Champion 1 KAB, 1 KACB Service Manual

The Dishwashing Machine Specialists

Equipment Manual

Champion

Dish Washer Models 1 KAB & 1 KACB

Part No. 108108 January 1990

Champion Industries, Inc. P.O. Box 4149 Winston-Salem, NC 27115 336/661 -1556 Fax 336/661 -1979

GENERAL Introduction Directional Reference

Ordering Parts 1 INSTALLATION Installation Instructions 23 OPERATION Operation Instructions 4,5 MAINTENANCE Procedures 6 Service Tips Trouble Shooting — Specific Problems

6,7,89

Maintenance Schedule 910 Special Maintenance PARTS BREAKDOWN AND LISTINGS

10,11,12,13,14

Hood and Base Assemblies For Model 1-KAB 15 For Model 1-KACB

Installation on Door Lever For Model 1-KAB 17 For Model 1-KACB

Control Panel 19 Upper Revolving Wash assembly Lower Revolving Wash and Rinse Assemblies

Wash System Installation 22 Pump assembly Drain Assembly Rinse and Fill Piping Electric Heat Installation Gas Heat Installation Steam Heat with Injector and Electric Thermostat Installation Closed Coil Steam Heat with Electric Thermoswitch Installation Steam Booster Piping Door Lock and Safety Switch Installation Electric Schematic Steam Heat Gas Heat

NOTE: Champion Industries, Inc reserves the right to modify the design and

specifications of the Model 1 -KAB dishwasher at anytime and without prior notice This would be done in the interest of maintaining equipment approval under applicable standards and codes and also to assure that Champion Industries products reflect the advantages of a continuing research and development program

CAUTION: DO NOT OPERATE PUMPS NOR TURN ON HEATER

NOTE: Exercise care when uncrating and

moving your dishwasher to Its permanent location. Protect your investment from the start.

1. Use a Nail Remover — NOT a hammer — remove the shipping case and move the machine on skids to a position near its permanent location.

2. Cut the steel strapping that secures the machine to the skids. With at least two men, tip the dishwasher enough to unscrew the adjustable feet about one inch to give a nominal table connection height of 34 inches. "Walk" the dishwasher off the skids and slide it into the permanent location.

3. Level the machine by placing a spirit level on the base and adjusting the feet Level side-to-side as well as front-to-back.

4. The electrician should check the electrical characteristics labeled on the machine against the power supply prior to connecting to the incoming service at a fused disconnect switch. See Figure 1 or 2 for the appropriate model.

MACHINE INSTALLATION

WITHOUT WATER IN THE TANK. Pumps operated dry will cause mechanical seal to burn up and leak.

8. Untie the upper and lower wash spray manifolds. i

9. Manually spin the revolving wash arms to make sure they rotate freely.

10. Open and close the doors several times to make sure they operate freely.

11. See that refuse screens are in position, resting on the angle supports above the tank.

NOTE: Close pet cock located In bottom of pump before filling tank.

12. When all plumbing and electrical connections are completed, fill the tank with water and let stand fora period of thirty (30) minutes: check for possible leaks in the service connections Run the pump to check for proper rotation in accordance with the indicating arrow on it. Also check out automatic time cycle and manual controls.

13. Open the drain valve and check all waste line' connections for leaks. (See Figure 3)

14. After completing Steps 1 through 13. attach dish tables to each end of the dishwasher.

NOTE: All wiring must be done according to local electrical codes.

5. The plumber should make all connections for water, steam and/or gas — if your dishwasher is so equipped — as well as the drain to the sewer line. (See Figure 1 or 2 for the appropriate model).

6. Install shutoff valves in the steam and water supply lines at points nearthedishwasher before installing the hot water and steam connections. All plumbing connections should comply with local codes.

7. Check the interior of the dishwasher and remove any foreign material.

NOTE: Dish tables are pitched slightly toward machine for proper draining.

MACHINE INSTALLATION

OPERATION

Operation of the Champion Dishwasher Model 1KAB or 1-KACB is fairly simple; however, you should pay close attention to the following instructions and recommendations for ensuring efficient operation as well as long life.

1. Be sure that all wash and rinse spray pipes, rinse nozzles and scrap screens are clean and in place. Close the doors.

2. Close the tank drain valve (See Figure 3). Open the fill valves; shut off when the tanks are fulKSee Figure 4).

3. Spread a half-pound (one cup) of detergent over the screens in the wash compartment or. if an electronic dispenser is used, check-and replenish the supply of detergent in the dispenser. Turn on the dispenser switches.

