Insinger USN-72 User manual

S6161-ZB-FSE-010
0910-LP-102-5490
TECHNICAL MANUAL
FOR
DISHWASHING MACHINE, CHAMPION; MODEL
USN-72 INSTALLATION, OPERATION, AND
MAINTENANCE
“Distribution Statement “A”: Approved for public
release; distribution is unlimited.”
DEPARTMENT OF THE NAVY
NAVAL SEA SYSTEMS COMMAND
1 SEPTEMBER 2003
0910LP1025490
0910LP1025490

APPROVAL AND PROCUREMENT RECORD PAGE
APPROVAL DATA FOR: S6161-ZB-FSE-010
TITLE: Technical Manual for Dishwashing Machine, Champion; Model
USN-72; Installation, Operation, and Maintenance
APPROVAL AUTHORITY: Not Required
QUANTITY QUANTITY
CONTRACT OR SHIP OF OF BUILDING
PURCHASE ORDER APPLICABILITY MANUALS EQUIPMENT YARD
4500094413 CVN69 1 6 Northrop Grumman
Newport News
REMARKS:
Distributed to CVN69 in accordance with Contract No. N00024-98-C-2107, CDRL Item No. B002.
CERTIFICATION: Not Required DATE: September 1, 2003
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
CAGE 30793

Complete the information below for quick reference.
Model Number ___ Serial NumbFr
Voltage and Phase
-
For Service:
Ken-Tronics, Inc.
6207 Portsmouth Blvd.
Portsmouth, VA 2370
1
Phone: [phone]
Fax: [phone]
Email: kentron97
@ a01.corn
1-800-433-4586
Note:
When calling to order parts, be sure to have the model number, serial number,
voltage and phase
of your machine.
Machine Data Plate with I
Model & Serial Number
located on the remote
control cabinet. L
COPYRIGHT 0 2002 by Champion Industries, Inc.

TECHNICAL PUBLICATION SHEET
TECHNICAL PUBLICATION SHEET

TECHNICAL MANUAL VALIDATIONCERTIFICATE
TECHNICAL MANUALVALIDATION CERTIFICATE
ii

APPROVALAND PROCUREMENTRECORD
APPROVAL AND PROCUREMENT RECORD
iii

TECHNlCAL MANUAL DEFICENCY/EVALUATION IiEPORT (TMDERI
TECHNICAL MANUAL
DEFlClENCY/EVALUATION REPORT (TMDER)
(Form - NAVSEA 90861’10, REK 6/85)

REVISION RECORD
Revision Revised SerialNumber
Date Pages Effectivity Comments
4/29/98 All 90922 First Issue of Manual and replacement
parts lists
~
3/16/00 All J1050 Added electric tank heat to and
revised chain tensioner
3/9/01 58-59 J1051 Added end panels, front panels,
3/9/01 60-61 J1051 Revised tank fill piping assy
revised leg assy
3/9/01 62-63 J1051 Revised final rinse piping assy
3/9/01 66a-67a J1051 Revised track and guide assy
3/9/01 68a-69a J1051 Revised chain tension assy
~~
-
319101 70-7 1 J1051 Added end panel
3/9/01 86-87 J1051 Revised drain assy
3/9/01 90-91 J1050 Revised control cabinet
31910
1 90a-90b J1051 Revised control cabinet
31910
1 94-102 J1080 Added MRAN 90”
3/9/01 104-107 51080 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/”s 112606and 112607
with new part numbers 113398 and
113399.
4/8/02 102
103
Corrected spacer number for bubble 16
to 15.
Corrected part number 111064to
111603and 111605.
Corrected motor clamp
from 314351to
325622.
4/30/02 71 Replaced part number 112608 and 112783
with 110164.
Added V-belt 100795.

