It is estimated that it will take 1 person twenty min utes to perform this task not including all of the items indicat ed in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance evolution Become familiar with the parts and what actions need to be taken This will save time in the long run 2 The procedures demonstrated in this m...

Page 55: ... coil Take the new coil and attach the conduit reinstall tighten the conduit nut and pull the wires through so that you will be able to wire the valve back up 9 Reconnect the wires from the conduit to the wires from the solenoid as they had been connected previously Ensure that the wire nuts are on tight 10 Slide the coil wire cover back on taking care not to dam age the wires 11 If you are done p...

Page 56: ...tead it is recommended that the entire valve should be replaced These instructions do not provide information on replacing the solenoid valve 16 Note Even though an O ring may not appear damaged it is a good idea to go ahead and replace it if you have a new one This will help ensure that your valve remains leak free in the future 17 Remove the diaphragm retainer and then the diaphragm itself Many ...

Page 57: ...gn objects from the valve body that would obstruct flow 22 Reassemble the valve reversing the steps needed to take it apart Replace defective replacement parts with new parts from ordered kits Ensure that components are sufficiently tightened to prevent leakage AFTER MAINTENANCE ACTIONS Reconnect the incoming water if disconnected and turn on Then restore power to the unit Run the unit for at leas...

Page 58: ...l flathead screwdriver 2 Needle nose pliers TIME REQUIRED It is estimated that it will take 1 person twenty min utes to perform this task not including all of the items indicat ed in the section entitled PREPARATION IMPORTANT NOTES 1 Read these instructions thoroughly before attempt ing this maintenance evolution Become familiar with the parts and what actions need to be taken This will save time ...

Page 59: ...towel remove any grit grime or debris that may have gotten caught in the threads of both the cap retainer or the vacuum breaker body There is an O ring that should be present on the cap retainer as well Regardless of the condition of the plunger this O ring should be replaced once the cap is removed Using a small flathead screwdriver remove the old O ring 10 With the new O ring in place screw the ...

Page 60: ...flathead screwdriver 9 Medium phillipshead screwdriver 10 Medium hammer 11 Rubber mallet TIME REQUIRED It is estimated that it will take 1 person one and a quarter hours to replace the drive motor one and a quarter hours to just replace the gear reducer or two hours to do both at one time not including all of the items indicated in the sec tion entitled PREPARATION IMPORTANT NOTES 1 Read these ins...

Page 61: ...member to support and lay it gently on the floor or some other surface in order to continue working on it Be sure that you get the key checking the keyway on the motor shaft and in the gear reducer 7 If the purpose of this maintenance action is to replace the drive motor continue to step 8 If you wish to replace the gear reducer continue to step 21 8 With the motor laying on a level surface you ne...

Page 62: ...ough the hole pro vided Tighten the conduit nut 15 Using the wire nuts wire the motor back the same way the old one had been Refer to the schematic on the motor itself or contact Jackson Technical Service if you any questions 16 Once the wiring is done carefully push wires back into the motor and put the access cover back on Tighten down the screws for securing it 17 The drive motor now needs to b...

Page 63: ...nce the drive hub bolt bearing are removed loosen the set screw on the drive hub There is no need to remove it 23 Remove the gear drive by using the 9 16 socket and ratchet as well as the combination wrench as required to remove the nuts holding it to the mounting plate 24 Gently remove the gear reducer careful not to drop it 25 Set the gear reducer on a flat surface The drive hub needs tobe remov...

Page 64: ...ore power to the unit Run the unit for at least 10 minutes running an empty rack through the machine to ensure that it is carried all of the way through If you hear any grinding sounds while the motor is running immediately shut off the unit and secure power and water There is a seri ous problem that must be addressed If any problems arise you can contact Jackson Technical Service SPECIAL NOTES Wo...

Page 65: ...letely TOOLS REQUIRED The following tools will be needed to perform this maintenance evolution 1 3 8 Nutdriver 2 Ratchet 3 1 2 Socket 4 3 8 Socket 5 Phillipshead Screwdriver 6 Needlenose Pliers 7 Torque Wrench 8 Silicone Sealant 9 Amp Meter TIME REQUIRED It is estimated that it will take 1 person ninety min utes to perform this task not including all of the items indicat ed in the section entitled...

Page 66: ...the tub weldment 9 Remove the gasket 10 Before proceeding any further it is important to verify that the tub wall is free of any excess debris so that when the new gasket is applied there are no gaps that could lead to leaking around the heater 11 Apply the new heater gasket from your service kit 12 Slide the heater onto the studs and apply by hand the lock washers and nuts Tighten the nuts by han...

Page 67: ...he well and hold the thermostat probe in place 15 Reattach the incoming power lines to the heater ensuring that you wire the heater correctly for either single or three phase operation 16 Using the torque wrench or a torque nutdriver if available torqe the nuts holding the wires jumpers and bus bars to 16 in lbs 17 Ensuring that all non essential personnel are clear of the area close the drain val...

Page 68: ...then verify the torque of all fasteners covered in this instruction SPECIAL NOTES Work performed on Jackson dishmachines by unau thorized or unqualified personnel may void the warranty Before beginning this or any other maintenance evolution on a unit under warranty you should contact a certified Jackson technician or Jackson Technical Service You can find a list of qualified service agencies in t...

