Champion cg4 User Manuals

Table of Contents

• 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
• Unpacking Parts

  6
• Machine Measurements

  7
• Wash Tank

  9
• Plumbing Diagram

  12
• Main Frame Assembly

  18
• Spray Assembly

  20
• Main Tank Assembly

  22
• Lift Bracket and Drive Assembly

  24
• Hood Assembly

  26
• Control Box

  28
• Control Box Cover/Chemical Injector Board

  30
• Detergent Tank

  32
• Inlet Plumbing

  34
• Sanitizer Plumbing

  36
• Vacuum Breaker Plumbing

  38
• Wash Pump Assembly

  40
• Cleaning Accessories

  42
• Optional Accessories

  43
• Electrical Diagram (S/N 5181 through 6105)

  44
• Electrical Diagram (S/N 6106 through 6215)

  45
• Electrical Diagram (beginning with S/N 6216)

  46
• 0707561 Frame Assembly, SW600

  1
• 0707673 Frame Assembly, SW400

  1
• 0501873 Grey Cast Foot

  4
• 0703003 Hinge Rail, Right Side

  1
• 0501412 Screw, 10-32 x 3/8"

  8
• 0703002 Hinge Rail, Left Side

  1
• 0308100 Front Side Panel, SW600 only

  2
• 0501921 Door Handle

  2
• 0501885 Magnetic Door Catch

  2
• 0501464 Screw, 10-24 x 3/8"

  4
• 0707514 Door Assembly, Right Hand

  1
• 0707515 Door Assembly, Left Hand

  1
• 0507836 Label, Wiring Schematic

  1
• 0507582 Label, Cleaning

  1
• 0501746 Manifold Cap

  10
• 0501753 O-Ring

  10
• 0301790 Manifold, Triple

  2
• 0501745 O-Ring

  10
• 0503589 O-Ring

  10
• 0501716 Manifold Retaining Nut

  10
• 0307502 Manifold Plug

  1
• 0301795 Manifold, Double

  2
• 0303009 Retaining Rod, Triple

  2
• 0303010 Retaining Rod, Double

  2
• 0501718 Spray Tube, Rinse (14 Holes)

  2
• 0501719 Spray Tube, Rinse (13 Holes)

  2
• 0501717 Spray Tube, Wash

  5
• 0501407 Screw, 8-32 x 1/4"

  10
• 0501497 Washer, Lock

  10
• 0303091 Retainer, L.H.

  6
• 0303092 Retainer, R.H

  4
• 0707562 Main Tank, SW600

  1
• 0707497 Main Tank, SW400

  1
• 0707498 Main Tank Standpipe

  1
• 0303221 Pick Up Plate, Load End

  1
• 0307500 Wash Return Pan

  1
• 0303224 Pick Up Plate, Slotted, Unload End

  1
• 0707485 Shut-off Rod

  1
• 0501736 Bushing, Shut-off Rod

  2
• 0501728 Pivot Cap

  2
• 0501721 Pivot, Activator Channel

  2
• 0302975 Slide Washer

  2
• 0501727 Activator Channel Guide

  2
• 0501408 Screw, 8-32 x 1/4"

  4
• 0707576 Activator Channel, SW600

  1
• 0707503 Activator Channel, SW400

  1
• 0307518 Retainer, for Pick-up Plate

  4
• 0501539 Nut, 1/4-20

  4
• 0501501 Lock Washer, 1/4"

  4
• 0501412 Screw, 10-32 x 3/8"

  4
• 0703080 Disconnect Tube Assembly

  1
• 0504825 Label, Rating

  1
• 0302970 Door Catch Plate

  1
• 0507583 Label, Caution

  1
• 0307489 Switch Cover, SW600

  1
• 0307488 Switch and Chain Cover, SW400

  1
• 0503301 Label, (disconnect from supply)

  1
• 0503723 Screw, 6-32 x 1"

  2
• 0501375 Trip Switch

  1
• 0503574 Strain Relief Bushing

  1
• 0307506 Activating Switch Bracket

  1
• 0502977 Dual Weld Nut, 6-32

  1
• 107964 Bushing, snap 1/2"

