Manitowoc AJ-100CE Installation/Operation & Technical Manual Download Page 7

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VI.

PARTS SECTION

AJ-64 Control Box Assembly

AJ-86/AJ-100 Control Box Assembly

Motor Overload Chart

Heater Box Assembly

Heater Assembly

Frame Weldments/Front Dress Panels

Prewash Plumbing Assembly

Incoming Plumbing Assembly

Rinse Header Plumbing Assembly (CGP Models)

External Electric Booster Option Incoming Plumbing

External Electric Booster Option Outlet Plumbing

WPRK Plumbing Option

3/4” Solenoid Valve & 3/4” NPT Vacuum Breaker Repair Parts Kits

Steam Unit Wash Tank Coil Assembly

Steam Inlet Plumbing (Left to Right)

Steam Inlet Plumbing (Right to Left)

Steam Outlet Plumbing (Left to Right)

Steam Outlet Plumbing (Right to Left)

Gas Coil Assembly (CGP Models)

Rinse Booster Tank Assembly (CGP Models)

Recirculating Pump Assembly (CGP Models)

Hose Connections (CGP Models)

AJ-64 Series Drain Plumbing Assemblies

AJ-86 & AJ-100 Drain Plumbing Assemblies (Left to Right)

AJ-86 & AJ-100 Drain Plumbing Assemblies (Right to Left)

Drain Quench Assembly

Prewash & Wash Motor Assemblies

Prewash & Wash Pump Weldments

Prewash & Upper Wash Arm Assemblies

Lower Wash Arm Assembly

Upper & Lower Power Rinse Arm Assemblies

Final Rinse Assembly

Drive Assembly

Door Assemblies

Pawl Bar Roller Bracket

AJ-64 & AJ-86 Pawl Bar Assemblies

AJ-64 Rack Rail Assembly

Miscellaneous Parts & Weldments

Manifolds/Strainer Support Weldments

Strainers

100

Float Switch Components/Scrap Basket Assembly

101

Curtains/Tub Magnets

102

Vent Cowl Assembly/Vent Scoop Option

103

Exhaust Fan Control Option/Table Limit Switch Options

104

SIDE LOADER SECTION

Side Loader Track Assembly/Leg Replacements

105

Side LoaderPawl Bar Assemblies

106

Side Loader Vent Cowl Option

107

D226 STEAM BOOSTER SECTION

Control Box Assembly

108

Plumbing Assembly

109

Go*Box Components

111

Rinse Fill Motor Option

112

TABLE OF CONTENTS

PARTS

Summary of Contents for AJ-100CE

Page 1: ...DING 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 64 RACK CONVEYOR DISHMACHINE SERIES October 9 2009 P N 7610 002 30 93 Revision G AJ 64CE AJ 64CS AJ 86CE AJ 86CGP AJ 86CS AJ 100CE AJ 100CGP AJ 100CS ...

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: ...2 F 05 02 06 MAW 7572 7730 7634 7743 7428 7571 7554 7475 7463 7462 7367 7789 Pawl bar for AJ 86 R L unit with a side loader option Updated scrap basket drawings Vent cowl assembly for a hooded side loader Service instructions for replacing wash rinse motors Added prison pawl bar packages Thermostat replacement kits updated drain quench assembly replaced wash thermostat 05930 121 67 72 with 05930 0...

Page 5: ...SC 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 suppo...

Page 6: ...ide Loader Left to Right Dimensions 23 Side Loader Right to Left Dimensions 24 Side Loader Installed Dimensions 25 D226 Steam Booster Dimensions 26 D226 Steam Booster Plumbing Line Drawings 27 Typical Electric and Gas Booster Dimensions 28 II INSTALLATION OPERATION INSTRUCTIONS Installation Instructions 30 Deliming Operations 33 Curtain Installation Diagram 34 Side Loader Installation Operation In...