4. Turn on the steam valve if your dishwasher model is steam-heated (See Figure 5). Turn on the electric heat switch if electrically heated (See Figure 6). Turn on the gas valve; be sure the burners are lit if gas-heated (See Figure 7). Open the valves on the water and steam line to the booster (if your model has one).

OPERATION

wash-rinse cycle is complete when pilot light goes out. For manual operation, put the selector switch on "Manual". Switch the control to WASH for a minimum of 45 seconds. Depress the control to rinse and hold for 10 seconds minimum.

8. For best results, clean the tank-screens and change the wash water each hour of operation Renew the detergent according to Step No. 3.

9. When washing is complete, turn off the tank heat according to Step No. 4.

10. Throw the main power switch to the "OFF" position.

11. Remove and clean the scrap screens Place them on the dish table to allow the tanks to air out and dry. Remove the spray pipes and caps: clean the pipes with a brush. Replace the caps and install in the machine.

5. Throw the main power switch on the "ON" position.

6. Scrape or pre-flush all pieces to be washed. Place .all items in their proper racks. Do not overload racks. Sprays must hit all surfaces. Wash one layer only of silver in the rack. (See maintenance procedures for proper tank temperatures).

7. Slide the loaded rack to the center of the machine. Close the doors. Start the automatic timer by pressing the starter switch (See Figure 6). The

NOTE: Do not hammer the spray pipes.

12. Clean the tanks and flush with fresh water.

13. Leave the doors open between operations to allow the interior of the machine to dry.

14. Keep the machine clean and final rinse nozzles free of internal hard water deposits by using a straightened paper clip to remove solids from the nozzles. Consult your detergent supplier of the use of scale solvents.

15. Report unusual conditions to your supervisor.

PREVENTIVE MAINTENANCE

A well maintained Dishwasher periodically drained and cleaned will give better service. On the other hand. a machine that is neglected will soon clog up with deposits, break down prematurely. Keep your "machine on the job. not on the sidelines.

PROCEDURES

1. Each day — It will pay — to make a brief inspection of the Dishwasher. Check the pump motor for leaks around the shaft; check thermometers and gauges for proper readings. Proper tank temperatures are 150° F. minimum to 160° F. maximum (pumped) for the wash cycle, 180°F. minimum to 200° F. maximum (fresh water) for rinsing. If necessary, adjust the control(s) to the correct setting(s).

TROUBLESHOOTING

2. Certain parts of the Dishwasher should be inspected and cleaned each day. as required (See Maintenance Schedule).

3. Once a week, inspect all water lines for leakage and tightness at joints.

SERVICE TIPS (Trouble-Shooting)

1. Prior to determining the specific cause of any breakdown or abnormal operation of the Dish- • washer:

(a) Be sure all switches are ON. (b) Position the scrap screens in the tank. , (c) Check the position of the spray pipe (slots in the

upper pipe must be on the lower side. slots on the lower pipe must be on the upper side).

After all above items have been accomplished, con-sult the following table for particular service problems.

CONDITION

1. Insufficient Pumped Spray Pressure ward discharge outlet on pump: raised arrow on discharge port gives direction on rotation.

-Check scrap screens (screens must be

-Check and clean spray pipe.

- Check water level in tank (tank must be

-Check drain valve for leaks (valve must be closed when machine is in use.)

2. Low or no final rinse pressure -Check incoming pipe size (may be un dersized).

-Check ished; clean and adjust upward to 20psi

PROBABLE CAUSE and SOLUTION

-Check motor rotation (must rotate to

-Check for clogged pump intake and discharge.

kept clean).

full).

ressure reducing valve, if furn

optimum flow pressure at machine.

- Check for worn rinse nozzles; oversized or worn nozzle parts will tend to de crease rinse

ressure.

)

TROUBLE SHOOTING - (CONT'D)

CONDITION

2. Low or no final rinse pressure (cont'd

-Check for fault

3. Low final rinse temperature -Check incoming water — 140° F. mini

PROBABLE CAUSE and SOLUTION

vacuum breaker (sea

must be in good order).

