Champion 135-USN-72 Technical Manual Download Page 105

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Part 6: REPLACEMENT PARTS

TANK STEAM PIPING WITH BOOSTER

(R-L MACHINE SHOWN)

Fig. 6.10

Part

Item No.

No.

Part Description

Qty.

Coml

Nipple, 3/4 NPT x 16,

brass

.......................................................

Coml

Elbow, 3/4" NPT,

brass

........................................................................... 3

Coml

Nipple, 3/4" NPT x 7 1/2",

brass

............................................................ 1

Coml

Street elbow, 3/4" NPT,

brass

................................................................. 3

Coml

Tee, 3/4" NPT,

brass

............................................................................... 1

Coml

Nipple, 3/4" NPT x 5",

brass

.................................................................. 1

Coml

Union elbow, 3/4" NPT , female,

brass

.................................................. 1

Coml

Nipple, 3/4" NPT x 10 1/2",

brass

.......................................................... 1

Coml

Nipple, 3/4" NPT x 5",

brass

.................................................................. 1

Coml

Nipple, close, 3/4" NPT,

brass

................................................................ 5

109887

Valve solenoid steam 3/4" NPT ........................................................

109903

Repair kit steam valve, 3/4" ...............................................................

Coml

Union elbow, 3/4" NPT, male,

brass

...................................................... 2

Coml

Bushing, reducing, 3/4" x 1/2",

brass

..................................................... 1

109683

Flange block off .................................................................................

112257

O-ring .................................................................................................

Coml

Street elbow, 1/2" NPT,

brass

................................................................. 2

Coml

Nipple, close, 1/2" NPT,

brass

................................................................ 1

Coml

Elbow, 45

, 1/2",

brass

........................................................................... 1

Coml

Nipple, 1/2" x 2",

brass

.......................................................................... 1

Coml

Union, 1/2" NPT,

brass

........................................................................... 2

Coml

Nipple, close, 1/2",

brass

........................................................................ 2

111380

Steam trap, thermodynamic 1/2" SST ................................................

Coml

Nipple, 3/4" x 2",

brasss

.......................................................................... 1

Coml

Elbow reducing, 3/4" x 1/2", 90

brass

................................................. 1

Coml

Nipple, 1/2" NPT x 4" long,

brass

.......................................................... 1

Coml

Nipple, 1/2" NPT x 19" long,

brass

........................................................ 1

Coml

Nipple, 1/2" NPT x 10 1/4" long,

brass

.................................................. 1

Coml

Union elbow, female, 1/2" NPT,

brass

................................................... 2

Coml

Nipple, 1/2" NPT x 3 3/4",

brass

............................................................ 1

Coml

Nipple, 1/2" NPT x 5 1/2",

brass

............................................................ 1

Coml

Tee reducing, 3/4" x 1/2" x 1/2",

brass

................................................... 1

Coml

Nipple, 3/4" NPT x 12" long,

brass

........................................................ 1

Coml

Union, 3/4" NPT,

brass

........................................................................... 1

108516

Coil, solenoid valve, 3/4" 120v ..........................................................

Summary of Contents for 135-USN-72

Page 1: ......

Page 2: ...9 0291 Fax 757 825 1202 757 825 1202 904 241 4039 Website www thesource2000 com Email sales thesource2000 com Equipment information Darlene Ehrenfried dehrenfried thesource2000 com Parts information HQ Samantha Johnson sjohnson thesource2000 com Service information HQ Jim Luther jluther thesource2000 com U S Navy POC Judy Lowman jlowman thesource2000 com U S Navy POC Ken Height San Diego kheight t...

Page 3: ...TECHNICAL PUBLICATION SHEET i TECHNICAL PUBLICATION SHEET ...

Page 4: ...TECHNICAL MANUAL VALIDATION CERTIFICATE ii TECHNICAL MANUAL VALIDATION CERTIFICATE ...

Page 5: ...APPROVAL AND PROCUREMENT RECORD iii APPROVAL AND PROCUREMENT RECORD ...

Page 6: ...TECHNICAL MANUAL DEFICIENCY EVALUATION REPORT TMDER iv TECHNICAL MANUAL DEFICIENCY EVALUATION REPORT TMDER Form NAVSEA 9086 10 REV 6 85 ...

Page 7: ... Revised control cabinet 3 9 01 94 102 J1080 Added MRAN 90 3 9 01 104 107 J1080 Added CH 60 Electric Booster For USS RAmage Only 2 27 02 61 63 J1534 Added new vacuum breakers and kits 2 27 02 71 Replaced P N s 112606 and 112607 with new part numbers 113398 and 113399 4 8 02 102 Corrected spacer number for bubble 16 to 15 103 Corrected part number 111064 to 111603 and 111605 Corrected motor clamp f...

Page 8: ...pushbuttons lighted switches 8 14 03 93 93a 93b Replaced Furance Siemens overloads with Telemecanique Square D 11 6 03 11 13 14 16 J1872 Insert new junction box location and 21 installation information 11 6 03 76b 77b J1872 Inserted new pages for terminal block and strip drawing and parts 11 06 03 82a 83a J1872 Inserted new pages for wash and rinse tank junction boxes drawings and parts 11 06 03 J...

Page 9: ...vii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 10: ...tenance instructions contained in this manual are intended for qualified service personnel These instructions assume that you are trained in basic electricity and mechanical theory If you are not a trained technician then do not attempt to adjust or repair the dishwasher as serious personal injury or damage to the dishwasher may result Safety Symbols The following symbols appear throughout this ma...

Page 11: ...ngerous voltages are present at the dishwasher when it is connected to the local electrical distribution system Pg 13 When working on the dishwasher disconnect the electric service and place a red tag at the disconnect switch to indicate work is being done on that circuit Pg 14 The installation of electrical supplies and controls must conform to local codes or in the absence of local codes the Nat...

Page 12: ...n the dishwasher disconnect the electric service and place a red tag at the disconnect switch to indicate work is being done on that circuit Pg 34 When working on the dishwasher disconnect the electric service and place a red tag at the disconnect switch to indicate work is being done on that circuit Pg 35 Do not lubricate the stainless steel conveyor chain or shaft bearings inside the dishwasher ...

Page 13: ...ervice Pg 31 Do not hose down the exterior of the machine with water Pg 33 Only qualified service personnel should perform preventive maintenance on the dishwasher Pg 34 Only qualified service personnel should perform preventive maintenance on the dishwasher Pg 36 Only qualified service personnel should perform preventive maintenance on the dishwasher Pg 40 Only qualified service personnel should ...

Page 14: ...nt of clutches f Opening or closing of utility supply valves or switching of electrical supply current g Cleaning of valves strainers screens nozzles or spray pipes h Performance of regular maintenance and cleaning as outlined in operator s guide i Damages resulting from water conditions accidents alterations improper use abuse tampering improper installation or failure to follow maintenance and o...

Page 15: ...een the dishwasher and booster 8 2 6 Water Connections 10 2 7 Steam and Condensate Connections Steam heat only 10 2 8 Drain Connections 12 2 9 Ventilation Connections 12 2 10 Electrical Connections 13 2 11 Electrical Tank Heat Connections Electric heat only 14 2 12 Chemical Connections 16 PART 3 OPERATION 19 3 1 Theory of Operation 19 3 2 Description of Operator Controls and Indicators 20 3 2 1 Re...

Page 16: ... 5 3 8 Tank Heat Thermostat Adjustment and Replacement 43 5 3 9 Steam Booster Thermostat Adjustment and Replacement 43 5 3 10 Steam Solenoid Valve Repair 44 5 3 11 Steam Trap Repair 45 5 3 12 Steam Booster Service 45 5 3 13 Wash Manifold Restrictor Adjustment 47 5 3 14 Pump Seal Replacement 47 5 3 15 Rinse Saver Assembly Repair 48 5 3 16 Conveyor Chain Take up Assembly Adjustment 48 5 3 17 Take up...

Page 17: ...These Points 35 Figure 4 2 Conveyor Gearbox and Drive Chain Lubrication 36 Figure 6 1 Vents Curtains Doors Panels Scrap Screens and Water Level Gauges 58 Figure 6 2 Tank Fill Assembly and Temperature Gauges 60 Figure 6 3 Final Rinse Piping Assembly 62 Figure 6 4 Track Assembly 66 Figure 6 5 Conveyor Shafts Chains Bearings and Guides Prior to S N J1050 68 Figure 6 5a Conveyor Shafts Chains Bearings...

Page 18: ...ain and Overflow Assembly 88 Figure 6 16 Steam Booster and Steam Piping Assembly 90 Figure 6 17 Steam Remote Control Cabinet Prior to S N J1050 92 Figure 6 17a Electric Remote Control Cabinet For S N J1050 and above 92a Figure 6 17b Steam or Electric Control Cabinet For S N J1080 and above 92b Figure 6 18 Dishracks and PRV 94 Figure 6 19 MRAN 90 Guides 96 Figure 6 20 MRAN 90 Pawl Bar 98 Figure 6 2...