Page 69: ...N IMPORTANT NOTES 1 Read these instructions thoroughly before attempting this maintenance procedure Become familiar with the parts and what actions need to be taken This will save time in the long run 2 The procedures demonstrated in this manual are shown being performed on an AJ 44 rack conveyor dishma chine The actual maintenance steps however apply to any wash prewash or power rinse motor found...

Page 70: ...ver on the new motor assembly and pull the wires free Install the conduit fitting 11 Run the conduit to the motor pulling the machine wires through and into the motor wiring box 12 Rewire the motor exactly the same way the old one was wired and or refer to the motor schematic to determine how the motor should be wired for the incoming power If you require help on this do not hesitate to contact Ja...

Page 71: ...t Motor Support 05700 021 73 42 Clamp Motor Support 04730 002 32 15 CONTACT INFORMATION Jackson MSC Inc provides technical support for all of the dishmachines detailed in this manual We strongly rec ommend that you refer to this manual before making a call to our technical support staff Please have this manual with you when you call so that our staff can refer you if necessary to the proper page T...

Page 72: ...64 SECTION 6 PARTS SECTION ...

Page 73: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 6 PARTS SECTION AJ 54 CONTROL BOX ASSEMBLY 65 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 15 ...

Page 74: ...er 575 600 Volt Models Only 05950 002 23 77 15 2 Relay Top Mount 05945 111 72 51 16 1 Fuse Holder 460 575 600 Volt Models Only 05920 011 72 89 17 1 Fuse 460 575 600 Volt Models Only 05920 011 72 88 18 1 Control Relay 05945 111 35 19 19 1 Terminal Board 05940 021 70 70 20 1 Control Box Decal 09905 021 72 29 21 1 Thermometer Wash 06685 111 68 48 1 Decal Wash 160 F 09905 003 00 69 22 1 Thermometer Ri...

Page 75: ...Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 6 PARTS SECTION AJ 76 AJ 90 CONTROL BOX ASSEMBLY 67 1 2 3 4 5 6 4 7 10 11 12 8 4 9 10 14 14 14 15 16 17 18 18 20 21 22 23 24 25 26 26 27 26 28 29 31 30 30 13 26 19 26 ...

Page 76: ...21 89 41 20 2 Heater Contactor Not Available on Steam Models 05945 002 24 70 21 2 Screw 10 32 x 3 8 Long Phillips Trusshead 05305 173 12 00 22 1 Transformer 05950 011 68 35 1 Transformer 575 600 Volt Models Only 05950 002 23 77 23 4 Locknut 10 24 with Nylon Insert 05310 373 01 00 24 1 Fuse Holder 460 575 600 Volt Models Only 05920 011 72 89 25 1 Fuse 460 575 600 Volt Models Only 05920 011 72 88 26...

Page 77: ...AJ 76CE 575 60 3 05945 111 69 12 05945 111 68 41 05945 111 68 41 AJ 76CE 600 60 3 05945 111 69 12 05945 111 68 41 05945 111 81 33 AJ 76CS 208 60 1 N A N A N A AJ 76CS 230 60 1 N A N A N A AJ 76CS 208 60 3 05945 111 68 39 05945 111 68 41 05945 111 68 40 AJ 76CS 230 60 3 05945 111 68 39 05945 111 68 41 05945 111 68 40 AJ 76CS 460 60 3 05945 111 68 39 05945 111 68 41 05945 111 68 40 AJ 76CS 575 60 3 ...

Page 78: ... NOTE When replacing the tub heaters it is HIGHLY recommended that you also change out the gasket as well Once installed gaskets become compressed and are subjected to extreme temperature changes Replacing the gasket with a new one when replacing the heater may prevent future leaks SERVICE NOTE The nuts used to secure the heater to the tub should be torqued to 16 in lbs After tightening the unit s...

Page 79: ...ions 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 instruc tions Replace any defective elem...

Page 80: ...chines To order the thermostats and corresponding decals Kit Thermostat Wash Regulating CE Models 06401 003 18 20 Kit Thermostat Wash Regulating CS Models 06401 003 18 21 Thermostat High Limit Control 05930 011 49 43 1 4 Imperial Brass Fitting 05310 924 02 05 HEATER BOX COMPONENTS Heater Box Weldment 05700 031 66 81 Heater Box Cover 05700 031 66 82 Terminal Board 05940 002 78 97 FRAME WELDMENTS Mo...

Page 81: ...0 100 53 00 Nipple 3 4 Brass Close 04730 207 34 00 Vacuum Breaker 3 4 04820 002 53 77 Elbow 90 3 4 Brass 04730 206 04 34 Elbow 90 3 4 Brass 04730 206 04 34 Nipple 3 4 x 6 Long 05700 001 26 74 Fill Line Injector Replacement Kit 06401 003 09 93 A new gasket can be ordered using part num ber 05330 111 42 81 Replacement Kit Note The kit for the fill line injector comes with the injector weldment a new...

Page 82: ... 1 Tube Copper See Chart 13 1 Gauge Pressure 0 100 PSI 06685 111 88 34 1 Decal 15 25 PSI 09905 002 97 74 14 1 Valve Ball Test Cock 1 4 NPT 04810 011 72 67 15 1 Tube Copper See Chart 16 2 Tee 3 4 x 3 4 x 1 2 04730 411 03 01 17 1 Elbow Brass 90 3 4 Copper 04730 406 42 01 18 2 Tube Copper See Chart 19 1 Regulator Pressure 3 4 NPT Brass 06685 011 58 22 20 1 Nipple Brass 6 Long 05700 001 26 74 21 1 Tee...