  2
• 0507493 Insulation, tank (CG4)

  1
• 0507587 Insulation, tank (CG6)

  2
• 0501345 Drive Motor, 230 Volt c/w Fan

  1
• 0501355 Motor Fan, 2-5/8" Dia

  1
• 0501456 Bolt, 1/4-20 x 1/2"

  3
• 0702979 Motor Mount Assembly

  1
• 0501408 Screw, 8-32 x 1/4"

  4
• 0501793 Sprocket, 16 Tooth c/w Set Screw

  1
• 0501395 Set Screw, 1/4-20 x 5/16"

  2
• 0501899 Drive Chain

  1
• 0501706 Sprocket, 54 Tooth c/w Set Screw

  1
• 0501731 Spacer, Drive Shaft

  1
• 0501729 Drive Shaft Bushing

  2
• 0501419 Screw, 1/4-20 x 1/2"

  6
• 0501710 Sprocket, Conveyor

  4
• 0501732 Drive Shaft, 5/8" Dia

  1
• 0501702 Retaining Ring

  1
• 0704576 Slide Rail Assembly, SW600

  1
• 0703029 Slide Rail Assembly, SW400

  1
• 0501418 Screw, 1/4-20 x 1/2"

  6
• 0501593 Cross Rod

  2
• 0703213 Lift Bracket Assembly, SW600

  1
• 0703154 Lift Bracket Assembly, SW400

  1
• 0501733 Idler Shaft, 2 - 5/8" Dia

  1
• 0501722 Bushing, Idler Shaft

  2
• 0501420 Bolt, 1/4-20 x 1"

  2
• 0701724 Cam, Belt Adjustment

  2
• 0503401 Conveyor Belt, SW600

  1
• 0503705 Conveyor Belt, SW400

  1
• 0501590 Conveyor Belt Link, SW600

  1596
• 0501590 Conveyor Belt Link, SW400

  1036
• 0501589 Conveyor Rod, SW600

  57
• 0501589 Conveyor Rod, SW400

  37
• 0503664 Retaining Ring, SW600

  114
• 0503664 Retaining Ring, SW400

  74
• 0704862 Idler Shaft Assembly, (items 13, 20, 21)

  1
• 0704863 Drive Shaft Assembly, (items 9 - 15)

  1
• 0703244 Hood, with vacuum breaker at rear

  1
• 0708681 Hood, with vacuum breaker at front

  1
• 0501497 Lock Washer, #8

  4
• 0501408 Screw, 8-32 x 1/4"

  12
• 0302997 Curtain Bracket, Outer

  2
• 0501743 Curtain

  2
• 0302998 Curtain Bracket, Inner

  2
• 0501538 Nut, 8-32

  4
• 0703176 Curtain Assembly Complete

  2
• 0507011 Retaining Ring

  2
• 0703702 Disconnect Assembly

  2
• 0503703 O-Ring for Disconnect

  2
• 0703078 Plumbing Cover

  1
• 0707403 Control Box (prior to S/N 6226)

  1
• 0709049 Control Box (starting @ S/N 6226)

  1
• 0307405 Injector Motor Plate

  1
• 0501519 Tie, Nylon 4 in

  6
• 0706635 45CC Element Tube

  2
• 0706634 15CC Element Tube

  1
• 0707142 Rotor Assembly

  3
• 0506589 Screw, 6-32 x 7/8"

  6
• 0504822 Screw, 8-32 x 1/2"

  12
• 0501353 Chemical Injector Motor

  3
• 0507314 Start Capacitor (3 uF)

  1
• 0307422 Thermostat Bracket

  1
• 0501450 Screw, 6-32 x 3/16"

  4
• 0507323 Thermostat

  1
• 0503592 Label, Ground

  1
• 0501403 Screw, Ground, 10-32 x 3/4"

  2
• 0501533 Nut, Ground, 10-32

  2
• 0501493 Washer, Lock, Ground, #10

  2
• 0501472 Washer, Flat, Ground

  3
• 0503648 Screw, 8-32 x 5/16"

