Champion CG4 Technical Manual
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Champion CG4 Technical Manual

Pass-through glasswasher
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Champion
The Dishwashing Machine Specialists
June, 2001
P.O. Box 4149
Winston-Salem, North Carolina 27115-4149
Technical Manual
Pass-Through
Glasswasher
Machine Serial No.
Manual
Champion Industries, Inc.
www.championindustries.com
Model
CG4
CG6
111557
P/N
REV. E

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  • Page 1 Champion The Dishwashing Machine Specialists June, 2001 P.O. Box 4149 Winston-Salem, North Carolina 27115-4149 Technical Manual Pass-Through Glasswasher Model Machine Serial No. 111557 Manual Champion Industries, Inc. www.championindustries.com REV. E...
  • Page 2 _____________________________________________________________________________ Champion Service Agency___________________________________ _____________________________________________________________________________ Champion Industries Service: 1-800-858-4477 Champion Service Fax: 1-336-661-1660 We strongly recommend that you Fax your orders. NOTE: When calling to order parts, be sure to have the model number, serial number, voltage, and phase of your machine.

  • Page 3: Revision History

    Revision History Revision Revised Serial Number Date Pages Effectivity 02/18/91 5181 10/12/94 6106 05/10/95 6216 06/07/95 — 6226 02/02/97 02/28/00 06/18/00 38-39 G2182 06/18/01 Comments Issued manual and service parts list, Revision A Tank switch shuts down machine, revised the schematic Changed to new style chemical injection board, revised the schematic...

  • Page 5: Table Of Contents

    WARRANTY ... INTRODUCTION... INSTALLATION... Unpacking ... Measurements ... Utility Locations ... Electrical Connections... Plumbing Connections... Water Connections... Drain Connections ... OPERATION... General ... To Fill The Wash Tank ... Operating Instructions ... Approximate Chemical Settings... 10 Plumbing Diagram... 12 MAINTENANCE... 13 Daily Cleaning Instructions ...

  • Page 6: Limited Warranty

    Champion, whichever occurs first. [See below for special provisions relating to glasswashers.] The warranty registration card must be returned to Champion within ten (10) days after installation. If warranty card is not returned to Champion within such period, the warranty will expire after one year from the date of shipment.

  • Page 7: Introduction

    All information, illustrations and specifications contained in this manual are based upon the latest product information available at the time of publication. Champion constantly improves its products and reserves the right to make changes at any time or to change specifications or design without notice and without incurring obligation.

  • Page 8: Installation

    INSTALLATION INSTALLATION Unpacking Remove all packing from inside and on top of the machine. 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. Check the position of the splash curtains. 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.

  • Page 9: Measurements

    INSTALLATION (Cont’d) Measurements Uncrated SW-400 Height 38-1/2" (978) 38-1/2" (978) Width 48" (1219) 72" (1182) Depth 22" (559) 22" (559) Ship Wt. 225lb/102kg 285lb/129kg *adjustable foot height 1-3/4" (45) max. height 40-3/4" (1035) 6' [1829] ELECTRIC CORD SW400 19" [483] 24"...

  • Page 10: Electrical Connections

    INSTALLATION INSTALLATION (Cont’d) Electrical Connections The Glass Washer has a six foot power cord with a “U” ground tandem plug for connection to a power receptacle. 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).

  • Page 11: Operation

    OPERATION General The wash tank is equipped with a float assembly that operates a single cam- operated switch. 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 Ensure that the standpipe (A) is in place.

  • Page 12: Approximate Chemical Settings

    OPERATION OPERATION (Cont’d) APPROXIMATE CHEMICAL SETTINGS General Approximate chemical settings can be obtained by counting the revolutions of the injector rotors. For detergent, one revolution per second equals approximately 0.35% concentration. NOTE: Detergent pump only operates when hot water tank is filling. For sanitizer, one revolution in 5 seconds equals approximately 12.5 ppm Iodine or 50 ppm chlorine.
  • Page 13 OPERATION (Cont’d) To Adjust Rinse Agent Injector: When a new rinse agent container is installed, push the prime button in and hold until the rinse injector feed tube is full. Start the washer. Take a sample from the final rinse spray tubes. To increase the volume of rinse agent, turn the adjustment screw clockwise.

  • Page 14: Plumbing Diagram

    OPERATION OPERATION (Cont’d) Figure 4 — Plumbing Diagram...

  • Page 15: Maintenance

    MAINTENANCE CLEANING Daily Cleaning Instructions Clear the conveyor of glassware and turn glasswasher off by flipping the toggle switch located on the wash tank to the “off” position. Remove load and unload end pick-up plates and splash curtains. Wash them with hot soapy water, rinse thoroughly, then dry.