Page 83: ...3 4 NPT Brass 06685 011 58 22 4 Nipple 3 4 NPT x 2 Long Brass 04730 207 46 00 5 Elbow Brass 90 3 4 04730 206 13 00 6 Nipple 3 4 NPT Close Brass 04730 207 34 00 7 Coupling 3 4 FNPT x 3 4 FNPT Brass 04730 011 87 95 8 Adapter 3 4 Male 04730 401 11 01 9 Tube Copper 3 4 x 3 7 16 Long 05700 011 72 70 10 Adapter 1 2 NPT x Male 04730 401 07 01 11 Tee Copper 3 4 x 3 4 x 1 2 04730 411 03 01 1 8 9 11 9 8 2 1...

Page 84: ... 3 4 NPT x 2 Long Brass 04730 207 46 00 Union 3 4 NPT Brass 04730 212 05 00 Adapter 3 4 Brass 04730 401 11 01 Tube Copper 3 4 x 24 Long 05700 021 76 53 Elbow 3 4 Copper to Copper Female 04730 406 16 01 Tube Copper 3 4 x 49 1 2 Long 05700 031 87 98 Elbow 3 4 Copper to Copper Female 04730 406 16 01 Elbow 3 4 90 Street Copper to Copper 04730 406 40 01 Tube Copper 3 4 x 5 7 8 Long 05700 011 87 96 ...

Page 85: ...3 4 NPT Close Brass 04730 207 34 00 Water Arrestor 1 2 NPT 06685 100 05 00 Tee 3 4 x 3 4 x 1 2 04730 211 06 00 Water Arrestor 1 2 NPT 06685 100 05 00 Bushing 3 4 x 1 2 04730 002 01 34 Tee Brass 3 4 x 3 4 x 3 4 04730 211 01 34 Nipple Close 3 4 04730 207 34 00 Regulator Pressure 3 4 06685 011 58 22 WATER PRESSURE REGULATOR WITH ARRESTOR KIT OPTION WATER HAMMER ARRESTOR OPTION ...

Page 86: ...ly 3 4 06401 003 07 43 Screw Data Plate Coil Housing Valve Bonnet Spring 06401 003 07 40 Plunger 06401 003 07 40 Spring position is moved for clarity Goes below the plunger O Ring 06401 003 07 42 Diaphragm Retainer Diaphragm 06401 003 07 42 Screen Retainer Mesh Screen Valve Body Components of Repair Kit 06401 003 06 24 Cap Screw Data Plate Cap O Ring Plunger Body Cap Retainer Complete Vacuum Break...

Page 87: ...r 05700 002 11 78 Coil Weldment 05700 002 84 03 Stand C Weldment 05700 002 74 84 Stand D Weldment 05700 002 74 85 Coil Nut 05310 011 17 85 Flat Washer 05700 001 17 87 Coil Gasket 05700 001 17 86 SERVICE NOTE Jackson HIGHLY recommends that the Coil Gaskets be replaced any time the Coil Weldment is replaced or removed for an extended period of time Stand B Weldment 05700 002 74 83 ...

Page 88: ... 1 Valve Steam Solenoid 3 4 NPT 120V 04820 011 87 39 5 2 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 6 2 Elbow Street 90 3 4 NPT Black Iron 04730 011 87 37 7 1 Y Strainer 3 4 NPT Black Iron 04730 217 01 32 8 1 Valve Gate Steam 3 4 NPT 04820 100 19 00 9 1 Plug 3 8 NPT Black Iron 04730 909 02 34 10 1 Nipple 3 4 NPT x 47 Long 04730 021 89 26 11 1 Pipe 3 4 NPT x 2 Long Black Iron 04730 907 05 34 12 1...

Page 89: ...9 5 1 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 6 1 Elbow Street 90 3 4 NPT Black Iron 04730 011 87 37 7 1 Y Strainer 3 4 NPT Black Iron 04730 217 01 32 8 1 Valve Gate Steam 3 4 NPT 04820 100 19 00 9 1 Plug 3 8 NPT Black Iron 04730 909 02 34 10 1 Nipple 3 4 NPT x 10 Long 04730 907 06 34 11 1 Reducer 3 4 NPT to 1 2 NPT Black Iron 04730 911 02 34 12 1 Elbow 90 3 4 FNPT Black Iron 04730 906 10 34 ...

Page 90: ...stat Regulating 09905 011 84 31 6 1 Thermostat Wash Regulating 06401 140 00 32 7 2 Fitting 1 4 Imperial Brass 05310 924 02 05 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 Conne...

Page 91: ...g No 1 2 Plumbing Assembly Inlet Discharge Rinse Tank 05700 002 51 24 2 1 Tube Dispersion Weldment 05700 002 46 16 3 1 Tank GP Rinse 05700 002 45 05 4 1 Bracket Upper Rinse Tank 05700 002 67 13 5 1 Bracket Lower Rinse Tank 05700 002 67 14 6 1 Nipple 3 4 NPT x 4 Long 04730 207 05 00 7 3 Elbow 3 4 NPT 90 Brass 04730 206 13 00 8 1 Nipple 3 4 NPT x Closed Brass 04730 207 34 00 1 7 4 8 7 6 6 2 7 1 6 ...