-Check rinse solenoid valve for proper operation or possible burned out coil.

mum to booster. 180° F. minimum with out booster. Temperature at nozzles MUST be 180° F. MINIMUM.

-Check the booster — be. sure the.thermoswitch is set to maintain 180°F. tem

perature; check all valves. Be sure all are open. clean and operating.

-Check the piping, may need insulating.

NOTE: Dishwasher must not be installed on the same supply line with other equipment using hot water supply needed for the machine.

4 Low or No Tank Heat Temperature

Electric Heat

-Check: Heaters for correct voltage. phase, and operation. Power source to heater — be sure disconnect switch is in

"ON" position. Electrical heater thermostat for proper calibration and setting.

Heater contactor inoperative. For free operation of low water cut-off inside tank.

- Refer to electrical diagram in parts sec tion of manual. Steam Heat

-Check all valves and flow pressure as well as the trap. Gas Heat

-Check the burner and gas supply.

)

TROUBLE SHOOTING - (CONT'D)

CONDITION

4. Low or No Tank Heat Temperature (Confd) operation.

PROBABLE CAUSE and SOLUTION

General: (all types of heat)

- Check: Thermoswitch for setting and

Low water cut-off switch. Thermometer for proper cali

bration. Heat contactor and heat switch, Heaters and coils for soil build

up -- clean if evident.

NOTE: Tank temperatures should be: Wash cycle - 150°F. Min.

160° F.Max, (pumped Rinse cycle - 180' F. Min.

200° F. Max. (fresh water)

5. Low water condition in tank

6. Poor Washing Results For overloaded rack causing

-Check: Drain valve — be sure, it is closed.

Drain valve and overflow box for leaks.

- Check: For proper amount of detergent.

blocked sprays. Wash water and detergent not

changed often enough.

NOTE: Water in wash tank should be changed after each hour of oper

ation.

Dishware improperly placed in rack.

NOTE: Be sure operator is not pushing rach of dishes into machine past

washing cycle.

TROUBLE SHOOTING - (CONT'D)

CONDITION PROBABLE CAUSE and SOLUTION

7. Poor Drying Results -Check: For excessive humidity in dish antry.

Exhaust fans for proper function.

Final rinse water temperature — 180° F. Min.

Improperly stacked dishes after

washing.

MAINTENANCE OF THE DISHWASHER

Scheduled maintenance saves down time and headaches. The chart below is designed to aid you in keeping your dishwasher on the job. It's a well known and widely accepted fact that well maintained machines do not break down as frequently as machines receiving only occasional care — or no attention at all. It will take only a few minutes to give your Champion Dishwasher the small amount of care it deserves. Take the time — your dishwasher will pay you dividends in the form of many troublefree hours of faithful service.

The time intervals shown in the maintenance schedule represent the average lengths of time that various parts of the Champion Dishwasher should go without service Maintenance intervals should be shortened: whenever the machine is faced with poor working conditions— hard water, etc. — or multiple shift operation.

REGULAR MAINTENANCE

Daily or Every 10 Hours: Shut down machine — pull main switch —

• Leave doors raised to air interior.

As Required — daily, or otherwise: Check thermometers and gauges for read

Every Week: Thoroughly clean detergent residue from ex

check following and clean, if required:

- Drain tank and flush with water.

-Empty and clean scrap screens

• Flush out 'garbage disposer.

- Remove all spray pipes (wash and rinse) —

inspect and clean.

-Wash inside of machine with fresh water.

also tank, side and top of machine.

ings and adjust controls to proper settings.

terior of machine.

REGULAR MAINTENANCE (CONT'D)

Every Month: Check the drain valve for leakage (drop in

Every Three (3) Months: Grease or oil all shafts with fittings except

Every Six (6) Months: Grease motors with fittings (if no fittings, see

water level in still tank of over 1 to 2 inches per hour).

Electric Heat (see Special Maintenance).

Clean accumulated scale and coating off heat ing elements.

Check and clean stem of float switch.

Check operation of thermostat.

pump motor with good grade of ball bearing

grease or high Quality lubricating oil.

Special Maintenance) with good grade of ball -.

bearing grease or according to label on each.

SPECIAL MAINTENANCE

CHAMPION MOTOR-PUMP UNIT: D-756

The integral motor-pump assembly, shown in Figure 8, was developed for maximum performance, adherence to the latest sanitation reQuirements and sound engineering design. New NEMA frame sizes have been adopted; however, they are interchangable with the older and larger NEMA frame sizes.

