Page 1 Installation and Service Guide with Service Replacement Parts Beginning with Serial No. R3448 and above E-series Rack Conveyor Dishwasher Models Basic Single Tank Single Tank w/Prewash 66 PW Single Tank 70 FFPW Model 44 80 HDPW 44 LT 66 LTPW...
Page 2 For future reference, record your dishwasher information in the box below. Model Number__________________________ Serial Number_______________________ Voltage________________Hertz_____________ Phase__________________ Champion Service Agent __________________________________ Tel:______________________ Champion Parts Distributor _________________________________ Tel:______________________ For all models: The data plate mounts to one side of the top-mounted control cabinet.
Page 5: Revisions To This Manual
Revisions to this manual ________________________ Revisions to this manual • This is where we record changes to the manual. A revision might be a part number change, new instructions, or information that was not available at print time. • We reserve the right to make changes to this manual without notice and without incurring any liability by making the changes..
Page 6 Electric high temperature single tank and multiple tank rack conveyor dishwashers with built-in electric boosters in 40°F/22°C rise or optional 70°F/39°C rise. Steam high temperature single tank and multiple tank rack conveyor dishwasher with built-in steam booster in 40°F/22°C rise or an optional 70°F/39°C rise booster.
Page 7: Table Of Contents
Table of Contents E series Rack Conveyor Dishwashers Revisions to this manual ___________________________________________________________ i Limited Warranty _________________________________________________________________ iv Installaton _____________________________________________________ Unpack and Place Plumbing Connections Drain Connections Electrical Connections Ventilation Initial Start-up Operatng Instructons __________________________________________ How to Operate your Dishwasher: Cleaning and Maintenance Troubleshooting Basc Servce...
Page 8: Limited Warranty
"Champion" and installed within the United States and Canada to be free from defects in material and workman ship for a period of one (1) year after the date of installation or fifteen (15) months after the date of shipment by Champion, whichever occurs first.
Page 9 Single Tank with 26" Front Feed Prewash ..70 FFPW,80 FFPW, 70 WS FFPW • The 44 DR and 54 DR basic models are high temperature 180°F/80°C hot final rinse water sanitizing dishwashers. Prewash options are available in 22", 36", and 26"...
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Page 11: InstallatOn
Connections must meet local plumbing and sanitary codes. Improper installation is not covered by the dishwasher limited warranty. 1. Connect a 3/4" NPT hot water supply line to the line strainer located at the top rear of the dishwasher. For a dishwasher without a booster heater, the hot water connection must supply a minimum of 180ºF/80ºC (measured at the dishwasher).
Page 12: Plumbing Connections
Connection is located at the top rear of the dishwasher load end. 2. Connect a 1/2" NPT cold water supply line for dishwashers equipped with a drain cold water tempering option. Connection location can vary depending on site requirements.
Page 13: Electrical Connections
1. The Main incoming power to the dishwasher is made at the top of machine in the control cabinet. 2. The electrician must connect the incoming power based on the information that is stamped on the Machine Electrical Connection Plate.
Page 14 8. Motor rotation was set at the factory. 9. The conveyor drive motor rotation is indicated by a red arrow located on the side of the motor. 10. The single phase drive motor (208-240V only) rotation must be changed at the drive motor junction box.
Page 15: Chemical Connections
High hood short curtains 24” x 20-1/4” • Final rinse curtain 24” x 6-1/4” 2. Make sure the that the short flaps of the curtains face the load end of the dishwasher. The longest curtains always go on each end of the dishwasher.
Page 16 3. The dishtables must angle toward the dishwasher so water on the tables will drain into the dishwasher. The dishtables should have adjustable feet to adjust the angles. 4. Use a food grade silicon sealant to seal the joints between the dishtables and the dishwasher.
Page 17 Contact your supervisor immediately if you have questions about the dishwasher. Contact your local authorized Champion service agency for technical support. Our National Service Department provides 24 hour support 365 days a year with a Toll-free number in the United States.
Page 18 11. The pumps and the conveyor drive will automatically stop after the last rack exits the machine. 12. The machine may be stopped at any time during the cycle by pressing the red STOP pushbutton. The green light will go off on the green START pushbutton.
Page 19 Dishwasher access doors are equipped with a door safety switch that automatically stops the dishwasher pumps and conveyor drive if a door is raised while the dishwasher is running. In addition, the diswasher will not start if a door is left open.