  2
• 0503647 Strain Relief Bushing (Medium)

  1
• 0503574 Strain Relief Bushing (Small)

  2
• 0501887 7/8" Button Plug

  1
• 0507372 Power Cord

  1
• 0503749 Terminal Board

  2
• 0701933 Water/Heater Cam c/w Set Screw

  1
• 0501397 Set Screw, 6-40 x 3/16"

  1
• 0501379 Float Switch

  1
• 0307369 Nut Plate for Float Switch (starting @ S/N 6226)

  1
• 0501433 Screw, 4-40 x 5/8"

  2
• 0501411 Screw, 10-32 x 1/4"

  8
• 0309053 Float Switch Support (starting @ S/N 6226)

  1
• 0503642 Label, 2.5 Amp Fuse

  1
• 0503693 Label, Switch Up

  1
• 0501373 3-Position Switch

  1
• 0501412 Screw, 10-32 x 3/8"

  8
• 0507470 Label, Injector Prime

  1
• 0508433 Circuit Board (starting @ S/N 6216)

  1
• 106695 Screw, 6-32 x 1/2”

  4
• 0508710 Spacer, 5/16 lg

  4
• 0309037 Support Bracket (starting @ S/N 6216)

  1
• 0503637 Fuse, 2.5 Amp

  1
• 0508920 Transformer (starting @ S/N 6216)

  1
• 0501450 Screw, 6-32 x 3/16"

  4
• 0501411 Screw, 10-32 x 1/4"

  2
• 0503695 Label, Detergent

  1
• 0505483 Label, Rinse

  1
• 0503694 Label, Sanitizer

  1
• 0307408 Control Box Cover (prior to S/N 6226)

  1
• 0309052 Control Box Cover (starting @ S/N 6226)

  1
• 0503301 Label, Warning

  1
• 0509061 Label, Circuit Board (starting @ S/N 6216)

  1
• 0503343 Label, Warranty Void

  1
• 0300986 Hinge, Cover

  2
• 0501408 Screw, 8-32 x 1/4"

  4
• 0501538 Nut, 10-32

  4
• 0307409 Injector Pump Cover

  1
• 0306363 Dip Tube

  3
• 0501869 Strainer

  3
• 0507577 Wiring Harness (Drive Motor, Solenoid Valves)

  1
• 0507578 Wiring Harness, Circuit Board (prior to S/N 6216)

  1
• 0509039 Wiring Harness, Circuit Board (starting @ S/N 6216)

  1
• 0503739 Aluminum Spacer, Float Switch (prior to S/N 6226)

  2
• 0707415 Detergent Tank (up to S/N 6226)

  1
• 0709054 Detergent Tank (starting @ S/N 6226)

  1
• 0307296 Detergent Tank Cover Lid

  1
• 0307378 Detergent Tank Rear Cover

  1
• 0707375 Detergent Tank Screen Assembly

  1
• 0507471 Label, Clean Screens Daily

  2
• 0700948 Standpipe Assembly

  1
• 0503670 Float Ball

  1
• 0507426 Float Rod

  1
• 0703673 Cam Bushing c/w Set Screw

  1
• 0501397 Set Screw, 6-40 x 3/16"

  1
• 0503701 Timer Shaft Bearing (not req’d after S/N 6226)

  2
• 0504864 Label, Data

  1
• 0501896 Thermometer Seal

  1
• 0501600 8" Thermometer

  1
• 0503588 Heater “O” Ring

  1
• 0507315 3 KW Heater c/w “O” Ring

  1
• 0507323 Thermostat (Capilary only shown)

  1
• 0501650 Thermostat Adaptor

  1
• 0501836 Adaptor “O” Ring

  1
• 0501419 Bolt, 1/4-20 x 1/2"

  1
• 0707383 Drain Pan Screen Assembly

  1
• 0707380 Drain Pan Assembly

  1
• 0307423 Heater Cover

  1
• 0503301 Label, Warning

  1
• 0501412 Screw, 10-32 x 3/8"