SAFETY SUMMARY
Safety Symbols
The following symbols appear throug,out this manual alerting you to potentie
Statements associated with each symbol are printed in italics. hazards.
WARN IN G :
Warning statements indicate any condition or practice that
could result in personal injury
or possible loss of life.
CAUTlO N:
Caution statementsindicate any condition or practice which,
if
not strictly observed or remedied, could result in damage to
or destruction of the dishwasher.
3 NOTE:
Note statements indicate any condition or practice which,
if observed, will help in the safe completion of a task.
General Safety Rules
.
The following general safety rules must be observed in addition to the specific cautions and
warnings presented in this manual.
Your Champion dishwasher is a heated machine using very hot water to clean and sanitize a
variety of wares. Machine surfaces and wares become hot during and immediately following
normal operations. Consult your supervisor and wear protective gear as directed to avoid possible
injury.
Your dishwasher contains moving conveyor parts.
Use caution when working around the dishwasher especially when loading or unloading wares.
Operators must NOT bypass a safety interlock or control to operate the dishwasher.
The service and maintenance 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.

SAFETYSUMMARY
Warning and Caution Statement Listing
The following listing gives the page number and text of all the warning and
caution statements that appear
in this manual.
Warning Statements
Pg. 8- The installation of this unit must conform to localcodes or, in the absence of local codes, to the National
ElectricalCode and all NationalCodes governing plumbing, sanitation, safety and good trade practices.
Pg.
10- The installation of water supplies must conform to local codes or, in the absence of local code, all National
Codes governing plumbing, sanitation, safety and good trade practices.
Pg.
10- The installation of steam supplies must conform to local codes or, inthe absence of local code, all National
Codes governing plumbing, sanitation, safety and good trade practices.
Pg.
12- The installation of drains must conform to localcodes or, in the absence of local code, all National Codes
governing plumbing, sanitation, safety and good trade practices.
Pg.
12- The installation of ventilation must conform to local codes or, inthe absence of local code, all National Codes
governing plumbing, sanitation, safety andgood trade practices.
Pg.
13- The installation of electrical supplies andcontrols must conformto local codes or, in the absence of local
codes, the National Electrical Code and good trade practices.
Pg.
13- Dangerous voltages are present at the local electrical distribution system.
Dangerous voltages are present at the dishwasher when it is connected to the local electrical distribution
s ystem.
to indicate work is beingdone on that circuit.
codes, the National Electrical Code and goodtrade practices.
Dangerous voltages are present at the dishwasherwhen it is connected
to the local electrical distribution
system.
to indicate work is being done onthat circuit.
Dangerous voltages are present at the dishwasher when it is connected
to the local electrical distribution
system.
to indicate work is being done onthat circuit.
Pg.
13- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch
Pg.
14- The installationof electrical supplies and controls must conform to local codes or, inthe absence of local
Pg.
14- Dangerous voltages are present at the local electrical distribution system.
Pg.
14- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch
Pg.
24- Dangerous voltages are present at the local electrical distribution system.
Pg.
24- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch
Pg.
25- Perform the following checks before placing the machine into service for normal operation.
Pg.
25- Never bypass a safety device in order to operate the dishwasher for normal operation.
Pg.
26- The conveyor drive contains moving parts.
Pg.
27- Perform the following checks beforeplacing the machine into service for normal operation.
Use caution when working around the conveyor drive assembly.