Page 19: ...sses theory of operation operator controls initial start up and shutdown procedures Part 4 Cleaning and Maintenance discusses lubrication preventive maintenance cleaning and deliming Part 5 Basic Service discusses basic troubleshooting service procedures and corrective maintenance Part 6 Replacement Parts discusses replacement parts procurement and provides parts diagrams and parts lists Part 7 El...

Page 20: ... joints in tanks Remote mounted NEMA 4X control cabinet Common utility connections 440 60 3 power supply 120VAC control circuit Steam coil or electric tank heat Detergent Chemical connection provisions Float switch low water heat protection with 5 second delay Door safety switches Conveyor jam limit switch Easily removable scrap screens Rinse saver device for water conservation Dishracks peg rack ...

Page 21: ...r 20 psig Wash make up 60 0 gal hr 20 psig Total water usage 360 0 gal hr Dimensions Height 56 188 inches w o piping Width 25 0 inches Length 72 0 inches w o vents Volume crated 125 cu ft Shipping weight crated 1000 lbs Weight uncrated 850 lbs Utilities Hot water 3 4 NPT 140 F hot water connection 20 22 psig flow pressure Drain 1 1 2 NPT drain connection 15 gal min maximum flow rate Electric 440 6...

Page 22: ...trol Circuit 1 1 Amps Each heat circuit has a separate power source Circuit Voltage Booster Rise Machine Power Requirement Hz Ph Steam Full Load Amps 125 Service Factor Motor Control 440 60 3 70 6 9 Amps 9 0 Amps Heat Voltage KW Amps Power Requirement Circuit Hz Ph Electric Full Load 125 Service Factor Wash tank heat 440 60 3 20KW 27 Amps 33 Amps Power Rinse tank heat 440 60 3 30KW 40 Amps 50 Amps...

Page 23: ...ped on a single pallet The booster is disconnected from the dishwasher The remote mounted control cabinet is shipped in a separate carton Perform the following steps to unpack the dishwasher 1 Remove protective wrap and hold downs from the pallet 2 Inspect for any shipping damage If damage is found save the packing material and contact the carrier immediately 3 Check the interior of the dishwasher...

Page 24: ...h vertical fill pipe Remove the upper fill pipe assemblies 6 Turn the conveyor chain tension adjusters until the conveyor chain is slack 7 Locate the master links in the conveyor chain and remove Disconnect the chains and pull them to the chain adjuster in the wash tank 8 Remove 1 4 20 hardware and U clip protecting the inside tank joint 9 Remove hardware securing outside front tank flange 10 Remo...

Page 25: ...around the tank hood 5 Adjust the rinse tank adjustable legs to align the bolt holes 6 BOLT THE HOOD SECTIONS FIRST Make sure the U clip removed in Step 8 Part 2 2 is installed Start the bolts and tighten nuts hand tight 7 Check the alignment of the 1 1 2 drain union underneath the machine Adjust tanks as required 8 Start the bolts and hand tighten the nuts to join the bases 9 Connect the 1 1 2 dr...

Page 26: ...r heater at the unload end of the dishwasher Check alignment of common plumbing connections between booster and dishwasher 6 Install deck plates and bolt dishwasher and booster to deck per standard procedures 2 5 Connections between the dishwasher and booster Refer to Figure 2 2 on the next page WARNING The installation of this unit must conform to local codes or in the absence of local codes to t...

Page 27: ...2 INSTALLATION Figure 2 2 Connections Between Dishwasher and Steam Booster Right to left model shown 1 2 3 4 3 4 water line Conduit Harness 3 4 steam union 1 2 condensate union C h a m p i o n C h a m p i o n ...

Page 28: ...nections Steam heat only Perform the following steps to connect the steam supply and condensate return Refer to Figure 2 3 on the next page WARNING The installation of steam supplies must conform to local codes or in the absence of local code all National Codes governing plumbing sanitation safety and good trade practices NOTE A manual shut off valve for steam supplied by others should be installe...

Page 29: ...r booster 2 1 2 NPT hot water supply line for dishwasher 3 1 2 NPT steam supply line 4 1 2 NPT steam condensate line 5 1 1 2 NPT drain line 6 1 2 NPT vent collar drain line 7 Dishwasher main electrical junction box prior to S N JXXXX 7A Wash Rinse tank electrical junction box after S N JXXXX 8 11 13 x 3 87 vent collar connection 9 1 4 rinse aid injection point 10 Detergent injection point 7A 7A ...

Page 30: ...3 page 11 2 Connect 1 2 NPT drain lines to the load and unload vent collars 2 connections per collar See No 6 Fig 2 3 page 11 2 9 Ventilation Connections Perform the following steps to connect the ventilation system Refer to Figure 2 3 on the preceding page WARNING The installation of ventilation must conform to local codes or in the absence of local code all National Codes governing plumbing sani...

Page 31: ...dware conduit and electrical wiring to connect the remote control cabinet to the local electrical distribution system are supplied by others Hardware conduit and electrical wiring to connect the remote control cabinet to the dishwasher are supplied by others 3 Install the dishwasher remote control cabinet on a bulkhead adjacent to the dishwasher Controls must be easily accessible to the operator R...

Page 32: ...wer Requirements page 4 for full load amp ratings 2 Connect the incoming 440V 60 3PH power supply to the heat contactor marked for the wash tank heater circuit Refer to Part 1 5 Electrical Power Requirements page 4 for full load amp ratings 3 Item A Figure 2 5 page 15 illustrates the incoming power connections to the remote control cabinet Connections are shown entering the top of the cabinet but ...

Page 33: ...871 Tank Heaters Incoming Power Remote Control Cabinet Prior to S N J1871 After S N J1872 Junction Box After J1872 Junction Box After J1872 After S N J1872 Prior to S N J1871 15 Part 2 INSTALLATION Figure 2 5 Tank Heater Conduit Routing Right to left model shown A B C ...

Page 34: ...s being done on that circuit 1 Chemical dispensing signal connection points are provided on the main terminal board in the remote control cabinet See No 4 Fig 2 6 page 17 Beginning with serial number J1872 these same connection points are also located in the wash tank junction box No 7 A Fig 2 6 page 11 Either connection location can be used A yellow label indicates the connection points 2 The det...

Page 35: ...AL BLOCK MAIN TERMINAL BOARD TIMERS 120V 120V 120V 120V 4120V 120V 120V 120V 3MOL 2MOL MOTOR OVERLOADS MOTOR CONTACTORS CONTROL FUSES CIRCUIT BREAKER 1MOL 3M 2M 1M FU1 FU2 CB RINSE WASH DRIVE RINSE WASH DRIVE GROUND RT WT MACHINE ELECTRICAL CONNECTION PLATE 2 3 1 SIGNAL ONLY 120V 120V RINSE AID SANI COMMON DETERGENT 4 ...

Page 36: ...THIS PAGE INTENTIONALLY LEFT BLANK 18 ...

Page 37: ...cks loaded with wares through the tanks The wash tank water which is heated to a minimum of 150 F contains detergents Wares are conveyed to the wash tank where they are sprayed with the detergent solution Food particles and other soils are flushed from the wares and are collected in scrap screens above the water holding tank Wares continue on the conveyor system to the power rinse tank which is he...

Page 38: ...eat circuits pump contactors and drive contactor Power ON light Red pilot Signals control power connected to unit if ON OFF selector ON Start switch Green Starts pumps and Pushbutton conveyor motors Stop switch Red Stops pumps and pushbutton conveyor motors Booster low Red pilot Indicates final rinse temperature light light temperature has fallen below 180 F Dishwasher stops Final rinse water Gree...

Page 39: ...able 3 2 page 22 for the location and function of the dishwasher and steam booster operator controls and indicators 2 1 3 4 7 5 6 5 8 Figure 3 2 Controls and Indicators Dishwasher and Booster Right to left w steam booster shown 9 Champion Champion After S N J1872 Prior to S N J1871 ...

Page 40: ...sible in center of glass indicates correct water level in tank Tank water Scaled Indicates water temperature in temperature thermometer wash and rinse tanks gauges dial Wash 150 F minimum Rinse 160 F minimum Final rinse 0 60 PSI Indicates final rinse water pressure pressure gauge gauge during the final rinse 20 22 PSIG minimum flow pressure Final rinse Scaled Indicates final rinse temperature temp...

Page 41: ...h pipe has an o ring on the end of its manifold 4 Make sure the upper and lower spray arms are secure in the manifold and all end plugs are in place 5 Remove the scrap screens and make sure all overflow covers are down and the pump intake screens are in place 6 Replace the scrap screens NOTE Dishwasher curtains have long and short flaps Be sure the short flaps of all curtains face the load end of ...

Page 42: ...0 Press the GREEN start button on the front of the remote control cabinet Pumps and conveyor start 21 Check the direction of rotation of the conveyor drive Conveyor drive sprocket located behind stainless steel cover on unload end turns CCW for right to left operation CW for left to right operation 22 Check the direction of rotation of the pump motors Proper rotation is CW when viewing the motor f...