Page 92: ...207 34 00 Elbow 3 4 90 Brass 2 per 04730 206 13 00 Pump Recirculating with Adapters 05700 002 51 28 Pump Recirculating Modified 05700 002 81 22 Pump Recirculating 06105 002 05 26 Mounting Bracket 05700 002 25 74 Mounting Bracket 05700 002 23 61 Used only on AJ 76CGP left to right units Used on AJ 54CGP AJ 76CGP AJ 90CGP units right to left units and the AJ 54CGP left to right unit ...

Page 93: ...rculating Pump Suction 23 1 2 05700 002 65 57 18 05700 002 51 38 C Hose Wash Coil Assembly 34 05700 002 52 76 36 05700 002 89 72 D Hose Wash Fill Supply 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...

Page 94: ...406 42 01 10 1 Tee 3 4 CUB x CUB x CUB 04730 411 46 01 11 2 Tee 3 4 x 3 4 x 1 2 04730 411 03 01 12 2 Fitting Adapter 1 2 to 1 4 04730 401 41 01 13 1 Plug 1 4 NPT Brass 04730 209 01 00 14 1 Test Cock Valve Ball 1 4 NPT 04810 011 72 67 15 1 Gauge Pressure 0 100 PSI 06685 111 88 34 1 Decal 15 25 PSI 09905 002 97 74 16 1 Nipple Brass 6 Long 05700 001 26 74 17 1 Fill Injector 05700 011 67 99 1 Gasket 0...

Page 95: ...ng Assembly 05700 002 51 15 Incoming Plumbing Support Bracket 05700 002 50 70 Nipple 3 4 Close Brass 04730 207 34 00 Solenoid Valve 3 4 110V 04810 100 53 00 Valve 3 4 Pressure Reducing 04820 002 51 53 Y Strainer 3 4 Brass 04730 717 02 06 Inlet Plumbing Mounting Bracket 2 per 05700 002 51 41 Clamp Pipe 2 per 05700 000 35 06 Elbow 3 4 NPT 90 Brass 04730 206 13 00 Nipple 3 4 Close Brass 04730 207 34 ...

Page 96: ...53 AJ 54CGP Ball Valve Handle Assembly 05700 021 84 74 Ball Valve 1 1 2 NPT 04820 111 71 46 Elbow 1 1 2 Brass 90 Street 04730 206 32 00 AJ 54CGP Complete Drain Assembly 05700 002 52 71 AJ 54 Series Complete Drain Assembly 05700 031 70 10 Nipple 1 1 2 Brass Close 04730 207 40 00 Tee 1 1 2 Brass 04730 011 69 93 Nipple Rinse Weldment 05700 021 84 61 Fitting Barbed 1 1 2 NPT x 1 1 2 04730 011 69 92 ...

Page 97: ...ft to Right Plumbing Assembly Connector No Hub 1 1 2 4720 604 06 00 Valve Ball 1 1 2 04820 111 71 46 Ball Valve Handle Assembly 05700 021 84 74 Nipple Brass Close 1 1 2 NPT 04730 207 40 00 Nipple Brass 3 NPT 04730 011 87 04 Tee Brass 1 1 2 x 1 1 2 x 1 1 2 04730 011 69 93 Tube Copper 1 1 2 x 6 3 8 Long 05700 002 98 99 Tube Copper 1 1 2 x 4 5 8 Long 05700 002 98 98 Tube Copper 1 1 2 x 10 1 8 Long 05...

Page 98: ...Plumbing Assembly Adapter Male to Female 1 1 2 04730 401 25 01 Tube Copper 1 1 2 x 5 1 16 Long 05700 021 88 13 Tube Copper 1 1 2 x 13 3 4 Long 05700 021 88 17 Connector No Hub 1 1 2 4720 604 06 00 Ball Valve Handle Assembly 05700 021 84 74 Nipple Brass Close 1 1 2 NPT 04730 207 40 00 Nipple Brass 3 NPT 04730 011 87 04 Tee Brass 1 1 2 x 1 1 2 x 1 1 2 04730 011 69 93 Nipple Rinse Weldment 05700 021 ...

Page 99: ...207 40 00 6 2 Elbow Brass 90 1 1 2 FNPT 04730 011 73 77 7 1 Tube Copper 1 1 2 x 1 3 4 Long 05700 000 75 57 8 1 Rinse Nipple Weldment 05700 021 84 61 9 2 Tube Copper 1 1 2 x 3 1 2 Long 05700 011 84 23 10 2 Tube Copper 1 1 2 x 7 1 2 Long 05700 002 50 98 11 1 Nipple Brass 1 1 2 NPT x 3 Long 04730 011 87 04 12 1 Tube Copper 1 1 2 x 4 1 4 Long 05700 011 88 40 1 Entire Assembly 05700 002 89 64 6 6 5 2 2...

Page 100: ... 10 as required Mount the Thermostat Item 1 to the tub using the Thermostat Bracket Item 2 and set it for 120 F 140 F Install the Solenoid Valve Item 3 to the second Tee Item 7 and then attach to the incoming cold water line Use pipe dope or thread tape as required to prevent any leaks Thermostat 05930 121 67 72 Thermostat Bracket 05700 002 73 72 Solenoid Valve 04810 100 09 18 To Cold Water Supply...

Page 101: ...06401 003 10 41 600 3 60 06105 002 48 31 06401 003 10 41 AJ 90 s 208 1 60 06105 121 70 57 06401 003 10 42 230 1 60 06105 121 70 57 06401 003 10 42 200 3 60 06105 121 70 58 06401 003 10 43 220 3 60 06105 121 70 58 06401 003 10 43 230 3 60 06105 121 70 58 06401 003 10 43 460 3 60 06105 121 70 58 06401 003 10 43 575 3 60 06105 002 48 31 06401 003 10 41 600 3 60 06105 002 48 31 06401 003 10 41 See Mot...