SAFETY SUMMARY (cont.)
Warning. Statements (Cont.1
Pg. 27- Neverbypass a safety device in order to operatethe dishwasherfor normaloperation.
Pg.
28- Dishwashersurfaces,dishracks and wares become hot during and immediatelyafter washing operations.
Pg.
29- Dishwashersurfaces,dishracks and wares become hot during and immediatelyafter washing operations.
Pg.
32- Delimingsolutions or other acids must not come in contactwith householdbleach (sodiumhypochlorite)or
Wear protectivegear per your supervisor's directions.
Wear protectivegear per your supervisor'sdirections.
any chemicalscontainingchlorine, iodine,bromine,or fluorine.
Mixingwill cause hazardousgases to form.
Skincontactwith delirning solutions can cause severe irritation and possiblechemical burns.
Pg.
32- Consult your chemicalsupplier for an appropriatedelimingsolution, protective gear and safety procedures.
Pg.
33- Whenworking on the dishwasher,disconnectthe electric service and place a redtag at the disconnect switch
Pg.
34- When working on the dishwasher,disconnectthe electricservice and place a redtag at the disconnect switch
Pg.
35- Do not lubricatethe stainlesssteel conveyorchain or shaft bearings insidethe dishwasherwash and power
Pg.
36- The conveyor drive contains moving parts.
Pg.
37- When workingon the dishwasher,disconnectthe electric service and place a redtag at the disconnectswitch
Pg. 40- Whenrepairinga circuit,disconnect thepower at the main service disconnectswitch andplace a red tag at
Pg.
40- UseExtreme Cautionwhenperforming tests on energizedcircuits.
Pg.
40- Theconveyor drive containsmovingparts. Usecaution when workingaround the conveyordrive assembly.
to indicatework is being done on that circuit.
to indicatework is beingdone on that circuit.
rinsetanks.
Use cautionwhen working around the conveyordrive assembly.
to indicatework is beingdone on that circuit
the disconnectswitch to indicate that work is being performed on the circuit.

Caution Statements
Pg. 5- Check piping mounted underneath dishwasher before lifting to avoid damaging the machine.
Pg.
8- Check piping mounted underneath dishwasher beforelifting to avoid damaging the machine.
Pg. 2 1 - Perform the following checks before placing the machine into service.
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 servicepersonnel should perform preventive maintenance on the dishwasher.
Pg.
36- Only qualified service personnel should perform preventive maintenance on the dishwasher.
Pg.
40- Only qualified servicepersonnel should perform adjustments and repairs to the dishwasher.

LIMITED WARRANTY
Champion Industries lnc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 271 15,
and P.0. Box 301, 2674 N. Service Road, Jordan Station, Canada, LOR 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 workman-
ship for a period of one (1) year after the date of installation orfifteen
(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 oneyear from the date of shipment.
Chainpion 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, how
ever, as to glasswashers, Champion's obligation with respect to labor associated with any repairs shall end
(a) 120days 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
workmg 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.
b.
d.
e.
f.
g.
h.
C.
1.
Lighting of gas pilots or burners.
Cleaning of gas lines.
Replacement of fuses orresetting of overload breakers.
Adjustment of thermostats.
Adjustment of clutches.
Opening or closing of utility supply valves or switching of electrical supply current.
Cleaning of valves, strainers, screens, nozzles, or spray pipes.
Performance of regular maintenance and cleaning as outlined in operator's guide.
Damages resulting from water conditions, accidents, alterations, improper use, abuse,
tampering, improper installation, or failure
to follow maintenance and operation procedures.
Wear on Pulper cutter blocks, pulse vanes, and auger brush.
Examples of the defects riot covered by warranry include, bur are not linziied 10: (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) lnadequate 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
THE EXCLUSNE REMEDIES FOR ANY DEFECTS FOUND TO EXIST
IN CHAMPION DISHWASHING
MACHINES AND CHAMPION PARTS,
AND ALL OTHER REMEDIES ARE EXCLUDED,
MCLUDING
ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES.
INCIDENTAL OR CONSEQUENTIAL DAMAGES. THE REMEDIES SET OUT ABOVE ARE
Champion doesnot authorize any other person, including persons who deal in Champion dishwashing
machines to change this warranty or create any other obligation
in connection with Champion Dishwashing Machines.