Page 43: ... below Dishwasher Condition The dishwasher is full of water steam or electric heat energized and dishwasher power is on Temperature gauges indicate proper temperatures The pumps and conveyor are running Door Safety Switch Check 1 Slowly raise the wash tank lift out door approximately 1 inch Dishwasher pumps and conveyor stop 2 Lower wash tank door Press green start button Pumps and conveyor run 3 ...

Page 44: ... Repeat Steps 1 5 for the power rinse tank Conveyor Jam Switch Check Refer to Figure 3 3 below WARNING The conveyor drive contains moving parts Use caution when working around the conveyor drive assembly 1 Using a hydraulic jack or lever raise the conveyor drive table A approximately 2 inches to simulate a jam condition 2 The conveyor jam switch B operates 3 Pumps and conveyor stop 4 Lower the con...

Page 45: ...s indicate proper temperatures The pumps and conveyor are running Booster Low Temperature Check 1 Insert several racks into the machine to operate the final rinse 2 Monitor the final rinse temperature gauge located on the top of the dishwasher in the upper final rinse piping Minimum temperature required is 180 F 3 Close the steam supply valve to the dishwasher so the booster will not heat the fina...

Page 46: ... the rack into the load end of the dishwasher The conveyor advances the rack through the dishwasher 5 Monitor the wash temperature gauges Wash tank temperature must maintain 150 F minimum Power rinse tank must maintain 160 F minimum 6 Monitor the final rinse temperature gauge as the dishrack moves into the final rinse area Minimum temperature required is 180 195 F 7 Monitor the final rinse pressur...

Page 47: ...and lower spray arms Turn arms CCW 1 4 turn Pull gently 10 Inspect spray arm o rings on manifolds Replace if missing or damaged 11 Remove end caps from spray arms and flush arms with water 12 Replace end caps in spray arms Set spray arms aside 13 Flush interior of machine to remove debris on upper hood surfaces 14 Remove scrap screens from dishwasher interior 15 Flush both sides of screens in remo...

Page 48: ...to ON 9 Wait for tank water temperatures to reach operating temperature Wash tank temperature 150 F minimum Power rinse tank temperature 160 F minimum 10 Press GREEN start button on control cabinet Pumps and conveyor run 11 Scrap and prerinse wares Place in dishracks Do not overload racks 12 Slide dishrack into load end of dishwasher 13 Check the final rinse temperature and the final rinse pressur...

Page 49: ...ary for the proper performance of your machine Intervals should be shortened whenever your machine is faced with abnormal working conditions hard water or multiple shift operations 4 2 Daily Cleaning Schedules After Each Meal Period 1 Drain the machine 2 Flush interior with fresh water 3 Clean scrap screens and pump intake screens 4 Clean spray arms 5 Clean the final rinse nozzle openings with a p...

Page 50: ...t cleaning results WARNING Deliming solutions or other acids must not come in contact with household bleach sodium hypochlorite or any chemicals containing chlorine iodine bromine or fluorine Mixing will cause hazardous gases to form Skin contact with deliming solutions can cause severe irritation and possible chemical burns WARNING Consult your chemical supplier for an appropriate deliming soluti...

Page 51: ...rking on the dishwasher disconnect the electric service and place a red tag at the disconnect switch to indicate work is being done on that circuit 4 Turn the power selector switch to OFF at the remote control cabinet 5 Drain the dishwasher if required and inspect the float switches and probes in the bottom of each tank Float switches should move freely Clean if necessary 6 Check the conveyor driv...

Page 52: ... to indicate work is being done on that circuit 5 Disconnect the power to the dishwasher at the main service disconnect switch Tag the circuit to indicate work is being performed on that circuit 6 Disconnect the power to the electric booster if applicable at the main service disconnect switch Tag the circuit to indicate work is being performed on that circuit 7 Open the control cabinet enclosure s...

Page 53: ...es prior to J1050 Refer to Figure 4 1 above 1 NEVER LUBRICATE the stainless steel conveyor chains A located inside the dishwasher 2 NEVER LUBRICATE the drive shaft bearings B located inside the dishwasher on each side of the conveyor drive shaft The grease fittings on the top of each bearing serve to keep out water 3 NEVER LUBRICATE the idle shaft bearings B located inside the dishwasher on each s...

Page 54: ...the drive chain located at the unload end of the dishwasher 3 Apply a thin coat of oil Browning GL32LT or comparable to the drive chain A Wipe off any excess 4 Remove the oil level plug B from the top of the gearbox 5 Remove the breather plug C from the side of the gearbox 6 Remove the drain plug D from the bottom of the gearbox and drain the oil 7 Flush the gear case with a light weight 5 or 10W ...

Page 55: ...cal schematic in the control cabinet of every machine before it is shipped Schematics are included at the back of this manual as well Be aware that these schemat ics include options that may not apply to your machine Options are enclosed in dashed lines with the words IF USED next to them on the schematic Disregard any options that appear on the schematics which are not a part of your machine Elec...

Page 56: ...rocedure 5 3 20 Water level low in tank s Check float switch s and fill tanks Defective float switch Refer to Repair Procedure 5 3 5 Motor overload tripped Refer to Repair Procedure 5 3 24 Blown fuse or circuit breaker Refer to Repair Procedure 5 3 23 Low or no water Main water supply is turned off Turn on main water supply Machine not filled initially Close drains Open manual fill valves Tank dra...

Page 57: ...rature temperature temperature 110 F minimum for 70 rise booster 140 F minimum for 40 rise booster Booster steam supply shut off Turn on steam supply Booster water supply shut off Turn on water supply Rinse nozzle or pipe cap missing Replace missing part Defective final rinse thermostat Refer to Repair Procedure 5 3 9 Defective thermometer Refer to Repair Procedure 5 3 7 Low steam pressure Correct...

Page 58: ...er supply before the final rinse booster assembly To adjust the pressure setting on the PRV loosen the locknut on the adjusting screw in the top of the PRV Turn the adjusting screw clockwise to increase the pressure setting Turn the screw counterclockwise to decrease the pressure setting The USN 72 dishwasher requires a flowing pressure of 20 22 PSI during the final rinse With the dishwasher in no...

Page 59: ...he interior of the vacuum breaker Remove any mineral deposits and inspect the float seating surfaces for pitting If badly pitted replace the entire vacuum breaker assembly Install a new float repair kit and reassemble in reverse order Turn on power and water supplies Operate the dishwasher and check for leaks 5 3 4 Water Solenoid Valve Repair A 3 4 water solenoid is located in the final rinse wate...

Page 60: ... cover tilts up to allow inspection and cleaning Lift up the hinged cover and inspect the overflow tube if an obstruction is suspected Item 10 shows the drain screen This screen should be inspected daily and cleaned Item 12 illustrates the drain assembly It consists of soldered copper pipe and if defective must be replaced as a unit Note the cleanout plug to the left of the drain valve This plug c...

Page 61: ...ostat assembly Install a new thermostat in reverse order Be sure to apply plumber s putty Champion P N 104889 to seal the thermostat bulb fitting in the tank Return the dishwasher to normal operating condition and adjust the thermostat as described above 5 3 9 Final Rinse Steam Thermostat Adjustment and Replacement Refer to Fig 6 16 Part 6 Replacement Parts for a detailed drawing of the steam boos...

Page 62: ...he final rinse and bleed off any water pressure from the line Turn power off to the dishwasher at the dishwasher control Remove the protective cap and round cover from the thermostat body Note the location of the wires and disconnect Disconnect the conduit Remove the thermostat from the booster piping Install the replacement in reverse order Return the dishwasher to normal operation and perform th...

Page 63: ...sate return line downstream from the steam trap Return the dishwasher to normal operation and observe the discharge coming from the steam trap If you do not observe small amounts of water periodically discharged then the stream trap is most likely defective To clean a steam trap Turn off the steam and water supplies Turn off the power at the dish washer control cabinet Bleed any steam pressure fro...

Page 64: ...e removal then unscrew each thermostat from its piping Break the unions item 12 and remove the piping assemblies from the booster header Remove the eight 8 bolts from each header Remove the flow and return headers Inspect the exposed copper tubes and clean as necessary using the cleaning brush Champion P N 112806 Clean the headers as required Install new header gaskets and reassemble in reverse or...

Page 65: ...al 1 Disconnect the power to the machine at the main breaker panel or fuse box 2 Drain the machine 3 Remove the front and side panels if applicable 4 Remove drain plug on the pump volute and drain the pump 5 Remove the pump hoses 6 Disconnect the wires to the motor at the motor junction box 7 Unbolt motor from machine base and remove the pump motor assembly 8 Remove bolts on volute and carefully r...

Page 66: ...ation Insert a dishrack into the machine to verify proper final rinse operation 5 3 16 Conveyor Chain Take up Assembly Adjustment Refer to Fig 6 6 Part 6 Replacement Parts for a detailed drawing of the take up assembly The take up assembly provides the means to compensate for wear in the conveyor chains Ad justment is made by turning the two adjusting screws Item 1 to maintain proper tension NOTE ...

