Champion The Dishwashing Machine Specialists Technical Manual Pass-Through Glasswasher Model CG4 CG6 Machine Serial No. June, 2001 P.O. Box 4149 Winston-Salem, North Carolina 27115-4149 Manual P/N 111557 REV. E Champion Industries, Inc. www.championindustries.
Complete the information below so it will be available for quick reference.
REVISIONS Revision History Revision Date Revised Pages Serial Number Effectivity Comments 02/18/91 All 5181 Issued manual and service parts list, Revision A 10/12/94 4 6106 Tank switch shuts down machine, revised the schematic 05/10/95 4 6216 Changed to new style chemical injection board, revised the schematic 06/07/95 — 6226 Changed to narrow control box, eliminated float rod bearing 02/02/97 All — Reissue of manual and service parts lists, Revision B 02/28/00 43 — Revised wash
CONTENTS CONTENTS Page WARRANTY ............................................................................................................................. INTRODUCTION...................................................................................................................... INSTALLATION........................................................................................................................ Unpacking ...............................................................................
WARRANTY LIMITED WARRANTY Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115, and P.O. Box 301, 2674 N. Service Road, Jordan Station, Canada L0R 1S0, warrants machines, and parts, as set out below.
INTRODUCTION INTRODUCTION Welcome to Champion... and thank you for allowing us to take care of your glass washing needs. This manual covers the Models CG4 and CG6 glasswashers. Your machine was completely assembled, inspected, and thoroughly tested at our factory before it was shipped to your installation site.
INSTALLATION INSTALLATION Unpacking 1. Remove all packing from inside and on top of the machine. 2. Remove all packing from glass operated switch and left and right pick-up plates. Check that the left and right hand pick-up plates are positioned properly. 3. Check the position of the splash curtains. 4. Check that the conveyor is aligned with the drive sprockets and the lift bracket on the right hand side is firmly engaged over track adjusters. 5.
INSTALLATION INSTALLATION (Cont’d) Measurements Uncrated Crated SW-400 SW-600 SW-400 SW-600 Height 38-1/2" (978) 38-1/2" (978) 49" (1244) 46-1/2" (1181) Width 48" (1219) 72" (1182) 25-1/4" (640) 27" (685) Depth 22" (559) 22" (559) 25-1/8" (638) 27-1/2" (698) Ship Wt. 225lb/102kg 285lb/129kg 154lb/70kg 176lb/80kg *adjustable foot height 1-3/4" (45) max.
INSTALLATION INSTALLATION (Cont’d) Electrical Connections 1. The Glass Washer has a six foot power cord with a “U” ground tandem plug for connection to a power receptacle. 2. Provide a nonlocking 250 volt, 15 ampere, 2 pole, 3 wire grounding receptacle within four feet of the base of the Glass Washer(CSA TYPE 6-15R). This should be installed by a qualified electrician to meet the specifications of the local electrical code. 3. This machine operates from 208 to 240 volts.
OPERATION OPERATION General 1. The wash tank is equipped with a float assembly that operates a single camoperated switch. 2. The water temperature is controlled by a heater and a thermostat. The thermostat should be between 140°F/60°C and 160°F/ 71°C. To Fill the Wash Tank B A Figure 3 — Wash Tank Ensure that the standpipe (A) is in place. Put switch (B) up to the “ON-FILL” position. The water will fill until the proper level is reached.
OPERATION OPERATION (Cont’d) APPROXIMATE CHEMICAL SETTINGS General Approximate chemical settings can be obtained by counting the revolutions of the injector rotors. 1. For detergent, one revolution per second equals approximately 0.35% concentration. NOTE: Detergent pump only operates when hot water tank is filling. 2. For sanitizer, one revolution in 5 seconds equals approximately 12.5 ppm Iodine or 50 ppm chlorine. 3. For rinse agent, one revolution in 8 seconds is recommended.
OPERATION OPERATION (Cont’d) To Adjust Rinse Agent Injector: 1. When a new rinse agent container is installed, push the prime button in and hold until the rinse injector feed tube is full. 2. Start the washer. Take a sample from the final rinse spray tubes. 3. To increase the volume of rinse agent, turn the adjustment screw clockwise. 4. To decrease the volume of rinse agent, turn the adjustment screw counter-clockwise. NOTE: To meet the requirements of N.S.F.