Page 102: ...4 94 Prewash Pump Weldment AJ 76 AJ 90 Right to Left models 05700 002 11 96 Wash Pump Weldment 05700 041 68 88 Prewash Pump Weldment AJ 76 AJ 90 Left to Right models 05700 002 10 62 Prewash Pump Weldment AJ 76CGP Left to Right model 05700 002 43 56 Scoop Intake Suction Wash Weldment 05700 002 51 20 Pump Discharge Weldment 05700 002 50 90 Gasket 05330 002 54 55 Wash Pump Weldment 05700 002 50 92 Pr...

Page 103: ...nded that a thread locking fluid be used to ensure that the screws do not back out during normal operation Replacement Kit Note The replacement kit for the end cap includes the endcap lanyard mounting screw and the locknut Upper Wash Manifold Support Bracket 05700 021 73 97 End Cap Replacement Kit 06401 003 10 19 Replacement Kit Note The replacement kit for the end cap includes the endcap lanyard ...

Page 104: ...sert 05310 373 01 00 Lower Wash Arm Manifold Weldment 05700 031 75 06 Manifold Quick Release Key 05700 011 94 45 SERVICE NOTE When replacing the 10 32 screws in the End Caps it is recommended that a thread locking fluid be used to ensure that the screws do not back out during normal operation Lower Wash Arm Support Bracket 05700 011 71 20 Secured with Locknut 1 4 20 with Nylon Insert 05310 374 01 ...

Page 105: ... 73 82 Curtain 24 1 2 Long x 20 1 2 Wide CGP MODELS ONLY 08415 002 47 37 Extra Long Curtain Decal CGP MODELS ONLY 09905 002 52 69 Middle Curtain Hook 05700 011 72 65 Curtain Hook 05700 011 83 54 Limit Switch Bracket 05700 021 71 18 Conveyor Switch Replacement Kit 06401 003 11 79 Replacement Kit Note The conveyor switch replacement kit comes with the switch a terminal and a wire nut Service Note Th...

Page 106: ... Plate 05700 002 53 62 Left Rinse Pan Locator Bracket 05700 021 92 38 Right Rinse Pan Locator Bracket 05700 021 92 37 Rinse Tray Weldment All models except CGP 05700 031 66 75 Rinse Tray Weldment CGP models only 05700 031 66 75 Optional Parts for CGP Models Locknut 1 4 20 with Nylon Insert 05310 374 01 00 End plugs can be ordered using part number 04730 209 07 37 O Ring 05330 011 74 55 Retaining R...

Page 107: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 6 PARTS SECTION DRIVE ASSEMBLY 99 1 2 3 4 11 12 13 18 17 14 15 16 5 6 7 8 9 10 See Detail A ...

Page 108: ... Drive Plate 05700 021 67 42 11 2 Pillow Block 03120 021 71 87 12 1 Drive Spring 05315 011 83 51 13 2 Shaft Collar 05700 011 89 18 14 1 Drive Motor Mounting Bracket 05700 031 73 56 15 1 Adjuster Spring 05315 011 71 90 16 1 Adjusting Handle Weldment 05700 021 72 28 17 1 Drive Motor Replacement Kits Drive Motor 50 Hz Models 06401 003 08 41 1 Drive Motor 208 230 Volt 60 Hz Single Phase Models 06401 0...

Page 109: ... Gear Oil AGMA 8 Gear Oil AGMA 7 Gear Oil N A N A Castrol Tribol 800 220 Tribol 1105 7C Tribol 1105 8C Tribol 1105 7C Tribol 800 680 Tribol 800 460 Chevron Tegra 220 Cylinder Oil W460 Cylinder Oil W680 Cylinder Oil W460 Tegra 680 Tegra 460 Conoco Syncon R O Inca Oil 460 Inca Oil 680 Inca Oil 460 N A Syncon R O 220 460 Exxon Esso Teresstic SHP220 Spartan EP 460 Spartan EP 680 Spartan EP 460 Teresst...

Page 110: ...92 6 1 Door Stop Weldment Right 05700 002 96 33 7 1 Door Stop Weldment Left 05700 002 96 32 8 2 Locknut 10 24 SS Hex with Nylon Insert 05310 373 01 00 9 2 Door Stop Weldment Prewash 05700 002 05 46 Wash Door Handle Weldment 05700 011 82 63 Prewash Door Handle Weldment 05700 011 80 45 Wash Door Hood Support 05700 031 84 13 22 Prewash Door Hood Support 05700 031 84 14 Door Stiffener Not Shown 05700 ...

Page 111: ...t a gasket and the mounting hardware The guide block kit con tains both blocks and a gasket Service Note It is highly recommended that when changing out one guide block that the other be changed out as well along with the gasket Guide Block Replacement Kit 06401 003 10 15 Pawl Bar Roller Replacement Kit 06401 003 11 80 Replacement Kit Notes The replacement kit for the pawl bar roller comes with th...

Page 112: ...A SECTION 6 PARTS SECTION AJ 54 PAWL BAR ASSEMBLY 104 Pawl Bar Dog Casting 12 per 05700 021 69 00 Pawl Bar Spacer 24 per 05700 011 71 45 Pawl Bar Weldment 05700 031 75 09 AJ 54 Complete Assembly with Hardware 06401 131 81 01 AJ 54 Prison Assembly with Hardware 06401 231 81 01 ...