Page 67: ...ft Bearing and Seal Replacement Refer to Fig 6 6 Replacement Parts for a detailed drawing of the take up assembly and the drawing below for a detailed view of the drive shaft seal assembly It is recommended to replace both drive shaft bearings at the same time To replace the bearings Refer to Fig 6 6 Replacement Parts Turn off all power to the dish washer Drain the tanks and remove the curtains an...

Page 68: ...on other than testing To replace a door safety switch Turn power off at the dishwasher control cabinet Note the orientation of the reed switch Mark the wires and disconnect Remove the two 2 retaining nuts holding the switch Install the new switch and reassemble in reverse order Turn power on and operate the dishwasher Check the switch operation by carefully lifting the door approximately 1 The dis...

Page 69: ...evice is to turn the machine on and off In the ON position the switch passes power from the circuit breaker CB to wire 3 With the switch ON the power on light PL will illuminate Wire 3 is the controlling voltage that allows other devices to operate with no other conditions satisfied other than the power being on These devices include A 1CR The relay 1CR monitors the state of the door switches If e...

Page 70: ...circuit is satisfied the pumps and conveyor ca then be restarted with the START button F TLS The device TLS is a table limit switch The state of this switch drives the relay 5CR The contacts of this relay are used in the pump and conveyor hold in circuit 3 PUMP AND CONVEYOR HOLD IN CIRCUIT The pump and conveyor hold in circuit consists of switches contacts and buttons used to energize the pump and...

Page 71: ...lly restart E 2CR and 3CR N O The 2CR and 3CR N O contacts prevent the pumps from running if there is not water in either of the two tanks The circuit controlling these contacts have a 5 second delay in them to allow for the ships rolling and pitching without false stopping F START BUTTON The start button has two functions in this machine The first and most obvious is to begin the machine operatin...

Page 72: ...verload to protect it from line voltage electrical overloads The overload disconnects 120VAC power to the motor contactor coil Refer to the picture to the right Note the Switch Lever on the Overload If the switch lever is off with the 0 showing then the overload has tripped To Reset the Motor Overload Flip the overload switch to the On position A 1 should be visible on the switch lever To Replace ...

Page 73: ...e timer dial again and set the timer dial to 5 for five seconds 5 3 24 Control Cabinet Pilot Light Bulb Replacement There are two pilot lights on the front of the dishwasher control cabinet One indicates Power On the other indicates either Low Booster Temperature or Reset Required If the dishwasher is equipped with a final rinse chemical sanitizing system then the pilot light indicates Reset Requi...

Page 74: ...56 Part 6 REPLACEMENT PARTS THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 75: ...breviation Coml which indicates the part may be available locally or fabricated from raw materials onboard ship The Coml part number is primarily used for common pipe and pipe fittings 6 2 Parts Procurement All parts are available from The Source 502 Rotary Street Hampton VA 23661 You also can contact The Source by telephone or fax Monday through Friday except for holi days from 8 a m Till 5 p m E...

Page 76: ...Figure 6 1 Vents Curtains Doors Panels Scrap screens and Water level gauges R L machine shown C h a m p i o n 1 2 4 24 25 25 26 28 27 29 5 6 7 8 8 9 10 11 13 14 15 31 32 30 30 16 17 18 20 19 21 23 22 12 1 2 1 3 34 33 37 36 35 1 3 ...

Page 77: ...32 8 12 322712 Assy lift out door 2 13 108966 Handle door 4 14 100779 Screw 1 4 20 x 5 8 8 15 106482 Washer lock 1 4 8 16 322839 U clip 1 17 100734 Screw 1 4 20 x 1 2 3 18 106482 Washer lock 1 4 3 19 10003 Nut 1 4 20 3 20 322763 Screen scrap 4 21 322705 Bracket screen support 2 22 106727 Screw flat HD 10 32 x 5 8 8 23 104985 Nut hex 10 32 8 24 322770 Vent Assy RH not shown 1 25 110235 Leg Assy 8 2...

Page 78: ...60 Part 6 REPLACEMENT PARTS Figure 6 2 Tank fill assembly and Temperature gauges R L machine shown 1 4 5 7 18 17 13 1 3 6 1 19 14 18 17 8 9 11 12 10 10 16 15 2 8 9 11 12 10 10 16 15 2 ...

Page 79: ...1 2 brass M x F 2 12 Coml Nipple close 1 2 NPT brass 2 13 325495 Bracket gauge top mounted double 1 14 112803 Label final rinse 1 15 100500 Vacuum breaker 1 2 brass 2 16 108349 Repair kit vacuum breaker 1 2 Prior to S N J1533 Bronze 2 16 113221 Repair kit vacuum breaker 1 2 After S N J1534 Plastic 2 17 201041 Washer 7 8 ID x 1 3 16 3 18 100547 Locknut 1 2 NPT SST 3 19 112090 Overlay final rinse 18...

Page 80: ...6 3 Final rinse piping assembly R L machine shown 2 4 12 2 5 9 10 6 2 11 7 19 2 20 21 22 23 8 24 25 26 17 16 18 2 3 2 13 1 15 14 36 38 37 45 46 To Incoming Water Supply 20 39 40 41 43 42 44 44 41 27 28 27 29 27 27 33 34 35 30 30 32 30 31 ...

Page 81: ...vacuum brkr 3 4 After S N J1534 1 900837 Kit Repair 3 4 Vacuum Breaker Includes one each of 108351 113223 20 102438 Elbow Street 1 2 X 90 2 21 100209 Nipple close 1 2 NPT brass 2 22 102549 Union 1 2 NPT brass 1 23 111287 Nipple 1 2 NPT x 5 1 2 brass 1 24 104749 Valve ball 1 2 1 25 102412 Coupling 1 2 NPT brass 1 26 107448 Adapter 1 2 x 1 2 Copper 1 27 107315 Tubing copper 3 8 Type L A R 28 112825 ...

Page 82: ...ty 44 106734 End cap plastic 2 45 107440 Thermometer 1 46 112090 Overlay final rinse 180 F 1 Kit 900837 was created to repair either style of vacuum breaker bronze or plastic Plastic style are no longer available for the complet vacuum breakers must replace with the bronze style when replacing complete vacuum breaker ...

Page 83: ...65 Part 6 REPLACEMENT PARTS THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 84: ...66 Part 6 REPLACEMENT PARTS Figure 6 4 Track Assembly R L machine shown 1 2 1 2 3 9 9 9 9 9 9 3 3 3 3 3 4 8 7 7 6 6 11 10 5 ...

Page 85: ...HR for L R machine 2 322866 Track 2 LHR for R L machine RHF for R L machine RHR for L R machine LHF for L R machine 3 322889 Bracket rear track 6 4 111296 Screw undercut 10 32 x 3 8 24 5 104985 Nut hex 10 32 24 6 106482 Washer lock 1 4 24 7 100003 Nut hex 1 4 20 24 8 112318 Screw 1 4 20 x 1 2 12 9 322890 Bracket front track 6 10 100141 Nut grip 1 4 20 8 11 100073 Screw 1 4 20 x 1 2 8 ...

Page 86: ...68 Part 6 REPLACEMENT PARTS Figure 6 5 Conveyor shafts chains bearings and guides For machines built prior to S N J1050 14 14 15 15 16 11 10 13 12 1 3 2 1 2 4 5 8 7 9 9 10 12 11 13 6 ...

Page 87: ... Chain front 1 9 112597 Sprocket conveyor 1 bore w set screw 4 10 111201 Screw 3 8 16 x 1 1 4 8 11 100143 Screw 3 8 16 8 12 104618 Washer flat 3 8 8 13 106407 Washer lock 3 8 8 14 900841 Kit Bearing Sleeve USN72 2 15 112599 Housing bearing 2 16 112708 Seal 1 113192 Master Link not shown 2 113193 Offset Link not shown 2 When replacing the seal in the bearing flange you must order the kit 900840 whi...

Page 88: ...a Conveyor shafts chains bearings and guides For machines beginning with S N J1050 and above 14 14 15 15 16 11 10 13 12 5 8 7 9 9 10 12 11 13 6 17 17 17 17 18 19 18 19 26 26 26 26 26 26 20 21 29 20 20 20 20 20 22 21 22 25 24 24 23 23 28 27 29 ...

Page 89: ... 104618 Washer flat 3 8 8 13 106407 Washer lock 3 8 8 14 113182 Bearing 4 15 112599 Housing bearing 4 16 113509 Seal 1 17 113181 Sleeve 1 SST 4 113192 Master Link not shown 2 113193 Offset Link not shown 2 18 322865 Track 2 RHR for R L machine LHF for R L machine RHF for L R machine LHR for L R machine 19 322866 Track 2 LHR for R L machine RHF for R L machine RHR for L R machine LHF for L R machin...

Page 90: ...70 Part 6 REPLACEMENT PARTS Figure 6 6 Conveyor chain take up assembly For machines built prior to S N J1050 13 14 1 2 2 4 3 5 6 7 12 11 10 9 8 5 6 7 ...