Page 20 Operation Removing the sprayarm end plugs for Cleaning Installing the lower sprayarm assembly...
Page 21 Operation Installing the upper sprayarm assembly Removing the sprayarm end plugs for cleaning...
Page 22 Operation Removing the Dual Rinse (DR) scrap screens...
Page 23 Operation Removing the Dual Rinse (DR) scrap screens (continued)
Page 24 Replace the end caps. Check the condition of the manifold O-ring. Reinstall the sprayarms. 4. Remove and clean the curtains. Allow them to dry at the end of the day. 5. Leave the doors open between operations, allowing the machine to dry.
Page 25 9. Check the idle pump actuator and the final rinse actuator for freedom of travel. Deliming The word SCALE refers to the mineral deposits that form as a white film inside and sometimes outside the dishwasher. If allowed to build-up, scale can significantly reduce the performance and life-span of a dishwasher.
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Page 27: Basic Service
Basic Service Basic Service...
Page 28: Electrical Service
DO NOT INCREASE THE FUSE RATING. Motor Overloads Motor overloads are located to the left of the fuse block inside the control cabinet. Each motor has one overload to protect it from line voltage electrical overloads. In addition, an auxiliary set of switch contacts is attaches to the overload. The switch contacts disconnect 120VAC power to the motor contactor coils in the event of an overload condition.
Page 29 • The pump timer begins to time down for its 90 seconds time setting. • The timer is reset each time the idle pump switch is activated. If the timer is reset only once it will time out and shut the pump(s) and drive motor off after the time delay.
Page 30 • The control relay for the float switch is de-energized. • The fill valve for the tank is energized and the tank begins to fill with water. • As the water level in the tank rises, the bottom float begins to move up.
Page 31 (continued) During Normal Operation • If the water level in a tank falls below the level of the top float, the top float moves down and its reed switch contacts open. • When the water level falls below the level of the bottom float, the bottom float moves down and its reed switch opens.
Page 32: Motor Connections
Motor runs hot and trips motor starter overload Check for proper voltage between L1-L2 or (L1-l2, L2-L3, L1-L3 for 3 phase). Check FLA on motor leads L1, L2, (also L3 for 3 phase) using amp tester. (Motor full load amp (FLA) ratings are stamped on motor nameplate).
Page 33 • The conveyor jam switch stops the conveyor if something obstructs the movement of of the rack conveyor. • The light on the green start switch goes out and the pumps and the conveyor drive motor stop running. • After clearing the jam, push the green start button and insert another dishrack to restart the pumps and conveyor.
Page 34 Disconnect the power to the machine. Disconnect the wires at the motor junction box. Make note of the motor connections in order to phase the replacement correctly. Remove pump/motor assembly to a clean work area. Follow the diagrams below for pump disassembly and seal replacement.
Page 35 Basic Service • Mechanical Mechanical Service • Pump Seal Replacement continued on next page...
Page 36 NOTE ! Replace the pump motor if motor shaft is grooved, pitted, or bent. Clean rust and debris from seal seat and motor shaft. Debur with fine finishing paper specifically designed for metal surfaces. Use a new seal assembly preferably from an unopened package.
Page 37 Minimum clearance must be .030” [0.76 mm]. Rotate the motor shaft CW to check proper clearance. Reinstall assembly and test run checking for leaks. Look at the rear of the motor to make sure motor shaft rotation is CW. continued on next page...
Page 38 USED IN AN ELECTRIC BOOSTER HEATER. IMPROPER INSTALLATION CAN CAUSE FINAL RINSE TEMPERATURE PROBLEMS. You will need a permanent marker such as a SHARPIE® or comparable in order to mark the control thermostat capillary tube. Do not crimp the thermostat capillary tube.
Page 39 Basic Service • Mechanical Mechanical Service • Replace Electric Booster Control Thermostat Slide ferrule 8” away from the end of the thermostat probe and mark. Thread gland nut into booster tank fitting. 1" 8" Insert thermostat probe into booster tank taking care not to crimp capillary tube.
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Page 41: Replacement Parts
Replacement Parts _________________Replacement Parts...
Page 42 • Replacement Parts Prewash Doors & Panels...