TABLE OF CONTENTS
TABLE OF CONTENTS
RevisionRecord ........................................................................................................... V
Safety Summary .......................................................................................................... v11-n
LimitedWarranty ......................................................................................................... X
...
PART 1 :
1.1
1.2
1.3
1.4
1.5
G EN E R AL S P E CI FI CAT1 0 NS ........................................................ . 1
About this Manual ............................................................................................... 1
Model Numbers ................................................................................................... 1
Standard Equipment. Options and Accessories
................................................... 2
Dimensions. Capacities. Ventilation. and Utilities ............................................... 3
Electrical Power Requirements
............................................................................ 4
PART 2: INSTALLATION .............................................................................. 5
2.1 Unpack the Dishwasher ....................................................................................... 5
2.2 Disassembly ......................................................................................................... 6
2.3 Reassembly .......................................................................................................... 7
2.4 Permanent Placement
............................................................................................ 8
2.5 Connections between the dishwasher and booster ............................................... 8
2.7 Steam and Condensate Connections (Steam heat only) ....................................... 10
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
2.6 Water Connections .............................................................................................. 10
2.8 Drain Connections
............................................................................................... 12
~ ~~~ ~~
PART 3: OPERATION ................................................................................... 19
3.1 Theory of Operation ............................................................................................. 19
3.2 Description
of Operator Controls and Indicators ................................................. 20
3.2.: XeiTioie coniro: C&biriCi ............................................................................ LU
on
3.2.2 Dishwasher and Booster ............................................................................
21
3.3 Start-up Procedure
............................................................................................... 23
3.4 Safety and Operation Checks
............................................................................... 25
3.5
Shutdown Procedure ............................................................................................ 29
3.6 Operation Summary
............................................................................................. 30

PART 4: CLEANING and MAINTENANCE ...............................................
4.1 Introduction .......................................................................................................
4.2 'Daily Cleaning Schedules .................................................................................
4.3 Deliming Schedule ............................................................................................
4.4 Preventive Maintenance Schedules ...................................................................
4.5 Lubrication Schedules .......................................................................................
31
31
31
32
33
35
PART 5: BASIC SERVICE .........................................................................
5.1 Introduction
5.2 GeneralTroubleshooting ...................................................................................
Pressure Reducing Valve (PRV) Adjustment .......................................
5.3
Component Repair and Replacement ................................................................
5.3.1
5.3.2
Water Line Strainers ............................................................................
5.3.3 Vacuum Breaker Repair .......................................................................
5.3.4
Water Solenoid Valve Repair ...............................................................
5.3.5 Float Switch Replacement ...................................................................
Drain Valve and Overflow Assembly ..................................................
5.3.7 Thermometer Replacement ..................................................................
5.3.8 Tank Heat Thermostat Adjustment and Replacement ..........................
5.3.9 Steam Booster Thermostat Adjustment and Replacement ...................
5.3.10 Steam Solenoid Valve Repair ..............................................................
5.3.11 Steam Trap Repair ...............................................................................
Wash Manifold Restrictor Adjustment .................................................
5.3.6
5.3.12
Steam Booster Service .........................................................................
5.3.13
5.3.14
Pump Seal Replacement ......................................................................
5.3.15 Rinse SaverAssembly Repair ..............................................................
5.3.16 Conveyor Chain Take-up Assembly Adjustment .................................
5.3.17 Take-up Bearing Replacement .............................................................
Drive Shaft Bearing and Seal Replacement .........................................
5.3.18
5.3.19
Door Safety Switch Replacement ........................................................
5.3.20 Control Circuit Explanation .................................................................
5.3.21 Control Cabinet Fuse Replacement .....................................................
5.3.22 Motor Overload Adjustment and Replacement ...................................
5.3.23 Timer Settings .......................................................................................
5.3.24 Control Cabinet Pilot Light Bulb Replacement ...................................
37
38
40
40
41
41
41
42
42
42
43
43
44
45
45
47
47
48
48
49
49
50
50
54
54
55
55
xii