The pump mounting ring bolts onto the motor "End Shield" and the motor shaft extends into the pump housing, eliminating the need for a separate pump. One seal only is reouired in this assembly.

The exclusive "inside suction" design of this pump premits removal of the entire cover of the pump housing as an access plate, allowing unrestricted access to the impeller and interior of the pump chamber. When the seal has worn to the point of replacement, it is easily reached by removing the access plate cover of the pump and the bolt holding the impeller on the shaft. Withdraw the impellersleeve assembly. Oil the shaft lightly to facilitate withdrawing the seal.

NOTE: DO NOT over lubricate.

NOTE: A number 5 wheel puller will aid in removing the impeller.

Before installing the new seal, be sure the tapered cavity is smooth and free of dirt. Again lightly oil the shaft, the outside rubber ring of the seal and wall of the cavity of the pump.

After the impeller-sleeve assembly is in place — also the key — install the fibre washer, metal washer and bolt. As the bolt is tightened, the seal will be automatically compressed to the proper working height. No other adjustment is necessary.

Keep the pump motor clean and lubricate according tothe Maintenance Schedule. If the motor is not equipped with grease fittings, remove the plug (screw) on top front and rear of motor and install the fittings.

NOTE: DO NOT OVER LUBRICATE - one or

two pumps of the grease gun are sufficient.

SOLENOID VALVES

Periodically clean all solenoid valves. Time between cleanings will vary, depending on use and service conditions. Generally, if voltage to the coil is correct. sluggish valve operation or excessive leakage indicates cleaning is required.

If the valve fails to operate properly, compare the electrical service and line pressure with the service and pressure shown on the nameplate of the valve A metallic "click" is heard if the solenoid is operating Absence of the "click" indicates loss of power supply. Check for loose or blown-out fuses, grounded coil, broken lead wires or connections.

To replace the coil, TURN OFF ELECTRIC POWER AND LINE PRESSURE to the valve. Remove the coil cover, washers, gaskets and retaining clip and disconnect the coil lead wires. Replace the coil with a new coil of the same voltage. Replace the gaskets, washers and cover.

For leakage, examine the internal parts for wear or binding; also inspect the diaphragm or disc for weardirt may have accumulated on the valve seats or diaphragm and disc. If parts must be replaced, use only the same make of parts as the valve; also replace as supplied in repair kit (See section for description).

MANUAL VALVES

Leakage of water from the tank of the dish washer over 1 to 2 inches per hour when machine is not in use indicates wear on the internal parts of the drain valve. If the seat is worn, replace.the complete valve.

When dishwasher is not in use and tank continues to fill, wear on the internal parts of the fill valve is indicated. Replace the stem assembly or replace the complete valve if the seat is worn.

VACUUM BREAKER

Only the disc in the vacuum breaker can be replaced if leakage is excessive. If the seat is worn, replace the complete vacuum breaker.

PRESSURE REDUCING VALVE (PRV)

Leakage of water from the PRV valve wil cause loss of pressure to the machine. If the valve is leaking or networking, installthe complete service kit. (See Parts Section).,

ELECTRIC HEAT The electric heat with low water cut-off and thermostat

(Shown in Figure 9) was developed for maximum performance, adherence to the latest in sanitation reQuirements with minimum maintenance and replacement.

1. Every month clean the accumulated scale and coating off the heating elements. Check for pits.

2. Check and clean the stem of the float switch at least once a month. Check the spring clip on the float to be sure it is fastened securely. Be sure the float is installed correctly—the normally-open side should be up — and that the ball float moves up and down, freely.

3. Check operation of the thermostat at least once a month.

NOTE: Should the dishwasher be emptied of

water, and the heater left in operation, the low water cut-off will cut the heater off without damaging the heating element. The heater will come on when the tank is filled to its proper level and the heat switch is "ON".

In the event of failure of-a heater, the heater can be removed without removal of the low water cut-off and thermostat. Remove the heater from the tank by disconnecting the wiring to the heater — be sure the power is "OFF" — remove the locknut, and remove the heater from the tank. Install a new heater in the tank using a sealant on the face of the heater and on the locknut.

tn the event of failure of the low water cut-off thermostat. it can be replaced without removing the heater. Remove only the unit to be replaced. Be sure the power is OFF before removing.

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