  • Page 16: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING CONDITION Conveyor does not turn Excessive overspray from hood section Lack of pressure at wash spray tubes Lack of pressure in rinse spray tubes Water continues to flow to detergent tank or spray tubes with machine off CAUSE SOLUTION No power...Check fuse panel Turn power switch on...
  • Page 17 CONDITION CAUSE Water temperature low Thermostat setting low...Adjust thermostat in detergent tank Thermostat defective...Replace Defective float switch ...Replace Heater burnt out ...Check and replace Incoming water temp. low ...Hot water supply min. 145°F/66°C Water on floor around Pump seal leaking ...Replace machine Rinse drain in wash area plugged ...Clear obstruction, clean machine Wash return screen in detergent...Clean...

  • Page 19: Replacement Parts

    REPLACEMENT PARTS REPLACEMENT PARTS...
  • Page 20 REPLACEMENT PARTS Figure 5 — Main Frame Assembly...

  • Page 21: Figure 5 - Main Frame Assembly

    MAIN FRAME ASSEMBLY Fig. 5 Part Item No. 0707561 Frame Assembly, SW600... 0707673 Frame Assembly, SW400... 0501873 Grey Cast Foot ... 0703003 Hinge Rail, Right Side ... 0501412 Screw, 10-32 x 3/8"... 0703002 Hinge Rail, Left Side ... 0308100 Front Side Panel, SW600 only... 0501921 Door Handle ...
  • Page 22 REPLACEMENT PARTS Figure 6 — Spray Assembly...

  • Page 23: Figure 6 - Spray Assembly

    Fig. 6 Part Item No. 0501746 Manifold Cap ... 0501753 O-Ring... 0301790 Manifold, Triple ... 0501745 O-Ring... 0503589 O-Ring... 0501716 Manifold Retaining Nut ... 0307502 Manifold Plug... 0301795 Manifold, Double ... 0303009 Retaining Rod, Triple... 0303010 Retaining Rod, Double ... 0501718 Spray Tube, Rinse (14 Holes) ...
  • Page 24 REPLACEMENT PARTS Figure 7 — Main Tank Assembly (R-L Shown)

  • Page 25: Figure 7 - Main Tank Assembly

    Strain Relief Bushing ... 0307506 Activating Switch Bracket ... 0502977 Dual Weld Nut, 6-32 ... 107964 Bushing, snap 1/2" ... –– 0507493 Insulation, tank (CG4) ... –– 0507587 Insulation, tank (CG6) ... MAIN TANK ASSEMBLY Part Description REPLACEMENT PARTS Qty.
  • Page 26 REPLACEMENT PARTS Figure 8 — Lift Bracket and Drive Assembly 20 21...

  • Page 27: Figure 8 - Lift Bracket And Drive Assembly

    LIFT BRACKET AND DRIVE ASSEMBLY Fig. 8 Part Item No. 0501345 Drive Motor, 230 Volt c/w Fan ... 0501355 Motor Fan, 2-5/8" Dia... 0501456 Bolt, 1/4-20 x 1/2" ... 0702979 Motor Mount Assembly ... 0501408 Screw, 8-32 x 1/4"... 0501793 Sprocket, 16 Tooth c/w Set Screw ...
  • Page 28 REPLACEMENT PARTS Figure 9 — Hood Assembly...

  • Page 29: Figure 9 - Hood Assembly

    Fig. 9 Part Item No. 0703244 Hood, with vacuum breaker at rear... 0708681 Hood, with vacuum breaker at front ... 0501497 Lock Washer, #8... 0501408 Screw, 8-32 x 1/4"... 0302997 Curtain Bracket, Outer ... 0501743 Curtain... 0302998 Curtain Bracket, Inner... 0501538 Nut, 8-32 ...
  • Page 30 REPLACEMENT PARTS 17 18 12 13 Figure 10 — Control Box...

  • Page 31: Figure 10 - Control Box

    Fig. 10 Part Item No. 0707403 0709049 0307405 0501519 0502666 0706635 0706634 0707142 0506589 0504822 0501353 0507314 0307422 0501450 0507323 0503592 0501403 0501533 0501493 0501472 0503648 0503647 0503574 0501887 0507372 0503749 0701933 0501397 0501379 0307369 0501433 0501411 0309053 0503642 0503693 0501373 0501412 0507470...
  • Page 32 REPLACEMENT PARTS Figure 11 — Control Box Cover/Chemical Injector Board...

  • Page 33: Figure 11 - Control Box Cover/Chemical Injector Board

    CONTROL BOX COVER/CHEMICAL INJECTOR BOARD Fig. 11 Part Item No. 0508433 Circuit Board (starting @ S/N 6216) ... 106695 Screw, 6-32 x 1/2”... 0508710 Spacer, 5/16 lg... 0309037 Support Bracket (starting @ S/N 6216)... 0503637 Fuse, 2.5 Amp ... 0508920 Transformer (starting @ S/N 6216) ...
  • Page 34 REPLACEMENT PARTS Figure 12 — Detergent Tank...