Page 43 • Prewash Panels & Doors Replacement Parts 397970 Panel Assy. Front Perimeter 22" PW Prewash 328978 Panel Assy. Front Perimeter 36" Prewash 327857 Panel, 25" Prewash Perimeter 328030 Table Flange Support 4 329926 Baffle, Table Flange 328006 Support, 22" PW Rear Screen 108250 Rod Curtain 5/16 x 24-5/8"...
Page 44 • Replacement Parts Single Tank Doors & Panels...
Page 45 113486 Screw, 8-32 x 5/8 Flat Head SST 108250 Rod, Curtain 5/16 x 24-5/8 113720 Curtain 24 x 20-1/4 4 Ply (Load and Unload) 109723 Curtain 24 x 6 -1/4 (Not shown) 100007 Screw 1/4-20 x 1/2 Truss Head SST...
Page 46 • Replacement Parts Two Tank Doors & Panels...
Page 47 Door Handle 100073 Screw 1/4-20 x 1/2 Truss Head 113691 Guide, U-channel Door 327889 Panel, 25” Side Perimeter (Load, No Prewash) 327889 Panel, 25” Side Perimeter (Unload, No Booster) 328975 Panel, 64 Front Perimeter 328976-01 Panel, 84 Front Perimeter Right Hand...
Page 48 • Replacement Parts Drive Motor Assembly...
Page 49 113700 Bushing 3/8 x 3/4 x 1/16 Thrust Bronze 113703 Bushing, 3/4 x 7/8 x 3/8 x 1-1/8 Flg 113701 Bushing 1/4 x 3/8 x 1/2 x 1/16 Flg Bronze 113732 Motor, Gear 1/6HP 3PH 113679 Motor, Gear 1/6HP 1PH...
Page 50 • Replacement Parts Drive Assembly...
Page 51 Seal 5/8” 206303 Gasket/Bearing Seal 100382 Bearing Jaf #EK104-10 100007 Screw, 10-32 x 3/8 Truss Head 104925 Washer 1/4 x 1 x 16 Gauge 103180 Wiper Ring 104916 Key 3/16 x 3/16 x 3/4 SST 100794 V-belt 4L 310 113892...
Page 52 Replacement Parts • Prewash Track & Cradle Assembly Tank...
Page 53 Replacement Parts 113719 Switch, Reed Aleph 328045 Switch, PW Idle 111026 Magnet, SS 100764 Screw, 6-32 x 1/2 Round Head SST 108954 Nut, Grip 6-32 Hex Head W/Nylon Insert 106482 Washer Lock 1/4 Split 327833 Pin Idle Pump Switch 100736...
Page 54 Replacement Parts • SingleTank Track & Cradle Assembly...
Page 55 Bearing, Rack Cradle Slide 100412 Nut, Grip 5/16-18 100141 Nut, Grip 1/4-20 112318 Screw 1/4-20 x 1/2 100141 Nut, Grip 1/4-20 100736 Bolt 1/4-20 x 3/4 Hex Head SST 106482 Washer Lock 1/4-20 Split 414377 Cradle, E-44 Complete (Includes Items 10-13 and 16)
Page 56 • Replacement Parts Two Tank Track & Cradle Assembly...
Page 57 Two Tank Track & Cradle Assembly • Replacement Parts 113719 Switch, Reed Aleph 414344 Switch, Idle Assembly (Includes Items 3-8) 111026 Magnet, SS 100764 Screw, 6-32 x 1/2 Round Head SST 108954 Nut, Grip 6-32 Hex Head W/Nylon Insert 106482...
Page 58 Replacement Parts • Prewash Screens...
Page 59 Prewash Screens • Replacement Parts 328958 Screen Assy 328959 Refuse Basket...
Page 60 Replacement Parts • Single Tank Scrap Screens Tank Tank...
Page 61 Single Tank Scrap Screens • Replacement Parts 414328 Screen, E-44 L-R Front 414329 Screen, E-44 L-R Rear 414300 Basket, Rack 327888 Support, Screen 328653 Screen, Outboard, (E-54 Only)
Page 62 Replacement Parts • Two Tank Scrap Screens...
Page 63 Replacement Parts Two Tank Scrap Scr 414328 Screen, E-44 L-R Front 414329 Screen, E-S44 L-R Rear 414300 Basket, Rack 328653 Support, Screen (not shown) 327888 Screen, Outboard (E-64, E-84)
Page 64 Replacement Parts • Prewash Spray Arms...
