Champion CG4 Technical Manual Download Page 1

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Technical Manual

Pass-Through
Glasswasher

Machine Serial No.

Model

CG4

CG6

The Dishwashing Machine Specialists

Champion

June, 2001

P.O. Box 4149
Winston-Salem, North Carolina 27115-4149

Manual

P/N

111557

REV. E

Champion Industries, Inc.

www.championindustries.com

Summary of Contents for CG4

Page 1: ...gh Glasswasher Machine Serial No Model CG4 CG6 The Dishwashing Machine Specialists Champion June 2001 P O Box 4149 Winston Salem North Carolina 27115 4149 Manual P N 111557 REV E Champion Industries Inc www championindustries com ...

Page 2: ... _____________________________________________________________________________ Champion Service Agency___________________________________ Phone _____________ _____________________________________________________________________________ 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 su...

Page 3: ...d the schematic 05 10 95 4 6216 Changed to new style chemical injection board revised the schematic 06 07 95 6226 Changed to narrow control box eliminated float rod bearing 02 02 97 All Reissue of manual and service parts lists Revision B 02 28 00 43 Revised wash down Hose Assy Parts List 06 18 00 38 39 G2182 Revised vacuum breaker part nos 06 18 01 43 Added panels to optional accessories REVISION...

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Page 5: ...e 2 Machine Measurements 7 Figure 3 Wash Tank 9 Figure 4 Plumbing Diagram 12 Figure 5 Main Frame Assembly 18 Figure 6 Spray Assembly 20 Figure 7 Main Tank Assembly 22 Figure 8 Lift Bracket and Drive Assembly 24 Figure 9 Hood Assembly 26 Figure 10 Control Box 28 Figure 11 Control Box Cover Chemical Injector Board 30 Figure 12 Detergent Tank 32 Figure 13 Inlet Plumbing 34 Figure 14 Sanitizer Plumbin...

Page 6: ...oad breakers d Adjustment of thermostats e Adjustment 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 ...

Page 7: ...thin ten 10 days after the installation of your machine 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 For your...

Page 8: ...firmly engaged over track adjusters 5 Remove the packing from within and above the detergent tank 6 Ensure the standpipe is in position in the detergent tank Ensure the short standpipe is in position on the right hand side of the wash tank underneath the conveyor lift bracket NOTE The wash tank standpipe is located inside the wash return screen for shipping 7 Ensure that the wash return screen in ...

Page 9: ...ON Allow 2 50mm additional vertical clearance above hood to permit hood removal when installing unit under a counter top INSTALLATION 19 483 24 610 22 559 48 1219 6 1829 ELECTRIC CORD WITH PLUG 72 1829 48 1219 6 152 6 152 6 152 72 1829 12 305 2 22 559 12 305 2 57 1 4 14 362 1 4 10 261 VERTICAL CLEARANCE 10 261 VERTICAL CLEARANCE 1 4 1 4 23 591 1 4 38 978 1 2 9 235 1 4 12 311 1 4 6 152 1 2 3 1 2 1 ...

Page 10: ...res h Cold Water Connection 1 Connect a minimum 1 2 water line to the cold water solenoid valve Flow pressure must be between 25 95 PSI 172 656 kPa 2 Open mixing valve located between hot and cold solenoid valves for areas with very cold rinse water to heat the rinse water which will prevent glasses from cracking 3 Cold water consumption is approximately 2 4 Imp gpm 2 8 U S gpm 10 6 litres min NOT...

Page 11: ...d drain the tank Push the selector switch B down to the flush position Water will enter the detergent tank as long as the switch is held in the FLUSH position When desired flushing is complete release switch B NOTE Use a commercial grade NON CHLORINATED liquid detergent manufactured specifically for glassware washing machines Your chemical representative should test the solution to ensure the prop...

Page 12: ...tergent feeder will now feed detergent into the detergent tank with water fill 3 To increase detergent volume turn the detergent adjustment screw clockwise 4 To decrease the detergent volume turn the detergent adjustment screw counter clockwise To Adjust Sanitizer Injector 1 When a new sanitizer container is installed push the prime button in and hold until sanitizer feed tube is full 2 Start the ...

Page 13: ...2 Start the washer Take a sample from the final rinse spray tubes 3 To increase the volume of rinse agent turn the adjustment screw clockwise 4 To decrease the volume of rinse agent turn the adjustment screw counter clockwise NOTE To meet the requirements of N S F standards Iodophor in a concentration of 12 5 ppm or chlorine at 50 ppm must be used in the final rinse OPERATION ...