  • Page 35: Figure 12 - Detergent Tank

    Fig. 12 Part Item No. 0707415 Detergent Tank (up to S/N 6226)... 0709054 Detergent Tank (starting @ S/N 6226) ... 0307296 Detergent Tank Cover Lid... 0307378 Detergent Tank Rear Cover... 0707375 Detergent Tank Screen Assembly ... 0507471 Label, Clean Screens Daily... 0700948 Standpipe Assembly...
  • Page 36 REPLACEMENT PARTS COLD WATER VALVE TO VACUUM BREAKER TO DETERGENT TANK 16 17 Figure 13 — Inlet Plumbing HOT WATER VALVE...

  • Page 37: Figure 13 - Inlet Plumbing

    Fig. 13 Part Item No. 0502783 230V 60HZ Solenoid Valve ... 0503802 3/8" MPT Tee ... 0503801 3/8" Fem x 1/2" Fem Adapter... 0507324 3/8" Check Valve... 0502768 Mixing Valve... 0502653 3/8" x 1/2" 90° Hose Barb ... 0503679 7/16" Gear Clamp ... 0502665 1/2"...
  • Page 38 REPLACEMENT PARTS Figure 14 — Sanitizer Plumbing...

  • Page 39: Figure 14 - Sanitizer Plumbing

    Fig. 14 Part Item No. 0503668 Thermometer ... 0502583 3/8" FPT Cross Connector ... 0502653 3/8" MPT x 1/2" 90° Hose Barb ... 0502645 1/8" Hose Barb ... 0502666 1/8" Hose... 0502665 1/2" I.D. Braided Hose... 0503679 7/16" Gear Clamp ... 0503669 Injector Barb Fitting...
  • Page 40 REPLACEMENT PARTS Figure 15 — Vacuum Breaker Plumbing...

  • Page 41: Figure 15 - Vacuum Breaker Plumbing

    VACUUM BREAKER PLUMBING Fig. 15 Part Item No. 0502665 1/2" x 3/4" Inner Braided Tubing ... 0503679 7/16" Gear Clamp ... 0502651 1/2" MPT x 1/2” Hose Barb... 0502751 1/2" Vacuum Breaker (Prior to S/N G2182)... 0508366 Vac Breaker Kit (Prior to S/N G2182)... 0502650 1/2"...
  • Page 42 REPLACEMENT PARTS Figure 16 — Wash Pump Assembly...

  • Page 43: Figure 16 - Wash Pump Assembly

    WASH PUMP ASSEMBLY Fig. 16 Part Item No. 0507313 Wash Pump Complete ... 0307410 Wash Pump Base... 0501419 1/4-20 x 1/2" Bolt ... 0507320 1" I.D. X 1-1/4" O.D. PVC Hose... 0502563 1" Gear Clamp... 0502668 1" I.D. Braided Hose... 0501632 Pump Hose Connector ...
  • Page 44 REPLACEMENT PARTS Figure 17 — Cleaning Accessories...

  • Page 45: Figure 17 - Cleaning Accessories

    Hose, 1/2 male quick disconnect, 16" – 0708453 Hand Sink and Wet Waste Receiver (SW46) – 0701956 Wash Down Hose (Includes Items 4 - 8) – 0702882 Panel, Back CG4 – 0702886 Panel, Back CG6 Part Description Part Description REPLACEMENT PARTS Qty. Qty.

  • Page 46: Electrical Schematics

    ELECTRICAL SCHEMATICS DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. FLUSH AUTO WATER LEVEL CAM SWITCH FLOAT OPERATED SW M5 GLASS SHUTOFF ARM SWITCH BLACK BLACK 2.5A FUSE INJECTOR CONTROL BOARD TANK FILL TOGGLE SWITCH HEATER THERMOSTAT 208/230V 12.8A 60HZ SINGLE PHASE Figure 19 –...

  • Page 47: Figure 20 - Electrical Diagram (S/N 6106 Through 6215)

    GLASS SHUTOFF ARM SWITCH DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. FLUSH TANK FILL TOGGLE SWITCH AUTO FLUSH TANK FILL TOGGLE SWITCH AUTO WATER LEVEL CAM SWITCH FLOAT OPERATED SW M5 208/230V 12.8A 60HZ SINGLE PHASE Figure 20 –...

  • Page 48: Figure 21 - Electrical Diagram (Beginning With S/N 6216)

    ELECTRICAL SCHEMATIC DIAGRAM IS FOR L-R OPERATION. FOR R-L OPERATION USE N.O. TERMINAL. 240V PRIM. 18V SEC. WATER LEVEL CAM SWITCH FLOAT OPERATED TANK FILL TOGGLE SWITCH SW M5 Figure 21 – Electrical Diagram (beginning with S/N 6216) GLASS SHUTOFF ARM SWITCH BLACK BLACK...

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