Page 7: ...s Drain Plumbing Assemblies 82 AJ 86 AJ 100 Drain Plumbing Assemblies Left to Right 83 AJ 86 AJ 100 Drain Plumbing Assemblies Right to Left 84 Drain Quench Assembly 85 Prewash Wash Motor Assemblies 86 Prewash Wash Pump Weldments 87 Prewash Upper Wash Arm Assemblies 88 Lower Wash Arm Assembly 89 Upper Lower Power Rinse Arm Assemblies 90 Final Rinse Assembly 91 Drive Assembly 92 Door Assemblies 94 P...

Page 8: ...Primary Side 128 208 230 Volt 60 Hz 3 Phase Secondary Side 129 460 575 600 Volt 60 Hz 3 Phase Primary Side 130 460 575 600 Volt 60 Hz 3 Phase Secondary Side 131 AJ 86CS AJ 100CS 208 230 Volt 60 Hz 1 Phase Primary Side 132 208 230 Volt 60 Hz 1 Phase Secondary Side 133 208 230 Volt 60 Hz 3 Phase Primary Side 134 208 230 Volt 60 Hz 3 Phase Secondary Side 135 460 575 600 Volt 60 Hz 3 Phase Primary Sid...

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

Page 10: ...MACHINES 77 WATER TEMPERATURES AJ 64 86 100CE CS CGP MODELS WASH MINIMUM 150 F POWER RINSE MINIMUM 160 F FINAL RINSE MINIMUM 180 F FLOW PRESSURE PSI 20 5 FLOWRATE GPM AJ 64 86 100CE CS CGP 3 7 STEAM COIL TANK HEAT CS MODELS ONLY STEAM INLET PRESSURE PSIG 10 20 STEAM CONNECTION NPT 3 4 CONSUMPTION 15 PSIG lbs hr AJ 64 86 100CS CSL 100 MOTOR ELECTRICAL CHARACTERISTICS DRIVE MOTOR HP 1 4 WASH MOTOR H...

Page 11: ...5 AMP 230 1 60 19 A 25 AMP 208 3 60 13 A 20 AMP 230 3 60 13 A 20 AMP 460 3 60 7 A 15 AMP AJ 86CE MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 145 A 200 AMP 230 1 60 134 A 175 AMP 208 3 60 86 A 110 AMP 230 3 60 79 A 100 AMP 460 3 60 39 A 50 AMP AJ 86CGP MODELS TYPICAL TOTAL ELECTRICAL VOLTS PH HZ AMPS CIRCUIT 208 1 60 26 A 35 AMP 230 1 60 26 A 35 AMP 208 3 60 17 A 25 AMP 230 3 ...

Page 12: ...Always refer to the machine data plate for specific 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 PRESSU...

Page 13: ...imum Drain Line 25 637mm 64 1626mm 72 1829mm 80 2032mm 8 204mm 14 355mm Scrap Trough Minimum 21 535mm 65 1 2 1665mm A Drive Unit Front View 75 1 2 1915mm 62 1 2 1588mm 29 737mm 6 1 2 165mm 10 254mm 7 178mm D E C 4 102mm 8 203mm 14 354mm Minimum 10 High Table Backsplash Scrap Trough 32 3 4 833mm 35 891mm 5 127mm 8 1 2 218mm C B 24 1 2 622mm 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rai...

Page 14: ...Plate Floor Sink Or Drain With 3 76 mm Minimum Drain Line 25 637mm 64 1626mm 72 1829mm 80 2032mm 8 204mm 21 535mm 65 1 2 1665mm A Drive Unit Front View 75 1 2 1915mm 62 1 2 1588mm 29 737mm 6 1 2 165mm 10 254mm 7 178mm D E C 4 102mm 8 203mm 60 1 4 1528mm 32 3 4 833mm 35 891mm 5 127mm 8 1 2 218mm C B 24 1 2 622mm 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rail Height Above Dishtable 1 4 ...

Page 15: ...o be installed to meet local codes by installing contractor Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet 1 25mm K J H G 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rail Height Above Dishtable 1 4 6mm 5 16 8mm Rack Rail Tub Table Use Silicone Sealer Between Table and Lip of Machine to Prevent Leakage Recommended Table Fabrication Note Tub Will Accept a Ta...