Page 91: ...00841 Kit Bearing Sleeve USN72 2 7 309386 Track take up bearing 2 8 323231 Housing take up 1 9 100739 Screw 5 16 18 x 3 4 4 10 106013 Washer lock 5 16 4 11 109009 Nut lock 5 16 18 4 12 107967 Nut lock 1 4 20 8 13 112318 Screw 1 4 20 hex hd 4 14 100003 Nut hex 1 4 20 4 Effective 2 23 00 part number 112598 has been replaced by 900841 Kit Bearing Sleeve These bearings and sleeves will fit in housing ...

Page 92: ...NT PARTS Figure 6 6a Conveyor chain take up assembly For machines beginning with S N J1050 and above 70a 6 7 2 3 5 4 4 10 11 9 12 12 9 9 8 12 9 1 10 11 9 8 12 13 9 6 7 2 3 5 4 4 For S N J1050 Only For S N J1051 and above ...

Page 93: ...oner 2 3 325376 Support front chain tensioner 2 4 100754 Screw 10 32 x 1 2 slot flat 8 5 100735 Screw 1 4 20 x 3 4 hex cap 8 6 106026 Washer flat 8 7 106482 Washer lock 8 8 205971 Sprocket chain tensioner 2 9 113014 Bolt 3 8 16 x 1 5 shoulder with hex socket 6 10 325373 Shim tensioner 2 11 205969 T nut 5 16 18 2 12 205970 Roller chain tensioner 4 13 325567 Bracket chain tensioner Single Piece cons...

Page 94: ...72 Part 6 REPLACEMENT PARTS Figure 6 7 Conveyor drive assembly 1 2 4 3 5 6 7 8 9 10 11 12 13 14 17 18 19 20 15 9 10 16 24 25 26 32 27 28 9 10 29 33 34 30 31 23 21 22 17 18 19 20 ...

Page 95: ...sher flat 5 16 10 19 106013 Washer lock 5 16 6 20 100154 Nut 5 16 18 hex hd 6 21 112713 Sheave reducer 250RPH 1 112603 Sheave reducer 185RPH 1 112604 Sheave reducer 135 RPH 1 112784 Sheave reducer 85 60 RPH 1 22 103162 Sheave motor 250 185 135 85 RPH 1 110164 Sheave motor 60 RPH 1 23 100791 V belt 4L280 1 100795 V belt 4L320 1 24 112590 Motor drive 1 4 hp 440V 60 3ph 1 25 113398 Reducer gear L R m...

Page 96: ...74 Part 6 REPLACEMENT PARTS Figure 6 8 Rinse saver assembly 1 2 3 4 9 10 11 2 2 12 5 4 6 7 8 ...

Page 97: ... 2 108954 Nut 6 32 8 3 111026 Magnet 1 4 107967 Nut lock 1 4 20 5 5 322920 2 Side rinse paddle bracket 1 6 322920 1 Side rinse paddle bracket 1 7 106472 Screw 1 4 20 x 1 1 4 1 8 322919 Paddle rinse assembly 1 9 322891 Box switch 1 10 322892 Cover switch box 1 11 100007 Screw 10 32 x 3 8 1 12 112659 Switch magnetic reed 1 ...

Page 98: ...76 Part 6 REPLACEMENT PARTS Figure 6 9 Steam coil assembly Tank 4 8 9 10 7 6 5 4 1 2 3 ...

Page 99: ...tion Qty 1 323235 Coil steam 1 per tank 1 2 B2850 1 Bracket coil 1 3 B2850 2 Bracket coil 1 4 108345 Gasket 2 per coil 2 5 100740 Bolt 5 16 18 x 1 24 6 102376 Washer flat 5 16 48 7 106013 Washer lock 5 16 24 8 100154 Nut 5 16 18 hex hd 24 9 109683 Plate block off 2 10 112257 O ring 2 ...

Page 100: ...EMENT PARTS 76a Figure 6 9a Electric Tank Heat For machines beginning with S N J1050 and above 17 10 11 24 23 16 8 9 14 15 7 10 11 7 10 11 13 13 13 12 13 25 1 12 3 2 2 2 12 12 6 6 6 7 19 18 20 21 22 27 26 29 30 28 5 4 ...

Page 101: ...r flat 5 16 48 12 106013 Washer lock 5 16 medium split 24 13 100154 Nut 5 16 18 hex finish 24 14 109069 Thermostat with capillary 1 15 201041 Washer flat 7 8 ID x 1 8 1 16 109034 Gasket 1 2 NPT plug 1 17 100547 Locknut 1 1 2 NPT 1 18 111092 Switch float 1 19 111151 C clip 2 20 110750 Gasket float switch 1 21 107589 Washer lock 1 2 1 22 104584 Nut plain 1 2 13 1 23 323428 Wireway box right side 1 2...

Page 102: ...NT PARTS 76b 17 10 11 24 23 16 8 9 14 15 7 10 11 7 10 11 13 13 13 12 13 25 1 12 3 2 2 2 12 12 6 6 6 7 19 18 20 21 22 27 26 29 30 28 5 4 32 32 Figure 6 9b Electric Tank Heat For machines beginning with S N J1872 and above ...

Page 103: ...asher lock 5 16 medium split 24 13 100154 Nut 5 16 18 hex finish 24 14 109069 Thermostat with capillary 1 15 201041 Washer flat 7 8 ID x 1 8 1 16 109034 Gasket 1 2 NPT plug 1 17 100547 Locknut 1 1 2 NPT 1 18 111092 Switch float 1 19 111151 C clip 2 20 110750 Gasket float switch 1 21 107589 Washer lock 1 2 1 22 104584 Nut plain 1 2 13 1 23 323428 Wireway box right side 1 24 323427 Wireway box left ...

Page 104: ...PLACEMENT PARTS Figure 6 10 Tank steam piping with booster R L machine shown 1 2 10 10 10 11 12 11 12 13 14 24 15 17 17 18 19 20 21 29 30 31 32 33 34 34 35 35 21 22 22 23 16 13 3 4 4 4 5 6 7 8 9 2 2 25 26 27 28 23 ...

Page 105: ...ushing reducing 3 4 x 1 2 brass 1 15 109683 Flange block off 2 16 112257 O ring 2 17 Coml Street elbow 1 2 NPT brass 2 18 Coml Nipple close 1 2 NPT brass 1 19 Coml Elbow 45 1 2 brass 1 20 Coml Nipple 1 2 x 2 brass 1 21 Coml Union 1 2 NPT brass 2 22 Coml Nipple close 1 2 brass 2 23 111380 Steam trap thermodynamic 1 2 SST 2 24 Coml Nipple 3 4 x 2 brasss 1 25 Coml Elbow reducing 3 4 x 1 2 90 brass 1 ...

Page 106: ...EMENT PARTS Figure 6 11 Tank steam piping with booster L R machine shown 1 2 10 10 10 11 12 11 12 13 14 24 15 17 17 18 19 20 21 29 30 31 32 33 21 22 18 23 16 13 2 3 4 4 5 6 7 8 9 2 2 25 26 27 28 23 34 36 37 37 35 35 35 ...

Page 107: ...09683 Flange blockoff 2 16 112257 O ring flange blockoff 2 17 Coml Street ell 1 2 NPT brass 2 18 Coml Nipple close 1 2 NPT brass 1 19 Coml Elbow 45 1 2 NPT brass 1 20 Coml Nipple close 1 2 NPT brass 1 21 Coml Union 1 2 NPT brass 2 22 Coml Nipple 1 2 NPT x 4 lg brass 1 23 111380 Steam trap thermodynamic 1 2 NPT SST 2 24 Coml Nipple close 3 4 NPT brass 1 25 Coml Elbow reducing 3 4 x 1 2 NPT brass 1 ...

Page 108: ...82 Part 6 REPLACEMENT PARTS Figure 6 12 Junction boxes Float switches Door switches and Thermostats Prior to S N J1871 A A A B B C C B C 7 1 2 10 13 14 11 8 9 4 4 4 5 6 6 6 6 5 5 3 3 3 16 15 12 12 6 ...

Page 109: ...ffman 1 3 322891 Box switch 6 4 322892 Cover switch box 6 5 100007 Screw 10 32 x 3 8 6 6 108954 Nut 6 32 32 7 112659 Switch magnetic reed 2 8 109069 Thermostat 110 200 F 2 9 111092 Switch float 2 10 111151 C clip float switch 4 11 100094 Washer flat 1 2 2 12 104889 Putty sealing compound 440 2 13 107589 Washer lock 1 2 2 14 104584 Nut plain 1 2 13 Hex hd 2 15 201041 Washer 7 8 ID x 1 8 ThK 2 16 10...

Page 110: ... 82a A A A B C C B C 7 10 13 14 11 8 9 4 6 6 5 3 16 15 12 12 6 B Top of Junction Box Top of Junction Box 1 2 Figure 6 12a Junction boxes Float switches Door switches and Thermostats For machines beginning with S N J1872 and above ...

Page 111: ... Hoffman Rinse 1 3 322891 Box switch 6 4 322892 Cover switch box 6 5 100007 Screw 10 32 x 3 8 6 6 108954 Nut 6 32 32 7 112659 Switch magnetic reed 2 8 109069 Thermostat 110 200 F 2 9 111092 Switch float 2 10 111151 C clip float switch 4 11 100094 Washer flat 1 2 2 12 104889 Putty sealing compound 440 2 13 107589 Washer lock 1 2 2 14 104584 Nut plain 1 2 13 Hex hd 2 15 201041 Washer 7 8 ID x 1 8 Th...