Page 14: ...N SCREEN 4 DRAIN PAN 5 DRAIN SCREEN 6 WASH PUMP 8 CHEMICAL INJECTOR 9 INJECTION FITTING 10 WATER INLET VALVES 11 MIXING VALVE 12 VACUUM BREAKER FLOW HOT WATER IN COLD WATER IN WASH TO DRAIN 12 10 10 11 8 9 7 3 1 2 4 5 6 RINSE SAN DET 7 MAIN TANK STANDPIPE Figure 4 Plumbing Diagram ...

Page 15: ...tube lower lift bracket to adjusters and ensure brackets are solidly engaged over track adjusters 7 Replace spray hood ensuring hood hose connections are firmly engaged Replace curtains and pick up plates 8 Remove and clean upper and lower wash tank screens Remove standpipe from the detergent tank wash down then rinse the interior of the detergent tank 9 Replace stand pipe Replace both upper and l...

Page 16: ...k of pressure at wash No water in detergent tank Ensure water supply is on spray tubes Ensure detergent tank stand pipe is in postion Ensure the tank fill switch is in ON FILL position and that tank fills with water Ensure the float switch is activated by the float cam Ensure the tank fill solenoid valve is operational Obstruction in wash arm Clear obstruction Pump not operating Check power supply...

Page 17: ... condensation Fill chute has lime build up De scale detergent tank Spray tube clean out caps loose Tighten caps or o rings damaged Replace o rings Chemical containers filling Dirty rinse tubes Refer to cleaning section with water Element tube worn Replace Worn flow washer in solenoid Replace valve Chemicals not feeding No product in containers Refill container Product gelling or crystallizing Flus...

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Page 19: ...17 REPLACEMENT PARTS REPLACEMENT PARTS ...

Page 20: ...18 REPLACEMENT PARTS Figure 5 Main Frame Assembly 11 1 2 3 4 5 6 7 8 9 10 12 13 ...

Page 21: ...2 x 3 8 8 5 0703002 Hinge Rail Left Side 1 6 0308100 Front Side Panel SW600 only 2 7 0501921 Door Handle 2 8 0501885 Magnetic Door Catch 2 9 0501464 Screw 10 24 x 3 8 4 10 0707514 Door Assembly Right Hand 1 11 0707515 Door Assembly Left Hand 1 12 0507836 Label Wiring Schematic 1 13 0507582 Label Cleaning 1 MAIN FRAME ASSEMBLY Fig 5 Part Part Description Qty Item No No ...

Page 22: ...20 REPLACEMENT PARTS 1 2 3 4 5 6 8 7 10 11 12 13 10 9 11 12 13 9 14 16 15 17 Figure 6 Spray Assembly ...

Page 23: ... O Ring 10 6 0501716 Manifold Retaining Nut 10 7 0307502 Manifold Plug 1 8 0301795 Manifold Double 2 9 0303009 Retaining Rod Triple 2 10 0303010 Retaining Rod Double 2 11 0501718 Spray Tube Rinse 14 Holes 2 12 0501719 Spray Tube Rinse 13 Holes 2 13 0501717 Spray Tube Wash 5 14 0501407 Screw 8 32 x 1 4 10 15 0501497 Washer Lock 10 16 0303091 Retainer L H 6 17 0303092 Retainer R H 4 ...

Page 24: ...22 REPLACEMENT PARTS Figure 7 Main Tank Assembly R L Shown 1 2 3 4 5 6 8 7 9 10 11 12 14 15 17 17 18 17 22 24 25 26 15 16 13 19 20 21 23 27 28 16 29 ...

Page 25: ...4 4 13 0707576 Activator Channel SW600 1 13 0707503 Activator Channel SW400 1 14 0307518 Retainer for Pick up Plate 4 15 0501539 Nut 1 4 20 4 16 0501501 Lock Washer 1 4 4 17 0501412 Screw 10 32 x 3 8 4 18 0703080 Disconnect Tube Assembly 1 19 0504825 Label Rating 1 20 0302970 Door Catch Plate 1 21 0507583 Label Caution 1 22 0307489 Switch Cover SW600 1 22 0307488 Switch and Chain Cover SW400 1 23 ...

Page 26: ...24 REPLACEMENT PARTS Figure 8 Lift Bracket and Drive Assembly 1 2 3 4 5 6 8 7 9 10 7 11 12 13 14 15 16 17 18 19 20 21 24 25 20 26 27 23 22 ...