Page 65 328028 Standpipe, 22” PW 414292 Wash Manifold Assy 6” Upper 113738 Guide Block 113555 Plug, Wash Arm E-Series (qty per arm) Wash Arm Lock Fasteners (Qty per Arm) 107073 Stud Weld 1/4-20 x 1” 0501501 Lock Washer 1/4” 106026 Washer 1/4” x 5/8” x 1/16” SST...
Page 66 Replacement Parts • Single Tank Wash Spray Arms Back of machine...
Page 67 Single Tank Wash Spray Arms • Replacement Parts 414291 Wash Manifold Assembly 10” 15° Lower (L-R) 414290 Wash Manifold Assembly 10” 15° Lower (R-L) 113723 O-ring,1.75 ID 113738 Lock, Spray arm pin 113540 Locknut 2NPT SST 113542 Gasket, Flat EDPM 2-3/8 ID...
Page 68 Replacement Parts • Two Tank Wash & Rinse Spray Arms...
Page 69 Two Tank Wash & Rinse Spray Arms • Replacement Parts 113542 Gasket, Flat EDPM 2-3/8 ID 113540 Locknut 2NPT SST 113738 Lock, Pin spray arm 113723 O-ring,1.75 ID 414289 Wash Manifold Assembly 14” Straight Upper (L-R) 414288 Wash Manifold Assembly 14” Straight Upper (R-L) 414291 Wash Manifold Assembly 10”...
Page 70 Replacement Parts • Float Switches Two Tank Single Tank Prewash...
Page 71 Float Switches • Replacement Parts 104584 Nut, Plain 1/2-13 107589 Washer, Flat 1/2” 111151 C-Clip 110854 Float Switch, Dual Prewash 113291 Float Switch, Dual Wash/Rinse E-44 113291 Float Switch, Dual Wash/Rinse E-64 110750 Gasket, Float Switch (Not Shown)
Page 72 Replacement Parts • Single Tank Electric Heat...
Page 73 Heater 15/16.3KW 460/480V 113519 Heater 15KW 575V 100153 Bolt, 3/18-16 x 1 Hex Head 104618 Washer 3/8 x 7/8 x 1/16 SST 108345 Gasket 3 x 3 x 1/8” 2” Hole 106407 Washer Lock 3/8 Split 100140 Nut Plain 3/8-16...
Page 74 • Replacement Parts Two Tank Electric Heat Tank Rinse Wash...
Page 75 113517 Heater 15/16.3KW 230/240V(Wash) 113518 Heater 15/16.3KW 460/480V (Wash) 113519 Heater 15KW 575V (Wash) 108345 Gasket 3 x 3 x 1/8” 2” Hole 113804 Heater 10/12.1 KW 200/220V (Rinse) 118842 Heater 10/11KW 230/240V (Rinse) 113883 Heater 10/11KW 460/480V (Rinse) 113884...
Page 76 • Replacement Parts Single Tank Steam Heat Tank...
Page 77 Locknut, 3/4NPT SST 113918 Nipple, Rtoe 3/4 x 1-3/4 100740 Bolt 5/16-18 x 1 Hex Head 102376 Washer 5/16 X 3/4 x 1/16 108345 Gasket 3 x 3 1/8” 2IN Hole 106013 Washer Lock 5/16 Split 100154 Nut Plain 5/16-18...
Page 78 • Replacement Parts Two Tank Steam Heat Tank Tank...
Page 79 327907 Coil, Steam LH 100740 Bolt 5/16-18 x 1 Hex Head 102376 Washer 5/16 X 3/4 x 1/16 108345 Gasket 3 x 3 1/8” 2IN Hole 106013 Washer Lock 5/16 Split 100154 Nut Plain 5/16-18 327908 Coil, Steam RH 102554...
Page 80 • Thermostats Replacement Parts Two Tank Single Tank...
Page 81 Thermostat, Fixed Hi Limit - Single Tank 113200 Thermostat, Fixed Hi Limit -Two Tank 201041 Washer 7/8 ID x 1/8 Thk - Single Tank 201041 Washer 7/8 ID x 1/8 Thk - Two Tank 109034 Gasket. Plug - Single Tank 109034 Gasket.
