Champion CG4 Service Manual
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
Complete the information below so it will be available for quick reference.
Model Number __________________________ Serial Number ________________________
Voltage and Phase ______________________________________________________________
Champion Parts Distributor __________________________________ Phone _____________
_____________________________________________________________________________
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 sure to have the model number, serial number, voltage,
and phase of your machine.
COPYRIGHT © 2001 by Champion Industries, Inc.
Revision History
Revision Revised Serial Number Comments
Date Pages Effectivity
02/18/91 All 5181 Issued manual and service parts list, Revision A
10/12/94 4 6106 Tank switch shuts down machine, revised 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
REVISIONS
3
CONTENTS
Page
WARRANTY ............................................................................................................................. 4
INTRODUCTION...................................................................................................................... 5
INSTALLATION........................................................................................................................ 6
Unpacking .......................................................................................................................... 6
Measurements ...................................................................................................................... 7
Utility Locations .................................................................................................................. 7
Electrical Connections......................................................................................................... 8
Plumbing Connections......................................................................................................... 8
Water Connections...............................................................................................................8
Drain Connections ...............................................................................................................8
OPERATION.............................................................................................................................. 9
General ................................................................................................................................ 9
To Fill The Wash Tank ........................................................................................................ 9
Operating Instructions ......................................................................................................... 9
Approximate Chemical Settings.......................................................................................... 10
Plumbing Diagram............................................................................................................... 12
MAINTENANCE....................................................................................................................... 13
Daily Cleaning Instructions................................................................................................. 13
Weekly Cleaning Instructions.............................................................................................. 13
TROUBLESHOOTING ............................................................................................................. 14
REPLACEMENT PARTS.......................................................................................................... 17
ELECTRICAL SCHEMATICS ................................................................................................. 44
LIST OF FIGURES
Page
Figure 1 — Unpacking Parts ................................................................................................... 6
Figure 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 Plumbing............................................................................................... 36
Figure 15 — Vacuum Breaker Plumbing .................................................................................. 38
Figure 16 — Wash Pump Assembly ......................................................................................... 40
Figure 17 — Cleaning Accessories ........................................................................................... 42
Figure 18 — Optional Accessories ........................................................................................... 43
Figure 19 — Electrical Diagram (S/N 5181 through 6105)...................................................... 44
Figure 20 — Electrical Diagram (S/N 6106 through 6215)...................................................... 45
Figure 21 — Electrical Diagram (beginning with S/N 6216) ................................................... 46
CONTENTS
4
WARRANTY
LIMITED WARRANTY
Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115,
and P.O. Box 301, 2674 N. Service Road, Jordan Station, Canada L0R 1S0, warrants machines, and parts, as set out
below.
Warranty of Machines: Champion warrants all new machines of its manufacture bearing the name
“Champion” and installed within the United States and Canada to be free from defects in material and
workmanship for a period of one (1) year after the date of installation or fifteen (15) months after the date of
shipment by Champion, whichever occurs first. [See below for special provisions relating to glasswashers.] The
warranty registration card must be returned to Champion within ten (10) days after installation. If warranty card
is not returned to Champion within such period, the warranty will expire after one year from the date of
shipment.
Champion will not assume any responsibility for extra costs for installation in any area where there are
jurisdictional problems with local trades or unions.
If a defect in workmanship or material is found to exist within the warranty period, Champion, at its election,
will either repair or replace the defective machine or accept return of the machine for full credit; provided, however, as to glasswashers, Champion’s obligation with respect to labor associated with any repairs shall end
(a) 120 days after shipment, or (b) 90 days after installation, whichever occurs first. In the event that Champion
elects to repair, the labor and work to be performed in connection with the warranty shall be done during regular
working hours by a Champion authorized service technician. Defective parts become the property of Champion.
Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connection
with its warranty. In no event will Champion’s warranty obligation exceed Champion’s charge for the machine.
The following are not covered by Champion’s warranty:
a. Lighting of gas pilots or burners.
b. Cleaning of gas lines.
c. Replacement of fuses or resetting of overload 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 installation, or failure to follow maintenance and operation procedures.
j. Wear on Pulper cutter blocks, pulse vanes, and auger brush.
Examples of the defects not covered by warranty include, but are not limited to: (1) Damage to the exterior or
interior finish as a result of the above, (2) Use with utility service other than that designated on the rating plate,
(3) Improper connection to utility service, (4) Inadequate or excessive water pressure, (5) Corrosion from
chemicals dispensed in excess of recommended concentrations, (6) Failure of electrical components due to
connection of chemical dispensing equipment installed by others, (7) Leaks or damage resulting from such
leaks caused by the installer, including those at machine table connections or by connection of chemical
dispensing equipment installed by others, (8) Failure to comply with local building codes, (9) Damage caused by
labor dispute.
Warranty of Parts: Champion warrants all new machine parts produced or authorized by Champion to be free
from defects in material and workmanship for a period of 90 days from date of invoice. If any defect in
material and workmanship is found to exist within the warranty period Champion will replace the defective
part without charge.
DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY
. CHAMPION’S WARRANTY
IS ONLY TO THE EXTENT REFLECTED ABOVE. CHAMPION MAKES NO OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED, TO ANY WARRANTY OF
MERCHANTABILITY, OR FITNESS OF PURPOSE. CHAMPION SHALL NOT BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES. THE REMEDIES SET OUT ABOVE ARE
THE EXCLUSIVE REMEDIES FOR ANY DEFECTS FOUND TO EXIST IN CHAMPION DISHWASHING
MACHINES AND CHAMPION PARTS, AND ALL OTHER REMEDIES ARE EXCLUDED,
INCLUDING ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES.
Champion does not authorize any other person, including persons who deal in Champion dishwashing
INTRODUCTION
Welcome to Champion...
and thank you for allowing us to take care of your glass washing needs.
This manual covers the Models CG4 and CG6 glasswashers.
Your machine was completely assembled, inspected, and thoroughly tested at our factory before
it was shipped to your installation site.
This manual contains:
• Warranty Information
• Operation and Cleaning Instructions
• Maintenance Instructions
• Troubleshooting Guide
• Basic Service Information
• Replacement Parts Lists
• Electrical Schematics
Complete and return your warranty registration card within 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 protection, factory authorized parts should always be used for repairs.
Replacement parts may be ordered directly from Champion authorized parts distributor or
authorized service agency. When ordering parts, please supply the model number, serial number,
voltage, and phase of your machine, the part number, part description and quantity.
5
INTRODUCTION
6
INSTALLATION
Unpacking
1. Remove all packing from inside and on top of the machine.
2. Remove all packing from glass operated switch and left and right pick-up plates. Check
that the left and right hand pick-up plates are positioned properly.
3. Check the position of the splash curtains.
4. Check that the conveyor is aligned with the drive sprockets and the lift bracket on the right
hand side is firmly engaged over track adjusters.
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 the detergent tank is in position.
8. Check that the lower drain screen is in position.
INSTALLATION
Figure 1 — Unpacking Parts
SHUT-OFF
CURTAIN
PICK-UP
PLATE
MAIN TANK
STANDPIPE
7
6
DETERGENT
TANK
8
7
INSTALLATION (Cont’d)
Measurements
Uncrated Crated
SW-400 SW-600 SW-400 SW-600
Height 38-1/2" (978) 38-1/2" (978) 49" (1244) 46-1/2" (1181)
Width 48" (1219) 72" (1182) 25-1/4" (640) 27" (685)
Depth 22" (559) 22" (559) 25-1/8" (638) 27-1/2" (698)
Ship Wt. 225lb/102kg 285lb/129kg 154lb/70kg 176lb/80kg
*adjustable foot height 1-3/4" (45)
max. height 40-3/4" (1035)
Figure 2 — Machine Measurements
Utility Locations
1. Hot Water
2. Cold Water
3. Drain
CAUTION:
Allow 2" (50mm) additional vertical clearance above hood to permit hood removal when
installing unit under a counter top.
INSTALLATION
22" [559]
1
9 " [235]
1
23 " [591]
4
6" [152]
6' [1829] ELECTRIC CORD
WITH PLUG
19" [483]
24" [610]
12" [305]
1
2 " [57]
4
48" [1219]
Plan View Plan View
4
3
6" [152]
48" [1219]
Front View Front View
3
22" [559]
1
12 " [311]
4
6" [152]
1
2
1
10 " [261] VERTICAL
4
CLEARANCE
1
9 " [235]
4
1
38 " [978]
2
1
2
1
23 " [591]
4
6" [152]
DIMENSIONS SHOWN IN
INCHES AND MILLIMETERS
SW600SW400
12" [305]
72" [1829]
3
72" [1829]
6' [1829] ELECTRIC CORD
WITH PLUG
31" [787]
36" [914]
1
14 " [362]
4
10 " [261] VERTICAL
21
6" [152]
3
6" [152]
1
1
4
CLEARANCE
1
12 " [311]
4
2
1
38 " [978]
2
!
INSTALLATION (Cont’d)
Electrical Connections
1. The Glass Washer has a six foot power cord with a “U” ground tandem plug for
connection to a power receptacle.
2. Provide a nonlocking 250 volt, 15 ampere, 2 pole, 3 wire grounding receptacle within four
feet of the base of the Glass Washer(CSA TYPE 6-15R). This should be installed by a
qualified electrician to meet the specifications of the local electrical code.
3. This machine operates from 208 to 240 volts.
NOTE:
This machine is 50Hz and 60Hz capatable.
Plumbing Connections
Hot Water Connection
1. Connect a minimum 1/2" water line to the hot water solenoid valve. Supply temperature
must be minimun 140°F/60°C, with a flow pressure between 25-95 PSI/172-656 kPa.
2. Hot water consumption is approximately 10 Imp. gph./12 U.S. gph/45 litres/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.
NOTE:
Install check valves on the hot and cold water lines as close as possible to the water inlet.
Drain Connection
1. This machine is gravity drain. Connect a 1-1/2" drain line where indicated.
2. PVC pipe is generally recommended as copper is prone to attack by the sanitizing
chemicals.