TABLE OF CONTENTS
................................................................
PART 6: REPLACEMENTPARTS 57
6.1 Introduction .......................................................................................................... 57
6.2 Parts Parts Procurement
....................................................................................... 57
.........................................................
PART 7: ELECTRICALSCHEMATICS 95
PART 8: SPECIAL INSERTS ........................................................................
97
LIST OF FIGURES
Figure 2.1 .
Figure 2.2 .
Figure 2.3
.
Figure 2.4 .
Figure 2.5 .
Figure 2.6 .
Figure 3.1
.
Figure 3.2 .
Figure 3.3 .
Figure 3.4
.
Figure
3.5 .
Figure 4.1
.
Figure 4.2
.
Figure 6.1
.
Figure 6.2
.
Figure 6.3
.
Figure 6.4 .
Figure 6.5
.
Figure 6.5a -
Figure 6.6
.
Figure 6.6a .
Figure 6.7
.
Figure 6.8 .
Figure 6.9 .
Figure 6.9a
-
Figure 6.10 .
Figure 6.11
.
Disassembly ...............................................................................................
Connections Between Dishwasher and Steam Booster ..............................
Utility Connections ....................................................................................
Remote Control Cabinet Tank Heat Connections ......................................
Tank Heater Conduit Routing ....................................................................
Operator Controls Remote Control Cabinet ...............................................
Conveyor Jam SwitchCheck .....................................................................
Curtain Placement ......................................................................................
Spray Arm Assembly .................................................................................
Never Lubricate ThesePoints ....................................................................
Conveyor Gearbox and Drive Chain Lubrication ......................................
Tank Fill Assembly and Temperature Gauges ............................................
Final Rinse Piping Assembly .....................................................................
Conveyor Shafts, Chains, Bearings, and Guides (Prior to S/N Jl050) ......
Conveyor Chain Take-UpAssembly (Prior to S/N Jl050) ........................
Conveyor Chain Take-Up Assembly (For S/N 31050 and above) ...................
Conveyor DriveAssembly .........................................................................
Rinse SaverAssembly ................................................................................
Remote Control Cabinet .............................................................................
Controls and Indicators Dishwasher and Booster ......................................
Vents, Curtains, Doors, Panels, Scrap Screens, and Water Level Gauges .
Track Assembly ..........................................................................................
Conveyor Shafts, Chains, Bearings, and Guides (For S/N J1050 and above)
Steam Coil Assembly .................................................................................
Electric Tank Heat ......................................................................................
Tank SteamPiping with Booster .......................................
Tank Steam Piping with Booster .......................................
6
9
11
14
15
17
20
21
26
30
30
35
36
58
60
62
64
66
66a
68
68a
70
72
74
74a
76
78
xiii

TABLE OF CONTENTS
LIST OF FIGURES
(CONT.)
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
6.12
. Junction Boxes. Float Switches.Door Switches.and Thermostats ...........
6.13 . PumpAssembly ..........................................................................................
6.14 . Wash Spray System (R-L Machine Shown) ...............................................
6.15 Drain and Overflow Assembly
6.16
. SteamBooster and SteamPipingAssembly ..............................................
6.17 . SteamRemote Control Cabinet (Priorto SIN Jl050) ................................
6.17a - ElectricRemote Control Cabinet (For S/N 51050 and above) ...................
6.17b- Steam or Electric ControlCabinet (For SN 51080 and above) .................
6.18 Dishracks and PRV
6.19
- MRAN 90" Guides .....................................................................................
6.20 - MRAN 90" Pawl Bar .................................................................................
6.21 - MRAN 90"Table and Drain Assembly ......................................................
6.22 - MRAN 90" Base Assembly ........................................................................
6.23 - MRAN 90" Drive and MotorAssembly ....................................................
. ...................................................................
. ....................................................................................
6.24 - CH-60Electric BoosterPiping (For USS Ramage Only) ..........................
6.25 - CH-60ElectricBooster Piping (For USS RamageOnly) ..........................
LIST OF TABLES
80
82
84
86
88
90
90a
90b
92
94
96
98
100
102
104
106
Table 3.1
.
Controls and IndicatorsRemoteControl Cabinet ...................................... 20
Table
3.2 .
Controls and IndicatorsDishwasher and booster ....................................... 22
xix