Page 82 Replacement Parts • Prewash Drain-overflow Assembly Tank Bottom...
Page 83 Prewash Drain-overflow Assembly • Replacement Parts 108875 Cotter Pin 3/32 x 1/2 Uneven 328824 Lever Drain Lift 206419 Rod, Overflow Lift 22"PW 106026 Washer 1/4 x 5/8 x 1/6 SST 328430 Overflow PW Mtd 111532 O-ring, Overflow 100735 Bolt 1/4-20 x 5/8 Hex Head 112257 O-ring, drain...
Page 84 • Replacement Parts Single & Two Tank Drain-overflow Assembly Tank Bottom...
Page 85 Single & Two Tank Drain-overflow Assembly • Replacement Parts 113715 Cotter Pin 3/32 x 1/2 328611 Lever Drain Lift 206442 Rod, Overflow Lift 206444 Block, drain lift 107966 Nut, Grip 10-32 w/Nylon Insert 112257 O-ring 100735 Bolt 1/4-20 x 5/8 Hex Head...
Page 86 Replacement Parts • Final Rinse Piping with Booster From Booster Top of Hood...
Page 87 Bushing, Reducing 1/2”NPT x 1/4”NPT Brass 104429 Vacuum Breaker 3/4”NPT 900837 Kit*Repair, 3/4 Vacuum Breaker 102525 Tee, Red 3/4” x 1/2” x 3/4” NPT Brass 109879 Fitting Compression 3/4”NPT x 7/8” OD 100171 Bushing Red Face 3/4” NPT x 1/2 NPT Brass 102490 Nipple 1/4”NPT x 3-1/2”...
Page 88 • Replacement Parts Piping No Booster or Steam Booster...
Page 89 Piping No Booster or Steam Booster • 101259 Plug, 1/8” NPT Brass 105976 Bushing, Red 3/4” NPT x 18” NPT Brass 100171 Bush Red Face 3/4” NPT x 1/2” NPT Brass 100599 Cross, 3/4”NPT Brass 100184 Nipple 3/4” NPT Close Brass 100571 Union 3/4”...
Page 90 Replacement Parts • Final Rinse Drain Assembly...
Page 91 Final Rinse Drain Assembly • Replacement Parts 100141 Nut, Grip 1/4-20 305218 Strainer, F/R Drain 107342 Basket, Drain 107864 Washer, Packing-Neoprene 107345 Nut Slip 107473 Tailpiece 110245 Washer Tailpiece 110244 Nut Slip, Tailpiece...
Page 92 Replacement Parts • Prewash Pump Suction & Discharge Discharge Suction L-R Application Shown...
Page 93 311761 Strainer, Pump Suction (Not Shown) 112379 Suction, Flange Machined 112338 Gasket Pump Suction Flange (Not Shown) Pump Fasteners 100739 Bolt 5/16-18 x 3/4 Hex Head SST 102376 Washer 5/16 x 3/4 x 1/16 109009 Nut, Grip 5/16 w/Nylon Insert...
Page 94 • Wash & Rinse Pump Suction/Discharge Replacement Parts...
Page 95 Gasket Pump Suction 327906 Plate, Pump Suction 327904 Hood Pump Suction Pump Base Fasteners 100739 Bolt 5/16-18 x 3/4 Hex Head SST 102376 Washer 5/16 x 3/4 x 1/16 109009 Nut Grip 5/16 w/Nylon Insert Pump Fasteners 100739 Bolt 5/16-18 x 3/4 Hex Head SST...
Page 96 Replacement Parts • Pump/Motor Assembly...
Page 97 Pump Assy 2HP LH Complete (Wash/Rinse) 414505 Pump Assy 2HP RH Complete (Wash/Rinse) 900737 Kit*Gaskets, Jet Pump (Includes Items 5-7) 900183 Kit*Seal & 1HP Impeller (Includes Items 5-7, 11 and 12) 900861 Kit*Seal & 2Hp Impeller (Includes Items 5-7, 11 and 12)
Page 98 Replacement Parts • Electric Booster Assembly - 40°F/60°F Rise Insert thermostat probe into tube in center of element...