Page 113: ...EMBLIES 105 Left to Right Assembly Pawl Bar Weldment 05700 031 75 18 Pawl Bar Spacer 05700 011 71 45 Pawl Bar Dog Casting 05700 021 69 00 Pawl Bar Weldment 05700 031 82 00 Right to Left Assembly AJ 76 Complete L R Assembly 06401 141 81 04 AJ 76 Complete R L Assembly 06401 241 81 04 AJ 76 Prison Assembly 06401 341 81 04 ...

Page 114: ...ll associated hardware spacers and castings may be ordered using the part numbers indicated in the above assembly Pawl Bar Weldment 05700 041 82 01 Both assemblies contain 20 pawl bar dog castings Please note the direction of installation as indicated on the above drawings When replacing pawl bar dog castings ensure to re install in the appropriate direction If you do not then the rack will not be...

Page 115: ...07 Spacer 6 per 05700 011 71 44 Limit Switch Actuator Assembly 1 per 05700 021 77 03 Actuator Switch Replacement Kit 06401 003 10 14 Rack Rail Weldment 05700 031 81 95 Opposite Rack Rail 05700 041 75 29 Replacement Kit Note The replacement kit for the actuator switch comes with the switch two spac ers and the mounting hardware ...

Page 116: ...05700 002 91 11 Spacer 6 per 05700 011 71 44 Left to Right Assembly Rack Guide Weldment 05700 041 75 47 Opposite Rack Rail 05700 041 75 46 Actuator Switch Replacement Kit 06401 003 10 86 Actuator Switch Replacement Kit 06401 003 10 14 Actuator Assembly 05700 021 77 03 Spacer 6 per 05700 011 71 44 Right to Left Assembly Opposite Rack Rail 05700 041 75 46 Replacement Kit Notes The replacement kits f...

Page 117: ...1 11 Left to Right Assembly Actuator Switch Replacement Kit Rack Guide Spacer 05700 011 71 44 Right to Left Assembly Limit Switch Actuator Assembly 05700 021 77 03 Rack Guide Spacer 05700 011 71 44 Actuator Switch Replacement Kit 06401 003 10 85 Actuator Switch Replacement Kit 06401 003 10 14 Rack Guide Weldment 05700 031 81 56 Opposite Rail 05700 041 75 98 Replacement Kit Notes The replacement ki...

Page 118: ...e Replacement Kit 06401 003 10 00 Replacement Kit Note The kit for the hole direction plate comes with the plate a new gasket and the mounting hardware Pipe Clamp 05700 000 35 05 Rinse Drain Plate Replacement Kit CGP Models Only 06401 003 10 07 Rinse Drain Plug Replacement Kit 06401 003 10 06 Rinse Drain Weldment Replacement Kit 06401 003 10 05 Rinse Drain Plate Gasket 05330 011 72 27 Replacement ...

Page 119: ...ent AJ 80 Models Only 05700 002 24 94 Prewash Manifold Weldment CGP Models Only 05700 002 59 51 Wash Manifold Weldment 05700 031 71 13 Wash Manifold Weldment CGP Models Only 05700 002 51 14 Shoulder Bolt Wingnut Weldment 05700 002 46 02 Wash Fill Tube Weldment 05700 021 71 21 Prewash Fill Tube Weldment AJ 66 AJ 80 Models Only 05700 021 74 76 Vellumoid Gasket 05330 111 42 81 Wash Strainer Separator...

Page 120: ...Strainer Weldment 05700 021 85 11 Drain Guard Strainer Weldment 05700 002 09 15 Front Strainer Weldment 05700 021 85 10 Screen Strainer with Handle Weldment 05700 002 09 04 Overflow Strainer Support 05700 001 96 48 Tub Strainer Weldment CGP Models 05700 002 03 21 Wash Intake Strainer Weldment CGP Models 05700 002 51 52 ...

Page 121: ...loat Switch Replacement Kit 06401 003 11 75 Prewash Tank Float Switch Replacement Kit 06401 003 11 76 Replacement Kit Note The float switch replacement kits contain the float switch with associated terminals the flat washer and the nut Service Agent Note Remember than when reinstalling the float switch that the flat washer goes inside against the tub wall while the nut is on the outside of the tub...

Page 122: ...t Cowl Cover Replacement Kit 06401 003 10 16 Gasket Top Vent Cowl 05330 031 83 47 Vent Cowl Replacement Kit 06401 003 11 62 Gasket Side Vent Cowl 05330 031 83 48 VENT SCOOP OPTION Replacement Kit Note The kit for the vent cowl comes with the vent cowl weldment new gaskets and the lock nuts needed to mount it Vent Scoop Assembly 05700 002 04 08 ...

Page 123: ...Models 05700 003 14 59 Terminal Board 05940 011 84 41 Whisker Switch Assembly 05700 002 23 94 Whisker Limit Switch Lever 05930 303 40 01 Whisker Limit Switch Mounting Bracket 05700 000 14 55 Limit Switch 05930 002 62 81 Striker Plate Limit Switch Assembly 05700 002 62 94 Proximity Limit Switch Sensor 06685 002 94 15 Bracket Proximity Switch 05700 002 94 93 Photoelectric Limit Switch Assembly 05700...