6 5 Figure 4 — Plumbing Diagram 12 2 3 TO DRAIN WASH 4 1 7 RINSE RINSE 8 9 1) WASH WATER TANK 2) STAND PIPE 3) WASH RETURN SCREEN 4) DRAIN PAN 5) DRAIN SCREEN 6) WASH PUMP SAN DET FLOW 7) MAIN TANK STANDPIPE 8) CHEMICAL INJECTOR 9) INJECTION FITTING 10) WATER INLET VALVES 11) MIXING VALVE 12) VACUUM BREAKER 10 HOT COLD WATER IN WATER IN 11 10 12 OPERATION OPERATION (Cont’d)
MAINTENANCE MAINTENANCE CLEANING Daily Cleaning Instructions 1. Clear the conveyor of glassware and turn glasswasher off by flipping the toggle switch located on the wash tank to the “off” position. 2. Remove load and unload end pick-up plates and splash curtains. Wash them with hot soapy water, rinse thoroughly, then dry. 3. Lift and remove spray hood and set it aside. 4. At right hand side of machine, raise conveyor lift bracket to stop position.
TROUBLESHOOTING TROUBLESHOOTING 14 CONDITION CAUSE SOLUTION Conveyor does not turn No power.............................................Check fuse panel Turn power switch on Drive motor burnt out .........................Replace Obstruction in wash or rinse ..............Remove obstruction Micro-switch on switch support..........Adjust or replace bracket faulty or not making contact Conveyor not in position.....................Position properly Conveyor tension too loose.................
TROUBLESHOOTING CONDITION CAUSE SOLUTION Water temperature low in detergent tank Thermostat setting low........................Adjust thermostat Thermostat defective...........................Replace Defective float switch .........................Replace Heater burnt out ..................................Check and replace Ensure water level is above element Incoming water temp. low ..................Hot water supply min. 145°F/66°C Water on floor around machine Pump seal leaking ....................
REPLACEMENT PARTS REPLACEMENT PARTS 17
REPLACEMENT PARTS 6 5 1 7 8 9 4 13 12 11 10 Figure 5 — Main Frame Assembly 18 3 2
REPLACEMENT PARTS MAIN FRAME ASSEMBLY Fig. 5 Item No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 Part No. 0707561 0707673 0501873 0703003 0501412 0703002 0308100 0501921 0501885 0501464 0707514 0707515 0507836 0507582 Part Description Frame Assembly, SW600........................................................... Frame Assembly, SW400........................................................... Grey Cast Foot ........................................................................... Hinge Rail, Right Side .........
REPLACEMENT PARTS 10 11 12 13 10 8 14 15 9 1 2 3 4 5 11 6 16 12 13 7 9 Figure 6 — Spray Assembly 20 17
REPLACEMENT PARTS SPRAY ASSEMBLY Fig. 6 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part No. 0501746 0501753 0301790 0501745 0503589 0501716 0307502 0301795 0303009 0303010 0501718 0501719 0501717 0501407 0501497 0303091 0303092 Part Description Manifold Cap ............................................................................. O-Ring........................................................................................ Manifold, Triple .....................................................
REPLACEMENT PARTS 6 5 4 3 14 7 16 15 8 17 9 2 17 1 10 29 18 11 19 12 20 21 13 17 28 27 22 16 15 23 26 24 25 Figure 7 — Main Tank Assembly (R-L Shown) 22
REPLACEMENT PARTS MAIN TANK ASSEMBLY Fig. 7 Item No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 –– –– Part No. 0707562 0707497 0707498 0303221 0307500 0303224 0707485 0501736 0501728 0501721 0302975 0501727 0501408 0707576 0707503 0307518 0501539 0501501 0501412 0703080 0504825 0302970 0507583 0307489 0307488 0503301 0503723 0501375 0503574 0307506 0502977 107964 0507493 0507587 Part Description Main Tank, SW600 ..................................................