Page 112: ...84 Part 6 REPLACEMENT PARTS Figure 6 13 Pump assembly 1 2 6 7 8 9 2 3 4 5 10 11 12 13 14 15 16 17 18 19 20 24 25 26 27 28 24 25 32 33 34 35 36 37 5 4 1 3 29 30 24 31 21 23 22 ...

Page 113: ...1 21 112801 Hose pump discharge 1 22 111964 Clamp hose 2 23 102500 Plug 1 4 NPT Brass 2 24 106482 Washer lock 1 4 11 25 100736 Bolt 1 4 20 x 3 4 Hex hd 10 26 102504 Plug 1 2 NPT Brass 1 27 111725 O ring 1 28 112379 Flange suction machined Replaces 111841 1 112338 Gasket Pump Suction flange Not Shown 1 29 110248 Washer flat 1 30 110247 Nut jam 7 16 20 Hex hd 1 31 100734 Bolt 1 4 20 x 1 2 Hex hd 1 3...

Page 114: ... Part 6 REPLACEMENT PARTS Figure 6 14 Wash spray system R L machine shown 2 3 4 5 2 1 6 6 7 8 6 1 9 9 10 11 12 6 6 6 6 10 11 12 10 11 12 9 9 10 11 12 13 14 13 14 15 16 18 20 21 22 23 24 25 19 17 17 18 19 ...

Page 115: ...trictor 2 9 100739 Bolt 5 16 18 x 3 4 Hex hd 16 10 102376 Washer flat 5 16 16 11 106013 Washer lock 5 16 16 12 100154 Nut plain 5 16 18 Hex hd 16 13 112802 Hose connecting 2 14 111964 Clamp hose 4 15 323238 LH side tube 1 16 323239 RH side tube 1 17 317240 Manifold 4 hole 2 18 410697 Manifold 5 hole w restrictor 2 19 322983 Standpipe 2 20 111505 O ring spraypipe 18 21 111454 Plate locking 18 22 11...

Page 116: ...8 Part 6 REPLACEMENT PARTS Figure 6 15 Drain and overflow assembly LEFT SIDE VIEW TOP VIEW 1 1 3 8 1 1 2 5 4 2 6 6 7 7 9 9 15 15 14 11 11 10 12 13 16 16 17 17 18 18 20 21 22 23 24 24 25 25 26 19 20 19 12 ...

Page 117: ...4 x 1 1 2 copper 1 9 206139 Flange drain USN72 mod 2 10 202819 Tube 1 1 2 x 2 3 4 copper 1 11 206137 Tube 1 1 2 x 13 5 8 copper 1 12 206136 Tube 1 1 2 x 8 3 8 copper 1 13 206138 Tube 1 1 2 x 7 1 2 copper 1 14 205598 Tube 1 1 2 x 4 7 16 copper 1 15 109479 Union 1 1 2 copper solder connect 1 16 100739 Bolt 5 16 18 x 3 4 Hex hd 16 17 106013 Washer lock 5 16 16 18 102376 Washer flat 5 16 16 19 108345 ...

Page 118: ... 59 59 1 2 3 4 5 10 11 11 11 12 12 28 27 23 29 30 31 32 33 34 34 34 39 40 53 41 42 43 44 45 46 47 48 49 50 51 52 23 55 37 38 35 36 11 13 14 15 20 16 22 21 11 11 25 26 11 18 17 17 23 24 19 7 8 9 10 54 54 T o f i n a l r i n s e S t e a m i n C o n d e n s a t e o u t W a t e r i n S t e a m o u t 6 60 Control Thermostat ...

Page 119: ...1 2 Brass 1 26 Coml Plug 1 2 NPT Brass 1 27 100309 Junction box 1 28 107550 Pressure regulating valve 3 4 1 29 110768 Line strainer 3 4 NPT Brass 1 30 104828 Ball valve 3 4 NPT 1 31 100983 Bushing reducing 2 x 1 1 2 brass 1 32 107500 Street elbow 1 1 2 x 90 brass 1 33 100979 Bushing reducing 1 1 2 x 1 brass 1 34 105847 Nipple close 1 NPT brass 3 35 105733 Elbow 1 NPT brass 1 36 105851 Union 1 NPT ...

Page 120: ...s built prior to J1050 CONTROL RELAYS CONTROL TRANSFORMER POWER TERMINAL BLOCK MAIN TERMINAL BOARD TIMERS 120V 120V 120V 120V 4120V 120V 120V 120V MOTOR OVERLOADS MOTOR CONTACTORS CONTROL FUSES CIRCUIT BREAKER FU1 FU2 CB RINSE MRA WASH DRIVE MRAÊ RINSE DRIVE WASH GROUND RT WT MACHINE ELECTRICAL CONNECTION PLATE 18 19 20 21 22 23 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 ...

Page 121: ... 1 0A drive 1 20 111671 Bus bar 3 units w o MRAN 90 1 110812 Bus bar 4 units with MRAN 90 1 21 108122 Contractor mtr 12A 4 22 111153 Block fuse 600v 2 23 111821 Fuse 3A ATDR 3 2 24 106995 Circuit breaker 5A 1 25 304326 Bracket circuit breaker 1 26 107091 Transformer 500va 1 27 111833 Block terminal 185A 3 pole 600v 1 28 103310 Lug ground wire 1 29 111036 Socket relay 8 30 111068 Relay 2PDT 10A 120...

Page 122: ...RD GROUND 26 27 28 35 3MOL 2MOL MOTOR OVERLOADS 1MOL RINSE WASH DRIVE 19 20 CIRCUIT BREAKER CB 24 25 CONTROL RELAYS 120V 120V 120V 120V 120V 120V 120V 120V 29 30 29 30 36 TIMERS RT WT 32 31 MOTOR CONTACTORS 3M 2M 1M RINSE WASH DRIVE 21 CONTROL FUSES FU1 FU2 22 23 33 34 18 BOOSTER LOW TEMP OFF START PRIME STOP ON POWER ON 1 2 3 11 12 13 15 16 17 14 3 4 5 6 6 12 13 6 7 8 9 10 9 10 3 3 ...

Page 123: ...3 unit w o MRAN 90 1 110812 Bus bar 4 unit With MRAN 90 1 21 108122 Contactor mtr 12A 3 22 111153 Block fuse 600v 2 23 111821 Fuse 3A ATDR 3 2 24 106995 Breaker circuit 5A 1 25 304326 Bracket circuit breaker 1 26 107091 Transformer 500va 1 27 111833 Block terminal 185A 3 pole 600V 1 28 103310 Lug ground wire 1 29 111036 Socket relay 8 30 111068 Relay 2PDT 10A 120VAC 8 31 112352 Socket timer 2 32 1...

Page 124: ...E 21 MRA FU1 FU2 22 23 33 34 18 TIMERS RT WT 32 31 CONTROL RELAYS 120V 120V 120V 120V 120V 120V 120V 120V 29 30 29 30 OFF START FINAL RINSE WATER PRIME LOW RINSE TEMP ALARM STOP ON POWER ON 1 2 3 11 12 38 13 15 16 17 14 3 4 5 6 6 12 13 6 7 8 9 10 9 10 3 39 Figure 6 17b Steam or Electric Remote Control Cabinet For machines beginning with S N J1080 and above 92b ...

Page 125: ...s Below 1 18 111627 Overload mtr 2 4 4 0A wash rinse 2 19 111624 Overload mtr 0 6 1 0A drive 1 20 111671 Bus bar 3 unit w o MRAN 90 1 110812 Bus bar 4 unit With MRAN 90 1 21 108122 Contactor mtr 12A 3 22 111153 Block fuse 600v 2 23 111821 Fuse 3A ATDR 3 2 24 106995 Breaker circuit 5A 1 25 304326 Bracket circuit breaker 1 26 107091 Transformer 500va 1 27 111833 Block terminal 185A 3 pole 600V 1 28 ...

Page 126: ...94 Part 6 REPLACEMENT PARTS Figure 6 18 Dishracks and PRV 1 2 3 ...

Page 127: ...95 Part 6 REPLACEMENT PARTS DISHRACKS AND PRV Fig 6 18 Part Item No No Part Description Qty 1 101273 Rack flat bottom 1 2 101285 Rack peg 1 3 107550 Valve pressure reducing PRV 1 ...

Page 128: ...96 Part 6 REPLACEMENT PARTS 1 1 2 1 1 1 4 4 4 4 5 5 5 5 3 6 6 7 5 6 6 6 4 4 4 5 5 1 1 1 8 9 9 Figure 6 19 MRAN 90 Guides ...

Page 129: ...ty 1 100735 Bolt 1 4 x 5 8 Hex hd A R 2 310180 Guide rack advance 1 3 314640 Rack support inner 1 4 111370 Screw 10 32 x 5 8 Hex hd 7 5 107966 Nut grip 10 32 7 6 314466 Rack support 7 7 314641 Rack support outer 1 8 314649 Rack support inner 1 9 107967 Nut grip 1 4 20 w nylon insert A R ...