Page 27: ...00 1 16 0703029 Slide Rail Assembly SW400 1 17 0501418 Screw 1 4 20 x 1 2 6 18 0501593 Cross Rod 2 19 0703213 Lift Bracket Assembly SW600 1 19 0703154 Lift Bracket Assembly SW400 1 20 0501733 Idler Shaft 2 5 8 Dia 1 21 0501722 Bushing Idler Shaft 2 22 0501420 Bolt 1 4 20 x 1 2 23 0701724 Cam Belt Adjustment 2 24 0503401 Conveyor Belt SW600 1 24 0503705 Conveyor Belt SW400 1 25 0501590 Conveyor Bel...

Page 28: ...26 REPLACEMENT PARTS Figure 9 Hood Assembly 1 2 3 6 5 4 3 7 9 10 12 8 11 ...

Page 29: ...uum breaker at front 1 2 0501497 Lock Washer 8 4 3 0501408 Screw 8 32 x 1 4 12 4 0302997 Curtain Bracket Outer 2 5 0501743 Curtain 2 6 0302998 Curtain Bracket Inner 2 7 0501538 Nut 8 32 4 8 0703176 Curtain Assembly Complete 2 9 0507011 Retaining Ring 2 10 0703702 Disconnect Assembly 2 11 0503703 O Ring for Disconnect 2 12 0703078 Plumbing Cover 1 ...

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

Page 31: ...Label Ground 1 15 0501403 Screw Ground 10 32 x 3 4 2 15 0501533 Nut Ground 10 32 2 15 0501493 Washer Lock Ground 10 2 15 0501472 Washer Flat Ground 3 16 0503648 Screw 8 32 x 5 16 2 17 0503647 Strain Relief Bushing Medium 1 18 0503574 Strain Relief Bushing Small 2 19 0501887 7 8 Button Plug 1 20 0507372 Power Cord 1 21 0503749 Terminal Board 2 22 0701933 Water Heater Cam c w Set Screw 1 23 0501397 ...

Page 32: ...30 REPLACEMENT PARTS Figure 11 Control Box Cover Chemical Injector Board 10 12 11 9 13 14 20 8 6 5 4 1 2 3 7 17 18 19 16 15 ...

Page 33: ...1 Label Circuit Board starting S N 6216 1 13 0503343 Label Warranty Void 1 14 0300986 Hinge Cover 2 15 0501408 Screw 8 32 x 1 4 4 16 0501538 Nut 10 32 4 17 0307409 Injector Pump Cover 1 18 0306363 Dip Tube 3 19 0502666 Hose 1 8 I D x 1 4 O D AR 20 0501869 Strainer 3 NS 0507577 Wiring Harness Drive Motor Solenoid Valves 1 NS 0507578 Wiring Harness Circuit Board prior to S N 6216 1 NS 0509039 Wiring...

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

Page 35: ...Label Data 1 13 0501896 Thermometer Seal 1 14 0501600 8 Thermometer 1 15 0503588 Heater O Ring 1 16 0507315 3 KW Heater c w O Ring 1 17 0507323 Thermostat Capilary only shown 1 18 0501650 Thermostat Adaptor 1 19 0501836 Adaptor O Ring 1 20 0501419 Bolt 1 4 20 x 1 2 1 21 0707383 Drain Pan Screen Assembly 1 22 0707380 Drain Pan Assembly 1 23 0307423 Heater Cover 1 24 0503301 Label Warning 1 25 05014...

Page 36: ...34 REPLACEMENT PARTS Figure 13 Inlet Plumbing TO VACUUM BREAKER TO DETERGENT TANK COLD WATER VALVE HOT WATER VALVE 3 2 1 4 2 5 3 2 1 6 7 8 6 7 8 9 3 10 11 12 13 14 15 18 19 20 23 1 24 25 16 17 21 22 ...

Page 37: ...D Braided Hose AR 9 0509659 Brass Cap 1 10 0307688 Inlet Plumbing Clamp 1 11 0501419 Bolt 1 4 20 x 1 2 2 12 0504822 Screw 8 32 x 1 2 2 13 0306208 Cable Clamp Cover 1 14 0307373 Cable Clamp Assembly 1 15 0501404 Screw 10 32 x 3 8 Brass 2 16 0501493 Lock Washer 10 2 17 0501533 Nut 10 32 Brass 2 18 0505229 Solenoid Guide 1 19 0502811 Diaphragm Kit AR 20 0502810 Flow Washer 2 6 GPM 1 21 0502807 Washer...

Page 38: ...36 REPLACEMENT PARTS Figure 14 Sanitizer Plumbing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 39: ... 8 MPT x 1 2 90 Hose Barb 1 4 0502645 1 8 Hose Barb 2 5 0502666 1 8 Hose AR 6 0502665 1 2 I D Braided Hose AR 7 0503679 7 16 Gear Clamp 2 8 0503669 Injector Barb Fitting 1 9 0502577 3 8 x 1 4 MPT Reducer Bushing 1 10 0502781 Needle Valve 1 11 0507100 0 30 PSI Pressure Gauge 1 12 0300918 Plumbing Clamp 1 13 0501501 Lock Washer 1 4 2 14 0501539 Nut 1 4 20 2 ...