REPLACEMENT PARTS 9 7 10 11 12 15 14 13 16 17 18 19 20 21 1 2 23 8 6 7 5 4 22 3 24 25 26 20 27 Figure 8 — Lift Bracket and Drive Assembly 24
REPLACEMENT PARTS LIFT BRACKET AND DRIVE ASSEMBLY Fig. 8 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 19 20 21 22 23 24 24 25 25 26 26 27 27 — — Part No. 0501345 0501355 0501456 0702979 0501408 0501793 0501395 0501899 0501706 0501731 0501729 0501419 0501710 0501732 0501702 0704576 0703029 0501418 0501593 0703213 0703154 0501733 0501722 0501420 0701724 0503401 0503705 0501590 0501590 0501589 0501589 0503664 0503664 0704862 0704863 Part Description Drive Motor, 230 Volt c/w Fan .............
REPLACEMENT PARTS 8 1 2 3 6 5 4 12 10 11 9 7 3 Figure 9 — Hood Assembly 26
REPLACEMENT PARTS HOOD ASSEMBLY Fig. 9 Item No. 1 1 2 3 4 5 6 7 8 9 10 11 12 Part No. 0703244 0708681 0501497 0501408 0302997 0501743 0302998 0501538 0703176 0507011 0703702 0503703 0703078 Part Description Hood, with vacuum breaker at rear............................................ Hood, with vacuum breaker at front .......................................... Lock Washer, #8......................................................................... Screw, 8-32 x 1/4".......................................
REPLACEMENT PARTS 22 24 21 23 20 25 26 27 28 19 29 17 18 30 16 15 31 14 12 13 11 32 10 33 9 32 8 6 7 1 5 2 4 3 Figure 10 — Control Box 28
REPLACEMENT PARTS CONTROL BOX Fig. 10 Item No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 15 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 29 Part No.
REPLACEMENT PARTS 8 7 6 5 4 1 2 3 9 10 11 12 13 14 15 16 17 18 20 19 Figure 11 — Control Box Cover/Chemical Injector Board 30
REPLACEMENT PARTS CONTROL BOX COVER/CHEMICAL INJECTOR BOARD Fig. 11 Item No. 1 2 3 4 5 6 7 8 9 9 9 10 10 11 12 13 14 15 16 17 18 19 20 NS NS NS NS Part No. 0508433 106695 0508710 0309037 0503637 0508920 0501450 0501411 0503695 0505483 0503694 0307408 0309052 0503301 0509061 0503343 0300986 0501408 0501538 0307409 0306363 0502666 0501869 0507577 0507578 0509039 0503739 Part Description Circuit Board (starting @ S/N 6216) ......................................... Screw, 6-32 x 1/2”.........................
REPLACEMENT PARTS 2 3 5 4 6 7 8 32 1 33 34 9 10 11 12 26 27 31 13 30 14 15 29 16 28 36 17 18 19 20 35 21 5 22 23 24 25 Figure 12 — Detergent Tank 32
REPLACEMENT PARTS DETERGENT TANK Fig. 12 Item No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part No. 0707415 0709054 0307296 0307378 0707375 0507471 0700948 0503670 0507426 0703673 0501397 0503701 0504864 0501896 0501600 0503588 0507315 0507323 0501650 0501836 0501419 0707383 0707380 0307423 0503301 0501412 107435 107886 108051 0507431 0502563 0502668 0307427 0503679 0502665 0502662 0502571 Part Description Detergent Tank (up to S/N 6226)........
REPLACEMENT PARTS 8 7 6 8 TO VACUUM BREAKER 7 6 TO DETERGENT TANK 11 3 10 9 1 2 1 3 COLD WATER VALVE 2 4 2 5 3 HOT WATER VALVE 12 13 14 15 16 17 21 18 19 20 22 23 1 25 24 Figure 13 — Inlet Plumbing 34
REPLACEMENT PARTS INLET PLUMBING Fig. 13 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Part No. 0502783 0503802 0503801 0507324 0502768 0502653 0503679 0502665 0509659 0307688 0501419 0504822 0306208 0307373 0501404 0501493 0501533 0505229 0502811 0502810 0502807 0502804 0502803 0501406 0502806 Part Description 230V 60HZ Solenoid Valve ....................................................... 3/8" MPT Tee .........................................................................