Page 130: ...98 Part 6 REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 Figure 6 20 MRAN 90 Pawl Bar ...

Page 131: ...tem No No Qty 1 314605 Bar pawl 1 2 110240 Bolt pawl mounting 7 3 110236 Pawl rack advance 7 4 102376 Washer 5 16 x 3 4 x 1 16 7 5 106013 Washer lock 5 16 split 7 6 110553 Nut 8mm SST 7 7 106560 Pin cotter 1 8 x 1 1 2 1 8 320156 Washer 1 1 4 x 3 4 x 1 16 1 9 111062 Shaft pivot 1 ...

Page 132: ...REPLACEMENT PARTS 6 6 25 26 29 30 31 32 6 28 27 26 25 5 7 16 10 8 9 17 15 14 13 26 25 22 21 20 19 18 7 1 2 3 4 3 5 4 2 1 6 6 7 7 25 26 5 5 6 5 23 24 STUD 11 12 5 welded Figure 6 21 MRAN 90 Table and Drain Assembly ...

Page 133: ... 1 4 x 1 1 15 100771 Screw set 1 4 20 x 1 4 Socket hd 1 16 103180 Ring wiper 1 17 100153 Bolt 3 8 16 x 1 Hex hd 4 18 107864 Washer packing 1 19 107863 Outlet waste 1 20 304816 Strainer 6 1 21 106482 Washer lock 1 4 split 1 22 10003 Nut plain 1 4 20 SST 1 23 314354 Stiffener shaft 1 24 100747 Bolt 1 2 13 x 1 1 25 106026 Washer 1 4 x 5 8 x 1 16 SST A R 26 100141 Nut grip 1 4 20 SST A R 27 112145 Rec...

Page 134: ...102 Part 6 REPLACEMENT PARTS 1 2 5 3 4 5 6 16 6 7 6 8 7 6 8 7 12 7 13 14 15 7 8 9 10 11 Figure 6 22 MRAN 90 Base Assembly ...

Page 135: ...t 1 5 100735 Bolt 1 4 20 x 5 8 Hex hd 1 6 106026 Washer 1 4 x 5 8 x 1 16 SST A R 7 107967 Nut grip 1 4 20 w nylon insert A R 8 100141 Nut grip 1 4 20 SST A R 9 111114 Bolt 3 8 16 x 3 1 2 SST 1 10 106407 Washer lock 3 8 split 1 11 100141 Nut plain 1 12 104584 Nut plain 1 2 13 Hex hd 1 13 107589 Washer lock 1 2 external 1 14 107089 Nut jam 1 2 13 1 15 100003 Nut plain 1 4 20 SST 1 16 111095 Bolt eye...

Page 136: ...104 Part 6 REPLACEMENT PARTS 5 23 14 1 2 3 Welded to bottom of item 13 13 12 11 10 9 7 6 8 18 19 17 16 20 21 14 15 14 22 14 14 17 16 4 24 8 Figure 6 23 MRAN 90 Drive and Motor Assembly ...

Page 137: ...ance 1 8 111064 Coupler Shaft 2 9 100771 Screw set 1 4 20 x 1 4 socket hd 1 10 104916 Key 3 16 x 3 16 x 3 4 1 11 100870 Slinger water 1 12 110152 Reducer 1 13 314364 Base reducer 1 14 106026 Washer 8 15 105296 Spacer SST 4 16 100003 Nut plain 1 4 20 SST 6 17 100141 Nut grip 1 4 20 SST 6 18 112877 Motor 1 2 HP 115 208 240V 1HP 1 19 325622 Clamp motor 1 20 111095 Bolt eye 1 4 20 x 1 1 21 111076 Spri...

Page 138: ...t 6 REPLACEMENT PARTS Figure 6 24 CH 60 Electric Booster Piping For USS Ramage Only 27 25 25 10 5 2 3 6 9 10 11 19 7 10 18 17 20 2 24 23 21 22 2 14 13 2 15 16 10 12 4 26 6 7 8 4 27 28 28 29 29 1 5 30 29 29 30 ...

Page 139: ...ss 1 13 102489 Nipple 3 4 x 2 1 2 brass 1 14 102526 Tee reducer 3 4 x 3 4 x 1 2 2 15 102390 Bushing reducer 1 2 x 3 8 brass 1 16 113170 Probe water level 1 17 102676 Nipple 3 4 x 10 1 2 brass 1 18 100571 Union 3 4 NPT brass 1 19 104682 Thermometer 1 2 NPT stem 1 20 102653 Nipple 3 4 x 4 brass 1 21 102535 Tee reducer 1 x 1 x 3 4 brass 1 22 102396 Bushing reducer 1 x 3 4 brass 1 23 102394 Bushing re...

Page 140: ...108 Part 6 REPLACEMENT PARTS Figure 6 25 CH 60 Electric Booster Control Cabinet For USS Ramage Only 10 12 14 11 1 15 16 17 18 2 3 2 4 5 6 7 8 9 13 Front View Side View ...

Page 141: ...4 Block fuse 1 5 112887 Fuse ATDR 1 2A Time delay 2 6 109064 Transformer 1 7 113186 Board water level control 1 8 111827 Contactor 60FLA 2 9 112083 Fan blower 1 10 107351 Switch toggle DPDT 1 11 106364 Light pilot green 120V 1 12 109069 Thermostat control 2 13 110561 Thermostat high limit 2 14 325511 Panel corner post 1 15 325512 Panel RH side 1 16 325513 Panel LH side 1 17 325514 Panel Front 1 18...

Page 142: ...110 Part 6 REPLACEMENT P ARTS THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 143: ...111 Part 6 REPLACEMENT P ARTS PART 7 ELECTRICAL SCHEMATICS Part 7 ELECTRICAL SCHEMA TICS ...

Page 144: ... RINSE TANK STEAM SOLENOID VALVE HC1 WASH TANK STEAM SOLENOID VALVE FU FUSE TRASNSFORMER FRSW FINAL RINSE SWITCH FRV FINAL RINSE FILL VALVE DSS DOOR SAFETY SWITCH BC1 BOOSTER STEAM SOLENOID VALVE 3MOL RINSE MOTOR OVERLOAD 3M RINSE CONTACTOR 2MOL WASH MOTOR OVERLOAD 2M WASH CONTACTOR 1MOL DRIVE MOTOR OVERLOAD 1M DRIVE CONTACTOR 5CR TABLE LIMIT SWITCH RELAY 4CR FINAL RINSE SWITCH RELAY 3CR RINSE TAN...

Page 145: ...ATE BY P1 P2 TSR RINSE TANK THERMOSTAT TSK LOW TEMPERATURE CUT OFF THERMOSTAT TSB BOOSTER THERMOSTAT T1 440V 120V TRANSFORMER RT RINSE TANK FLOAT TIMER HC2 RINSE TANK HEAT CONTACTOR HC1 WASH TANK HEAT CONTACTOR FU FUSE TRASNSFORMER FRSW FINAL RINSE SWITCH FRV FINAL RINSE FILL VALVE DSS DOOR SAFETY SWITCH BC1 BOOSTER HEATER CONTACTOR 3MOL RINSE MOTOR OVERLOAD 3M RINSE CONTACTOR 2MOL WASH MOTOR OVER...

Page 146: ...V B REV The Dishwashing Machine Specialists SCALE DR BY DATE SHEET OF REV DESCRIPTION DATE BY P1 P2 TSR RINSE TANK THERMOSTAT TSK LOW TEMPERATURE CUT OFF THERMOSTAT TSB BOOSTER THERMOSTAT T1 440V 120V TRANSFORMER RT RINSE TANK FLOAT TIMER HC2 RINSE TANK HEAT CONTACTOR HC1 WASH TANK HEAT CONTACTOR FU FUSE TRASNSFORMER FRSW FINAL RINSE SWITCH FRV FINAL RINSE FILL VALVE DSS DOOR SAFETY SWITCH BC1 BOO...

Page 147: ...F REV DESCRIPTION DATE BY P1 P2 20 5 M CLUTCH 6 2 4 1 7 8 OFF DELAY 5 OFF DELAY 2 7 M 8 6 CLUTCH 1 4 L3 L1 L2 L1 L2 L3 L1 L2 L3 33 41 39 40 37 38 36 35 34 17 3A 23 7 9 10 11 12 13 14 95 4 96 25 29 30 26 3 3C 22 DIAGRAM STATE END OF CYCLE TANKS EMPTY DOORS CLOSED POWER OFF 2 2B 31 32 51 SIGNAL DETERGENT 4 8 3 62B 61B 62A 60B 61A 60A 63B 65B 64B 64A 65A 63A 64C 65C 63C 16 GND 97 4 98 98 70 L1 L3 L2 ...