Page 40: ...38 REPLACEMENT PARTS Figure 15 Vacuum Breaker Plumbing 1 2 3 4 5 6 7 ...

Page 41: ...ose Barb 1 4 0502751 1 2 Vacuum Breaker Prior to S N G2182 1 5 0508366 Vac Breaker Kit Prior to S N G2182 AR 6 0502650 1 2 x 3 8 Reducer Bushing 1 7 0502653 3 8 MPT x 1 2 90 Hose Barb 1 8 113220 1 2 vacuum breaker 1 Beginning with S N G2182 and above 9 113221 Repair kit vacuum breaker 1 Beginning with S N G2182 and above NOTE Watts vacuum breaker repair kit is not available use item 4 ...

Page 42: ...40 REPLACEMENT PARTS Figure 16 Wash Pump Assembly 1 2 3 4 5 6 5 7 9 8 8 10 11 12 13 14 16 15 17 18 10 8 ...

Page 43: ...0502668 1 I D Braided Hose AR 7 0501632 Pump Hose Connector 1 8 0503679 7 16 Gear Clamp 2 9 0502665 1 2 I D Braided Hose AR 10 0502663 3 8 I D Braided Hose AR 11 0502734 Stub Shaft 1 12 0502730 Seal Kit c w Spring AR 13 0502729 Impeller 1 14 0502731 Pump Housing 1 15 0501635 O Ring 5 16 I D X 1 16W 1 16 0502732 Housing Seal Screw 1 17 0503648 Screw 8 32 x 5 16 4 18 0501406 Screw 8 32 x 1 2 4 NOTE ...

Page 44: ...42 REPLACEMENT PARTS Figure 17 Cleaning Accessories 1 2 3 4 5 6 5 7 8 ...

Page 45: ...06643 Faucet 1 OPTIONAL ACCESSORIES not shown Fig 18 Part Part Description Qty Item No No 0706204 Drain Tray and Waste Collector 0707258 Quick Disconnect Package Including Casters 0501874 Caster reg 2 0501876 Caster locking 2 0701962 Caster Kit 2 Locking 2 Regular 0507255 Hose 1 2 female quick disconnect 10 0507256 Hose 1 2 male quick disconnect 16 0708453 Hand Sink and Wet Waste Receiver SW46 070...

Page 46: ...INSE PUMP DET TANK HEATER WASH WATER VALVE OFF AUTO HEATER THERMOSTAT WATER LEVEL CAM SWITCH FLOAT OPERATED TANK FILL TOGGLE SWITCH WASH PUMP MOTOR CONV DRIVE MOTOR RINSE WATER VALVE 208 230V 12 8A 60HZ SINGLE PHASE GLASS SHUTOFF ARM SWITCH NC NO NO NC BLACK RED WHITE BLUE GREEN 0507836 BLACK RED SW M5 DIAGRAM IS FOR L R OPERATION FOR R L OPERATION USE N O TERMINAL FLUSH ...

Page 47: ...EATER WASH WATER VALVE OFF AUTO HEATER THERMOSTAT WATER LEVEL CAM SWITCH FLOAT OPERATED TANK FILL TOGGLE SWITCH WASH PUMP MOTOR CONV DRIVE MOTOR RINSE WATER VALVE 208 230V 12 8A 60HZ SINGLE PHASE GLASS SHUTOFF ARM SWITCH NC NO NO NC BLACK RED WHITE BLUE GREEN BLACK RED TANK FILL TOGGLE SWITCH OFF AUTO FLUSH 0507836 SW M5 DIAGRAM IS FOR L R OPERATION FOR R L OPERATION USE N O TERMINAL FLUSH ...

Page 48: ...IM 18V SEC TRANSFORMER DETERGENT DET TANK HEATER WASH WATER VALVE OFF AUTO FLUSH HEATER THERMOSTAT WATER LEVEL CAM SWITCH FLOAT OPERATED TANK FILL TOGGLE SWITCH WASH PUMP MOTOR CONV DRIVE MOTOR RINSE WATER VALVE GLASS SHUTOFF ARM SWITCH NC NO NO NC BLACK RED WHITE BLUE GREEN BLACK RED AUTO OFF TOGGLE SWITCH TANK FILL 208 230V 12 8A 60HZ SINGLE PHASE 0507836 SW M5 FLUSH DIAGRAM IS FOR L R OPERATION...

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