Page 16: ...m 21 535mm 60 1 4 1530mm Right to Left Legend to Drawing A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT 180 F Water Inlet for wash tank fill final rinse tank heating From gas booster heater Interconnecting hose provided by manufacturer G 3 4 NPT 140 F Water inlet for gas b...

Page 17: ...4 102mm 8 203mm 14 354mm Minimum 10 High Table Backsplash Scrap Trough 60 1 4 1528mm 32 3 4 833mm 35 891mm 5 127mm 8 1 2 218mm C Left to Right Legend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT Steam connection G 3 4 NPT Condensate return H Steam electrical connection J...

Page 18: ...l connection J 1 NPT Steam connection K 3 4 Condensate connection L 3 4 NPT Incoming 110 F water connection M 3 4 NPT 180 F water to dishmachine Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rail Height Above Dishtable 1 4 6mm 5 16 8mm Rack Rail Tub Table Use Silicone Sealer Between Table and Lip of Machine to P...

Page 19: ...3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F Prewash water inlet 3 4 NPT 110 F 140 F G Cold water thermostat plumbing connection 3 4 NPT Optional Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet Prewash Plan View Section with Cold Water Thermostat 16 3 4 425mm 16 1 4 415m...

Page 20: ...2mm 94 2385mm 102 2588mm 65 1 2 1665mm 8 1 2 218mm C B 64 1626mm 22 557mm Base Unit Prewash Prewash Plan View Section with Cold Water Thermostat 16 3 4 425mm 16 1 4 415mm F G 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rail Height Above Dishtable 1 4 6mm 5 16 8mm Rack Rail Tub Table Use Silicone Sealer Between Table and Lip of Machine to Prevent Leakage Recommended Table Fabrication Not...

Page 21: ... 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT 180 F Water Inlet for wash tank fill final rinse tank heating From gas booster heater Interconnecting hose provided by manufacturer G 3 4 NPT 140 F Water inlet for gas booster heater H 3 4 NPT 180 F Water Outlet connection to line on dishmachine Connection hose provided by manufacturer J 3 4 NPT Gas Connection K 4 OD Vent pipe connecti...

Page 22: ...chine Connection hose provided by manufacturer J 3 4 NPT Gas Connection K 4 OD Vent pipe connection Flue to be installed to meet local codes by installing contractor L Prewash water inlet 3 4 NPT 110 F 140 F M Cold water thermostat plumbing connection 3 4 NPT Optional Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet Table to Table Overall 4 102 mm wide x 16 406 mm long...

Page 23: ...10mm 8 1 2 218mm H J L M K F Legend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT Steam connection G 3 4 NPT Condensate return H Steam electrical connection J 1 NPT Steam connection K 3 4 Condensate connection L 3 4 NPT Incoming 110 F water connection M 3 4 NPT 180 F wate...

Page 24: ... B Dish Clearance Drive Unit Left Side 66 1 2 1692mm 3 79mm 1 2 15mm 84 2134mm A O N With Doors Open Rear of Machine 6 152mm 1 25mm 65 1 2 1665mm Legend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT Steam connection G 3 4 NPT Condensate return H Steam electrical connectio...

Page 25: ...l Note All vertical dimensions are 1 2 from floor due to adjustable bullet feet Prewash Plan View Section with Cold Water Thermostat 16 3 4 425mm 16 1 4 415mm F G 3 4 19 mm Table Turndown Flange 3 4 Max 21 533 mm Rack Rail Height Above Dishtable 1 4 6mm 5 16 8mm Rack Rail Tub Table Use Silicone Sealer Between Table and Lip of Machine to Prevent Leakage Recommended Table Fabrication Note Tub Will A...

Page 26: ...eakage Recommended Table Fabrication Note Tub Will Accept a Table Flange Up to 24 7 8 632 mm Drive Unit Left Side 66 1 2 1692mm 1 2 15mm 84 2134mm A With Doors Open Rear of Machine 6 152mm 1 25mm C 34 864mm 8 1 2 217mm 21 533mm 25 635mm 12 307mm 25 635mm B Dish Clearance 65 1 2 1665mm 60 1 4 1530mm 62 1 2 1590mm 75 1 2 1919mm Legend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimu...