Page 148: ...RATURE CUT OFF THERMOSTAT TSB BOOSTER THERMOSTAT T1 440V 120V TRANSFORMER RT RINSE TANK FLOAT TIMER HC2 RINSE TANK HEAT STEAM VALVE HC1 WASH TANK HEAT STEAM VALVE FU FUSE TRASNSFORMER FRSW FINAL RINSE SWITCH FRV FINAL RINSE VALVE DSS DOOR SAFETY SWITCH BC1 BOOSTER HEATER STEAM VALVE 3MOL RINSE MOTOR OVERLOAD 3M RINSE CONTACTOR 2MOL WASH MOTOR OVERLOAD 2M WASH CONTACTOR 1MOL DRIVE MOTOR OVERLOAD 1M...

Page 149: ... TIMER HC2 RINSE TANK HEAT STEAM VALVE HC1 WASH TANK HEAT STEAM VALVE FU FUSE TRASNSFORMER FRSW FINAL RINSE SWITCH FRV FINAL RINSE VALVE DSS DOOR SAFETY SWITCH BC1 BOOSTER HEATER STEAM VALVE 3MOL RINSE MOTOR OVERLOAD 3M RINSE CONTACTOR 2MOL WASH MOTOR OVERLOAD 2M WASH CONTACTOR 1MOL DRIVE MOTOR OVERLOAD 1M DRIVE CONTACTOR 5CR TABLE LIMIT SWITCH RELAY 4CR FINAL RINSE SWITCH RELAY 3CR RINSE TANK FLO...

Page 150: ...ODES BY DATE DESCRIPTION REV B REV The Dishwashing Machine Specialists SCALE DR BY DATE SHEET OF L1 L3 L2 30kW TOTAL 15KW 15kW 30 31 32 33 34 35 40 37 30kW TOTAL 15kW 38 41 15kW 39 36 L1 L2 L3 FUSE BOOSTER CONTACTOR BC_ FU_ F3 F5 F6 F8 GND 2 1 1 2 1 3 LT BC1 BC2 4 5 6 8 7 2 LT POWER ON LIGHT LOW WATER CUT OUT PROBE LWCO POWER SWITCH PSW THERMOSTAT TS_ WATER LEVEL BOARD N O CONTACT WL HLTS_ HIGH LI...

Page 151: ...OR GROUND GREEN TO DRIVE MOTOR GROUND GND 2M 3M FROM ASSOC OVLD FROM ASSOC OVLD FROM ASSOC OVLD FROM ASSOC OVLD 3 WHITE WIRES NUMBERED 2 FOR 120V NEUTRAL 1 GREEN FOR GROUND 20 WIRES FOR CONTROL CIRCUIT NUMBERED 3 3 4 5 6 98 9 10 16 17 19 20 22 29 30 31 32 97 SP1 SP2 14 AND 15 ADD ONE CONTROL WIRE NUMBERD 70 FOR MODELS WITH OPTIONAL MRA TABLE 3 GREEN WIRES FOR GROUND 9 WIRES FOR MOTOR WIRING NUMBER...

Page 152: ...5 TO TB2 6 TO TB2 14 TO TB2 8 TO TB2 10 TO TB2 11 TO TB2 12 TO TB2 15 TO TB2 16 TO TB2 17 TO TB2 18 TO TB3 10 TO TB3 11 TO TB3 12 TO TB3 13 TO TB3 14 TO TB3 15 TO TB3 16 TO TB3 19 TO TB3 20 TO TB3 23 TO TB3 25 TO TB3 26 MOTOR CONTACTORS DRIVE WASH RINSE TO TB2 TO TB3 22 COMPLETEREVISIONTOSHOWTERMINALBLOCKWIRINGCONNECTIONS 23OCT03 JAM TO TB3 SEE NOTE 1 SEE NOTE 2 SEE NOTE 2 SEE NOTE 1 NOTES 1 MAXIM...

Page 153: ...TO T35 6 39 40 41 38 36 37 35 34 33 FROM TB1 IN CONTROL CABINET CONTROL CABINET FROM TB1 IN IN CONTROL CABINET FROM DEVICE CONTACTORS IN CONTROL CABINET FROM DEVICE CONTACTORS TO TB2 4 TO TB2 5 TO TB2 6 TO TB2 8 TO TB2 9 TO TB2 10 TO TB2 11 TO TB2 12 TO TB2 15 TO TB2 16 TO TB2 17 TO TB2 18 TO TB3 10 TO TB3 11 TO TB3 12 TO TB3 13 TO TB3 14 TO TB3 15 TO TB3 16 TO TB3 19 TO TB3 20 TO TB3 23 TO TB3 25...

Page 154: ... ASSOC OVLD FROM ASSOC OVLD FROM ASSOC OVLD FROM ASSOC OVLD 3 WHITE WIRES NUMBERED 2 FOR 120V NEUTRAL 1 GREEN FOR GROUND 20 WIRES FOR CONTROL CIRCUIT NUMBERED 3 3 4 5 6 98 9 10 16 17 19 20 22 29 30 31 32 97 SP1 SP2 14 AND 15 ADD ONE CONTROL WIRE NUMBERED 70 FOR MODELS WITH OPTIONAL 3 GREEN WIRES FOR GROUND 9 WIRES FOR MOTOR WIRING NUMBERED 33 41 ADD 3 MOTOR WIRES NUMBERED 54 56 AND 1 GREEN WIRE FO...

Page 155: ...2 DIAGRAM STATE END OF CYCLE TANKS EMPTY DOORS CLOSED POWER OFF 2 2 2B 31 32 51 4 8 3 GND 97 4 98 98 70 L1 L3 L2 51 53 52 54 56 55 99 28 2 4 16 19 22 TB1 7 TB1 6 TB1 2 TB1 15 TB1 22 TB1 21 TB1 5 TB1 8 TB1 24 TB1 25 TB1 16 TB1 3 TB1 17 TB1 18 TB1 19 TB1 14 TB1 26 TB1 9 TB1 10 TB1 12 TB1 11 TB1 20 TB1 4 32 30 31 29 60 62 61 65 63 64 BOOSTER THERMOSTAT TSB LOW TEMPERATURE CUT OFF THERMOSTAT WASH TANK...

Page 156: ...B3 25 TB2 17 TB2 18 TB2 1 TB2 2 TB2 3 TB3 1 TB3 2 TB3 3 TB3 4 TB3 5 TB3 6 TB3 7 TB3 8 TB3 9 TB3 19 TB3 18 TB2 9 TB2 8 3A BOOSTER THERMOSTAT TSB LOW TEMPERATURE CUT OFF THERMOSTAT WASH TANK DOOR SAFETY SWITCH WFSW WT W TSW TSR TSK WASH TANK FLOAT SWITCH WASH TANK FLOAT TIMER WASH TANK THERMOSTAT RINSE TANK THERMOSTAT RINSE HEATER TERMINAL BLOCK WASH HEATER TERMINAL BLOCK RINSE TANK HEAT CONTACTOR W...

Page 157: ... OFF 2 2 2B 31 32 51 4 8 3 97 4 98 98 70 L1 L3 L2 51 53 52 54 56 55 99 28 2E 4 16 19 22 TB1 7 TB1 6 TB1 2 TB1 15 TB1 22 TB1 21 TB1 5 TB1 8 TB1 24 TB1 25 TB1 16 TB1 3 TB1 17 TB1 18 TB1 19 TB1 14 TB1 26 TB1 9 TB1 10 TB1 12 TB1 11 TB1 20 TB1 4 32 30 31 29 BOOSTER THERMOSTAT TSB LOW TEMPERATURE CUT OFF THERMOSTAT WASH TANK DOOR SAFETY SWITCH WFSW WT W TSW TSR TSK WASH TANK FLOAT SWITCH WASH TANK FLOAT...

Page 158: ...TB3 23 TB3 24 22 TB3 16 TB2 12 TB3 11 TB3 25 TB2 17 TB2 18 TB2 1 TB2 2 TB2 3 TB3 1 TB3 2 TB3 3 TB3 4 TB3 5 TB3 6 TB3 7 TB3 8 TB3 9 TB3 19 TB3 26 TB2 9 TB2 14 3A BOOSTER THERMOSTAT TSB LOW TEMPERATURE CUT OFF THERMOSTAT WASH TANK DOOR SAFETY SWITCH WFSW WT W TSW TSR TSK WASH TANK FLOAT SWITCH WASH TANK FLOAT TIMER WASH TANK THERMOSTAT RINSE TANK THERMOSTAT RINSE HEATER TERMINAL BLOCK WASH HEATER TE...

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Page 160: ...112 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 161: ...S PART 8 SPECIAL INSERTS In This Part Service Bulletins 8 1 Introduction Part 8 Special Inserts contains late breaking service information in the form of Service Bulletins and other printed information that may be useful to you ...

Page 162: ...the booster tank please follow the diagram listed below When replac ing the the thermostat use part number 109069 1 Mark off the measurement of 12 inches from the end of the bulb This will be at the end of the 1 2 nut that mounts inside of the tee 2 Insert the thermostat bulb 12 inches into the booster Ensure that the bulb is inside one of the copper water tubes and not coiled up inside of the hea...

Page 163: ...115 Part 6 REPLACEMENT P ARTS ...

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