  2
• 107435 Nut, M6

  4
• 107886 Inlet Chute Gasket

  1
• 108051 Elbow Flange

  1
• 0507431 Bolt, M6 x 25mm

  4
• 0502563 1" Gear Clamp

  1
• 0307427 Inlet Water Tube

  1
• 0503679 7/16" Gear Clamp

  2
• 0502665 1/2" I.D. Braided Hose

  1
• 0502571 1-1/2" Clamp, Hose

  1
• 0502783 230V 60HZ Solenoid Valve

  2
• 0503802 3/8" MPT Tee

  3
• 0503801 3/8" Fem x 1/2" Fem Adapter

  2
• 0507324 3/8" Check Valve

  1
• 0502768 Mixing Valve

  1
• 0502653 3/8" x 1/2" 90° Hose Barb

  2
• 0503679 7/16" Gear Clamp

  2
• 0509659 Brass Cap

  1
• 0307688 Inlet Plumbing Clamp

  1
• 0501419 Bolt, 1/4-20 x 1/2"

  2
• 0504822 Screw, 8-32 x 1/2"

  2
• 0306208 Cable Clamp Cover

  1
• 0307373 Cable Clamp Assembly

  1
• 0501404 Screw, 10-32 x 3/8", Brass

  2
• 0501493 Lock Washer, #10

  2
• 0501533 Nut, 10-32, Brass

  2
• 0505229 Solenoid Guide

  1
• 0502810 Flow Washer (2.6 GPM)

  1
• 0502807 Washer, Brass

  1
• 0502804 Washer, Brass

  1
• 0502803 Screen

  1
• 0501406 Screw, 8-32 x 1/2"

  2
• 0502806 Coil -230V 60HZ

  1
• 0503668 Thermometer

  1
• 0502583 3/8" FPT Cross Connector

  1
• 0502653 3/8" MPT x 1/2" 90° Hose Barb

  1
• 0502645 1/8" Hose Barb

  2
• 0503679 7/16" Gear Clamp

  2
• 0503669 Injector Barb Fitting

  1
• 0502577 3/8 x 1/4 MPT Reducer Bushing

  1
• 0502781 Needle Valve

  1
• 0507100 0-30 PSI Pressure Gauge

  1
• 0300918 Plumbing Clamp

  1
• 0501501 Lock Washer, 1/4"

  2
• 0501539 Nut, 1/4-20

  2
• 0503679 7/16" Gear Clamp

  2
• 0502651 1/2" MPT x 1/2” Hose Barb

  1
• 0502751 1/2" Vacuum Breaker (Prior to S/N G2182)

  1
• 0502650 1/2" x 3/8" Reducer Bushing

  1
• 0502653 3/8" MPT x 1/2" 90° Hose Barb

  1
• 113220 1/2" vacuum breaker

  1
• 113221 Repair kit, vacuum breaker

  1
• 0507313 Wash Pump Complete

  1
• 0307410 Wash Pump Base

  1
• 0501419 1/4-20 x 1/2" Bolt

  2
• 0502563 1" Gear Clamp

  4
• 0501632 Pump Hose Connector

  1
• 0503679 7/16" Gear Clamp

  2
• 0502734 Stub Shaft

  1
• 0502729 Impeller

  1
• 0502731 Pump Housing

  1
• 0501635 “O” Ring, 5/16 I.D. X 1/16W

  1
• 0502732 Housing Seal Screw

  1
• 0503648 Screw, 8-32 x 5/16"

  4
• 0501406 Screw, 8-32 x 1/2"

  4
• 0703390 Tube Scraper

  1
• 0501714 Tube Brush

  1
• 0501633 Jet Reamer c/w Drill

  1
• 0703454 Wash Down Nozzle

  1
• 0505320 1/2" Hose Washer

  1
• 0502779 Nozzle

  1
• 0501833 1/2" x 10' Hose Assembly

  1
• 0506643 Faucet

  1
• 0501874 Caster, reg

  2
• 0501876 Caster, locking

  2