REPLACEMENT PARTS 11 10 12 13 6 7 8 9 5 4 3 2 Figure 14 — Sanitizer Plumbing 36 1 14
REPLACEMENT PARTS SANITIZER PLUMBING Fig. 14 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. 0503668 0502583 0502653 0502645 0502666 0502665 0503679 0503669 0502577 0502781 0507100 0300918 0501501 0501539 Part Description Thermometer .............................................................................. 3/8" FPT Cross Connector ......................................................... 3/8" MPT x 1/2" 90° Hose Barb ................................................ 1/8" Hose Barb ................
REPLACEMENT PARTS 5 6 4 7 3 2 1 Figure 15 — Vacuum Breaker Plumbing 38
REPLACEMENT PARTS VACUUM BREAKER PLUMBING Fig. 15 Item No. 1 2 3 4 5 6 7 8 9 Part No. 0502665 0503679 0502651 0502751 0508366 0502650 0502653 113220 113221 Part Description 1/2" x 3/4" Inner Braided Tubing .............................................. 7/16" Gear Clamp ...................................................................... 1/2" MPT x 1/2” Hose Barb....................................................... 1/2" Vacuum Breaker (Prior to S/N G2182)..............................
REPLACEMENT PARTS 9 10 8 8 8 10 7 5 6 5 4 1 2 3 11 12 13 14 17 15 18 16 Figure 16 — Wash Pump Assembly 40
REPLACEMENT PARTS WASH PUMP ASSEMBLY Fig. 16 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part No. 0507313 0307410 0501419 0507320 0502563 0502668 0501632 0503679 0502665 0502663 0502734 0502730 0502729 0502731 0501635 0502732 0503648 0501406 Part Description Wash Pump Complete ................................................................ Wash Pump Base........................................................................ 1/4-20 x 1/2" Bolt ..................................................
REPLACEMENT PARTS 1 2 3 4 5 6 5 7 8 Figure 17 — Cleaning Accessories 42
REPLACEMENT PARTS CLEANING ACCESSORIES Fig. 17 Item No. 1 2 3 4 5 6 7 8 Part No. 0703390 0501714 0501633 0703454 0505320 0502779 0501833 0506643 Part Description Tube Scraper ............................................................................. Tube Brush ................................................................................. Jet Reamer c/w Drill .................................................................. Wash Down Nozzle...........................................................
ELECTRICAL SCHEMATICS RINSE WATER VALVE GLASS SHUTOFF ARM SWITCH CONV. DRIVE MOTOR NO BLACK NC DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. RED BLACK WASH PUMP WHITE BLUE MOTOR RED GREEN START CAPACITOR 2.5A FUSE J1 1 2 3 4 5 6 J2 DET PUMP SANI PUMP RINSE PUMP 1 2 3 4 INJECTOR CONTROL BOARD FLUSH TANK FILL TOGGLE SWITCH OFF WASH WATER AUTO VALVE NO WATER LEVEL CAM SWITCH NC HEATER THERMOSTAT DET TANK HEATER FLOAT OPERATED SW M5 0507836 208/230V 12.
ELECTRICAL SCHEMATIC RINSE WATER VALVE GLASS SHUTOFF ARM SWITCH CONV. DRIVE MOTOR NO BLACK BLACK WASH PUMP NC DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. RED WHITE BLUE MOTOR RED GREEN START CAPACITOR FLUSH TANK FILL TOGGLE SWITCH OFF AUTO 2.
ELECTRICAL SCHEMATIC RINSE WATER VALVE GLASS SHUTOFF ARM SWITCH CONV. DRIVE MOTOR NO BLACK BLACK NC WHITE BLUE MOTOR RED RED DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. WASH PUMP GREEN START CAPACITOR 240V PRIM. TRANSFORMER 18V SEC. RINSE AID PUMP SANITIZER PUMP DET PUMP WHITE POWER INJECTOR CONTROL BOARD DETERGENT 2.