Page 124: ...2 1 Actuator Switch Replacement Kit 06401 003 10 64 3 2 Spacer 05700 011 71 44 4 1 Leg Socket Replacement Kit 06401 003 09 79 5 1 Leg Support Replacement Kit 06401 003 09 80 6 1 Bullet Foot 05340 108 01 03 1 2 3 Side loader track assembly left to right model shown Replacement Kits Notes The actuator switch replacement kit comes with the actuator weldment mounting hardware and 2 spacers The leg soc...

Page 125: ...1 231 86 90 Replacement Kit Note The kits for the pawl bars come with the bar weldment 3 dogs and the hardware Replacement Kit Note The replacement kits for the drive linkages come also with the hardware for mounting them to the pawl bars Pawl Bar Roller Bracket 05700 031 77 94 Replacement Kit Note The conveyor switch replacement kit comes with the switch a termi nal and a wire nut Service Note Th...

Page 126: ...acement Kit Right to Left 06401 003 11 83 Replacement Kit Note The replacement kit s for the vent cowls come with the cowls the gaskets and mounting hardware Replacement Kit Note The cover kit contains the cover and the hardware for mounting it Vent Cowl Gasket Top 05330 031 83 47 Vent Cowl Gasket Side 05330 031 83 48 Service Note One of the side gaskets that come in the kit will need to be cut to...

Page 127: ...the inside of the control box cover 09905 002 78 56 Cover Control Box 05700 001 19 82 Decal L1 L2 09905 002 78 67 Ground Lug 05940 200 76 00 Spacer Terminal Block 05700 011 40 05 Decal Ground 09905 011 86 86 Thermostat 06680 500 01 77 Conduit Fitting 231 x 394 05975 011 49 03 Terminal Block 05940 500 09 61 Control Box with Decal 06401 002 78 87 Decal Only 09905 021 44 97 Light Red 05945 111 21 57 ...

Page 128: ...nical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 6 PARTS SECTION D226 STEAM BOOSTER PLUMBING ASSEMBLY 120 17 2 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 31 7 32 33 30 ...

Page 129: ...ge 06685 111 88 34 16 1 Steam Relief Valve 04820 100 07 06 17 2 Nipple 3 4 NPT x 4 Long Brass 04730 207 05 00 18 2 Tee 3 4 NPT x 3 4 NPT x 3 4 NPT Brass 04730 211 01 34 19 1 Bushing 2 NPT x 1 NPT Black Iron 04730 002 94 51 20 3 Elbow 90 1 NPT Black Iron 04730 906 03 34 21 2 Nipple 1 NPT x 4 Long Black Iron 04730 907 09 34 22 1 Elbow 90 Street 3 4 NPT Black Iron 04730 011 87 37 23 1 Nipple Pigtail ...

Page 130: ...e 06685 111 88 34 6 Glide Door Edge 05700 111 70 92 2 Magnet Door Reed Switch 05930 111 51 68 2 O Ring Prewash Manifold 05330 400 12 08 2 O Ring Wash Manifold 05330 011 74 56 1 Overload Drive Motor 05945 111 68 39 1 Overload Wash Motor 05945 111 68 40 1 Relay 120v 3 PDT 05945 111 72 51 1 Relay 120v 50 60Hz 3A Control 05945 111 35 19 1 Repair Kit 3 4 Vacuum Breaker 04820 001 60 57 4 Roller Pawl Bar...

Page 131: ... 1 Clamp Hose 5 5 8 to 6 04730 011 34 90 4 1 Reducer Bushing 1 1 4 to 1 04730 002 73 62 5 1 Reducer Bushing 1 to 3 4 04730 011 65 14 6 1 Elbow 90 Deg 1 Street 04730 002 11 99 7 1 Nipple 1 NPT x 6 Long Brass 04730 002 12 00 8 1 Elbow 90 Deg Brass Female 04730 002 12 55 9 4 Lockwasher 1 4 05311 274 01 00 10 4 Bolt 1 4 20 x 1 2 Long 05305 274 02 00 11 4 Nut Hex S S 1 4 20 05310 274 01 00 12 1 Rinse M...

Page 132: ...124 SECTION 7 ELECTRICAL SCHEMATICS ...

Page 133: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CE 208 230 VOLT 60 HZ SINGLE PHASE 125 09905 002 12 70 ...

Page 134: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CE 208 230 VOLT 60 HZ THREE PHASE 126 ...

Page 135: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CE 460 575 600 VOLT 60 HZ THREE PHASE 127 09905 031 95 56 ...

Page 136: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CS 208 230 VOLT 60 HZ SINGLE PHASE 128 ...

Page 137: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CS 208 230 VOLT 60 HZ THREE PHASE 129 ...

Page 138: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CS 460 575 600 VOLT 60 HZ THREE PHASE 130 ...

Page 139: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CE AJ 90CE 208 230 VOLT 60 HZ SINGLE PHASE 131 09905 031 80 35 ...

Page 140: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CE AJ 90CE 208 230 VOLT 60 HZ THREE PHASE 132 ...

Page 141: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CE AJ 90CE 460 575 600 VOLT 60 HZ THREE PHASE 133 ...

Page 142: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CS AJ 90CS 208 230 VOLT 60 HZ SINGLE PHASE 134 ...

Page 143: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CS AJ 90CS 208 230 VOLT 60 HZ THREE PHASE 135 09905 002 46 98 ...

Page 144: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CS AJ 90CS 460 575 600 VOLT 60 HZ THREE PHASE 136 ...