Page 99 220/230/240/380/415V 3Ph (40°F)(230-240/1PH & 3PH) 113886 Heater, 12KW 460/480V 3Ph (40°F)(460-480°/3PH) 112059 Heater, 12KW 208V 3Ph (60°F Rise)(200-220V/1PH & 3PH) 111334 Heater 12KW 240V 3Ph (60°F Rise) (230-240/1PH & 3PH) 112060 Heater 12KW 460/480V 3Ph(60°F Rise)(460-480/3PH) 112061 Heater 12KW 575V 3Ph (60°F Rise) 328254...
Page 100 Replacement Parts • Electric Booster Assembly - 70°F Rise...
Page 101 Thermostat w/Capillary 210°F 108576 Cover, Booster No Cutout 109069 Thermostat w/ Capillary 102505 Plug 3/4” NPT Brass (Not Shown) (On Opposite Side) 414331 Tank Booster 112059 Heater, 12KW 208V 3Ph (200-220V/1PH & 3PH) 111334 Heater 12KW 240V 3Ph (230-240/1PH & 3PH)
Page 102 Replacement Parts • Control Cabinet...
Page 103 Fuse T 80A 250V Fast Act (230-240V/1Ph) 180175 Fuse J 50A 600V Fast Act (208-220V/3PH) 180175 Fuse J 50A 600V Fast Act (230-240V/1PH)(Two Tank Only) 180174 Fuse J 45A 600V Fast Act (230-240V/3PH) 180243 Fuse J 25A 600V Fast Act (460-480V/3PH)
Page 104 111630 Starter Mtr 13.0-18.0 (Wash) (208-220V/1PH),(230/240V/1PH) (Single Tank) 111630 Starter Mtr 13.0-18.0 (Wash/Rinse) (208-220V/1PH), (230/240V/1PH)(Two Tank) 110807 Starter Mtr OL GV2-M14 W/Aux (Wash) (208-220V/3PH), (230-240V/3PH) (Single Tank) 110807 Starter Mtr OL GV2-M14 W/Aux (Wash/Rinse) (208-220V/3PH) (230-240V/3PH) (Two Tank) 110805 Starter Mtr 2.5-4.0A w/Auxillary(Wash) (460-480V/3PH)
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Page 106 Replacement Parts • Extended Vent Cowls...
Page 107 Screw 6-32 x 3/8” Round Head 328344 Vent Cowl 109158 Nameplate “Champion” 107015 Screw 4-40 x 1/4 Round Head 107016 Nut Grip 4-40 w/Nylon Insert Vent Cowl Fasteners (Qty per Cowl) 100734 Bolt 1/4-20 x 1/2 Hex Head SST 106482 Nut Grip 1/4-20 SST...
Page 108 Replacement Parts • Standard Vent Cowls...
Page 109 Standard Vent Cowls • Replacement Parts 401487 Vent Stack Assembly (Includes items 2-5) 201589 Regulator Assembly 112258 Nut, Wing 1/4-20 SST 108954 Nut, Grip 6-32 w/Nylon Insert 104883 Screw 6-32 x 3/8 Round Head 307228 Vent Hood 100734 Belt 1/4-20 x 1/2” Hex Head...
Page 110 • Dishracks Replacement Parts...
Page 111 Dishracks • Replacement Parts 101285 Rack Peg 101273 Rack Combination...
Page 112 Replacement Parts • E-44DR Dual Rinse Assembly Only available as an assembly Only available as an assembly...
Page 113 Tube, discharge L-R 206503 Tube, discharge R-L 114020 Hose, 1-1/8" OD x 2-3/4" 329276 Bracket, Pump 0502692 Recycle Pump (Parts breakdown on next page) 110454 Nipple, Toe 102444 Elbow, street 90º 601814 Upper piping assy E44DR, Auxiliary 110454 Nipple, Toe...
Page 114 Replacement Parts • E-44DR Recycle Pump Assembly...
Page 115 Stub Shaft 0502730 Seal Assembly (c/w spring) 0502729 Impeller 329281 Pump Housing 0501406 Screw, 8-32 x 1/2" 0501635 O-ring 0502732 Seal Screw, Housing 0502692 Pump Assembly, Complete (c/w motor and items 1-7) (Motor is not available as a separate service part)
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Page 117: ElectrCal SchematCs
Electrical Schematics...
Page 118 Blank Page This Page Intentionally Left Blank...

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