Page 27: ...52mm 7 178mm D E B 33 1 2 851mm 8 206mm 14 356mm Minimum 10 High Table Backsplash Scrap Trough 6 152mm 36 914mm 31 1 4 795mm 6 1 2 165mm 26 1 2 673mm Front View C 41 1040mm 20 3 4 527mm 8 3 4 222mm 11 3 4 298mm 14 3 4 375mm 6 154mm 30 763mm 14 357mm 7 1 4 185mm 1 1 4 35mm F H G J K H G J K Legend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain con...

Page 28: ...eater H 3 4 NPT 180 F Water Outlet connection to line on dishmachine Connection hose provided by manufacturer J 3 4 NPT Gas Connection K 4 OD Vent pipe connection Flue to be installed to meet local codes by installing contractor L Prewash water inlet 3 4 NPT 110 F 140 F M Cold water thermostat plumbing connection 3 4 NPT Optional Note All vertical dimensions are 1 2 from floor due to adjustable bu...

Page 29: ...9mm 62 1 2 1590mm 29 737mm 10 254mm O 4 102mm G 24 609mm 59 3 4 1519mm N A 23 1 2 598mm 6 152mm 7 178mm D E B 33 1 2 851mm 8 206mm 14 356mm Minimum 10 High Table Backsplash Scrap Trough Front View C 10 255mm 12 1 2 316mm F 17 1 2 442mm 6 1 2 162mm 11 1 2 295mm 15 3 4 400mm 16 1 2 417mm 43 1092mm L H J M 11 1 4 285mm 13 1 2 345mm 23 3 4 604mm 38 966mm 6 1 4 159mm 5 3 4 148mm 4 1 4 110mm 8 1 2 218mm...

Page 30: ...egend A Machine water inlet 3 4 NPT 180 F Hi temp 140 F Low temp minimum B Electrical connection C Drain connection 1 1 2 NPT D Vent collar Optional E Vent cowl standard F 3 4 NPT Steam connection G 3 4 NPT Condensate return H Steam electrical connection J 1 NPT Steam connection K 3 4 Condensate connection L 3 4 NPT Incoming 110 F water connection M 3 4 NPT 180 F water to dishmachine N Prewash wat...

Page 31: ... LENGTH 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 TODISHMACHINE DRAIN LINE CONVEYOR DISHMACHINE 15 for 30 Model 30 for 30 Model ...

Page 32: ... DISHMACHINE 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 33: ... INSTALLATION DIMENSIONS 25 Refer to chart above 34 23 or 30 10 4 23 SIDE LOADER DIMENSIONS 30 SIDE LOADER DIMENSIONS MODEL AJ 64 AJ 86 AJ 100 MODEL AJ 64 AJ 86 AJ 100 DIMENSIONS 95 117 131 DIMENSIONS 102 124 138 Left to Right installation shown for reference NOTE ALL DIMENSIONS ARE TYPICAL Depending on the width of the sideoloader ...

Page 34: ...l 7610 003 30 93 Issued 05 02 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER DIMENSIONS 26 16 6 16 16 13 11 NOTE All dimensions are in inches and are for reference only 43 11 24 14 4 43 11 14 4 24 11 16 16 13 6 16 ...

Page 35: ... 64 Conveyor Series Technical Manual 7610 003 30 93 Issued 05 02 2006 Revised N A SECTION 1 SPECIFICATION INFORMATION D226 STEAM BOOSTER PLUMBING LINE DRAWINGS 27 Steam Booster Piping Double Tank Machine ...

Page 36: ... below 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 ...

Page 37: ...29 SECTION 2 INSTALLATION OPERATION INSTRUCTIONS ...

Page 38: ...It is necessary to remove all foreign debris 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 pri...

Page 39: ...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 40: ...e the bulkhead plug in the side of the tub to install the deter gent concentration probe For more information concerning 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 th...

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