Page 145: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CGP 208 230 VOLT 60 HZ SINGLE PHASE 137 ...

Page 146: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CGP 208 230 VOLT 60 HZ THREE PHASE 138 ...

Page 147: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 54CGP 460 VOLT 60 HZ 3 PHASE 139 ...

Page 148: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CGP 208 230 VOLTS 60 HZ SINGLE PHASE 140 ...

Page 149: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CGP 208 230 VOLTS 60 HZ THREE PHASE 141 ...

Page 150: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS AJ 76CGP 460 VOLTS 60 HZ THREE PHASE 142 ...

Page 151: ...AJ 54C Series Technical Manual 7610 002 30 91 Issued 03 22 2006 Revised N A SECTION 7 ELECTRICAL SCHEMATICS CONVEYOR EXHAUST FAN HOOKUP 143 ...

Page 152: ...CHEMATICS D226 STEAM BOOSTER DRAIN QUENCH SYSTEM SIDE LOADER 144 E1 E2 FS1 TS1 S1 S1 L2 L1 GND OFF OFF ON ON TS1 THERMOSTAT FS1 SOLENOID COIL S1 POWER SWITCH E1 POWER LIGHT E2 SOLENOID LIGHT D226 STEAM BOOSTER 208 230 VOLT 60 HZ 1PH 09905 002 78 56 A DRAIN QUENCH SYSTEM 54 CONVEYORS 76 90 CONVEYORS ...

Page 153: ...145 SECTION 8 JACKSON MAINTENANCE REPAIR CENTERS ...

Page 154: ...414 FAX 650 635 1919 pndappl aol com P D APPLIANCE 4220 C ROSEVILLE ROAD NORTH HIGHLANDS CA 95660 916 974 2772 800 824 7219 FAX 916 974 2774 COMMERCIAL APPLIANCE SERVICE INC 281 LATHROP WAY 100 SACRAMENTO CA 95815 916 567 0203 800 464 2222 916 567 0324 FAX COLORADO GCS SERVICE INC SHERIDAN CO 303 371 9054 800 972 5314 FAX 303 371 4754 HAWKINS COMMERCIAL APPLIANCE SERVICE 3000 S WYANDOT ST ENGLEWOO...

Page 155: ...NAPOLIS IN 317 545 9655 800 727 8710 FAX 317 549 6286 B622 LA PAS TRAIL INDIANAPOLIS IN 46268 317 290 8060 800 410 9794 317 290 8085 FAX IOWA GOODWIN TUCKER GROUP 2900 DELAWARE AVENUE DES MOINES IA 50317 515 262 9308 800 372 6066 FAX 515 262 2936 parts goodwintucker com CONES REPAIR SVC 1056 27TH AVENUE SW CEDAR RAPIDS IA 52404 319 365 3325 800 747 3326 FAX 319 365 0885 KANSAS GCS SERVICE INC KANS...

Page 156: ...0 284 4427 FAX 314 638 0135 KAEMMERLIN PARTS SVC 2728 LOCUST STREET ST LOUIS MO 63103 314 535 2222 FAX 314 535 6205 petek kps stl com GENERAL PARTS INC 1101 EAST 13TH STREET KANSAS CITY MO 64106 816 421 5400 800 279 9967 816 421 1270 FAX MONTANA RESTAURANT APPLIANCE SVC 7219 ROOSEVELT WAY NE SEATTLE WA 98115 206 524 8200 800 433 9390 FAX 206 525 2890 info restappl com NEBRASKA GOODWIN TUCKER GROUP...

Page 157: ...RGO ND 58103 701 235 4161 800 279 9987 701 235 0539 FAX OHIO CERTIFIED SERVICE CENTER 890 REDNA TERRACE CINCINNATI OH 45215 513 772 6600 800 543 2060 FAX 513 612 6600 sbarasch certifiedsc com CERTIFIED SERVICE CENTER 171J K NORTH HAMILTON RD COLUMBUS OH 43213 614 751 3769 866 862 1252 FAX 614 751 5792 jadkins certifiedsc com CERTIFIED SERVICE CENTER 6025 N DIXIE DRIVE DAYTON OH 45414 937 898 4040 ...

Page 158: ... 800 442 5026 FAX 972 484 2531 GCS SERVICE INC HOUSTON TX 713 785 9187 800 868 6957 FAX 713 785 3979 GCS STOVE PARTS 2120 SOLANA STREET FORT WORTH TX 76117 817 831 0381 800 433 1804 FAX 817 834 7754 bud stoveparts com UTAH LA MONICA S RESTAURANT EQMT SVC 6182 SOUTH STRATLER AVENUE MURRAY UT 84107 801 263 3221 800 527 2561 FAX 801 263 3229 lamonica81 aol com VERMONT NORTHERN PARTS SVC 4874 S CATHER...

Page 159: ...532 FAX 303 778 0268 metroappls aol com INTERNATIONAL GLOBAL PARTS AND SUPPLY 7758 NW 72ND ST MIAMI FL 33166 305 885 6353 H D SHELDON AND CO 19 UNION SQUARE WEST NEW YORK NY 10003 212 627 1759 212 924 6920 CANADA THE GARLAND GROUP 1177 KAMATO ROAD MISSISSAUGA ONTARIO L4W 1X4 905 206 8380 SALES 905 624 1419 FAX 905 624 1851 SERVICE 800 427 6668 FAX 800 361 7745 AJ 54C Series Technical Manual 7610 0...

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