WARNING:
Plumbing and electrical connections should be made by a qualified workman who will
observe all the applicable plumbing, sanitary and safety codes. Before all utilities are
installed, ensure that all the bullet feet are in contact with the floor and at the desired
level.
8
INSTALLATION
!
OPERATION
General
1. The wash tank is equipped
with a float assembly that
operates a single camoperated switch.
2. The water temperature is
controlled by a heater and
a thermostat. The
thermostat should be
between 140°F/60°C and
160°F/ 71°C.
To Fill the Wash Tank
Ensure that the standpipe (A) is in place. Put switch (B) up to the “ON-FILL” position. The
water will fill until the proper level is reached. The heating element will then turn on
automatically once the tank has filled.
Detergent is fed from the supply container into the detergent tank in controlled amounts by the
detergent pump. Use detergent at a strength of 0.35% or as recommended by your chemical
supplier.
To Flush the Wash Tank
The selector switch (B) may be pushed down to the “FLUSH” position to clean the detergent
tank during cleaning operations. The glasswasher will not wash dishes in the flush position. To
use the flush function: Remove the standpipe (A) and 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 proper strength to achieve the best cleaning results.
NOTE:
Many of the chemicals used in glass and dishwashers are harmful to the skin and eyes in
their concentrated form. Use extreme caution when handling containers to prevent
accidental exposure.
Operating Instructions
1. Open front door, flip toggle switch located on wash tank to the “ON-FILL” position. Wash
tank will automatically fill.
2. Ensure there is product in the detergent, sanitizer and rinse agent containers.
3. Load glasses on the conveyor. Start machine with round start/stop knob located on the
front load side of unit. Machine will now stop with shut-off rod and can be restarted with
the round stop/start knob or shut-off rod.
9
OPERATION
Figure 3 — Wash Tank
A
B
10
OPERATION (Cont’d)
APPROXIMATE CHEMICAL SETTINGS
General
Approximate chemical settings can be obtained by counting the revolutions of the injector
rotors.
1. For detergent, one revolution per second equals approximately 0.35% concentration.
NOTE:
Detergent pump only operates when hot water tank is filling.
2. For sanitizer, one revolution in 5 seconds equals approximately 12.5 ppm Iodine or 50
ppm chlorine.
3. For rinse agent, one revolution in 8 seconds is recommended.
To Adjust Detergent Injector:
1. When a new detergent container is installed, push the prime button in and hold until the
detergent feed tube is full.
2. Install the detergent tank standpipe and switch tank fill toggle switch up to the “ON-FILL”
position. The detergent 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 washer with rocker switch located on the front of the machine. Take a sample
from the final rinse spray tube to check sanitizer level.
3. To increase the volume of sanitizer, turn the adjustment screw clockwise.
4. To decrease the volume of sanitizer, turn the adjustment screw counter-clockwise.
NOTE:
If Iodopher is being used as a sanitizer, it is not necessary to use a separate rinse agent. To
turn rinse agent injector “OFF” in this case, turn the adjustment screw counter-clockwise
until the pump stops turning.
NOTE:
OPERATION
11
OPERATION (Cont’d)
To Adjust Rinse Agent Injector:
1. When a new rinse agent container is installed, push the prime button in and hold until the
rinse injector feed tube is full.
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
OPERATION (Cont’d)
12
OPERATION
Figure 4 — Plumbing Diagram
12
10
COLD
WATER IN
11
10
HOT
WATER IN
FLOW
8) CHEMICAL INJECTOR
9) INJECTION FITTING
10) WATER INLET VALVES
11) MIXING VALVE
7) MAIN TANK STANDPIPE
12) VACUUM BREAKER
9
1) WASH WATER TANK
2) STAND PIPE
3) WASH RETURN SCREEN
4) DRAIN PAN
5) DRAIN SCREEN
6) WASH PUMP
RINSE
8
RINSE SAN DET
7
3
1
4
2
TO DRAIN
WASH
5
6
13
MAINTENANCE
MAINTENANCE
CLEANING
Daily Cleaning Instructions
1. Clear the conveyor of glassware and turn glasswasher off by flipping the toggle switch
located on the wash tank to the “off” position.
2. Remove load and unload end pick-up plates and splash curtains. Wash them with hot soapy
water, rinse thoroughly, then dry.
3. Lift and remove spray hood and set it aside.
4. At right hand side of machine, raise conveyor lift bracket to stop position. Remove any
debris from catch pan located below spray tubes and in area surrounding overflow tube.
5. Remove overflow tube at right side of upper tank area. Starting at the left side of the
machine, flush all debris from left to right side of machine using a wash down nozzle.
NOTE:
Do not leave water in tank overnight!!!
6. Replace overflow 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 lower screens.
10. Ensure there is product in the detergent, sanitizer and rinse agent containers. Close doors.
Weekly Cleaning Instructions
1. Lift and remove front spray-hood cover and open front doors. Remove upper and lower
manifold end caps and clean spray tubes with reamer, tube brush, and tube scraper
provided.
2. Remove detergent, sanitizer, and rinse agent feed lines from containers and place them in a
container of hot water. Hold prime buttons in until the feed lines have been thoroughly
flushed. Replace the feed lines to their proper container and prime product through lines.
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