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Olympia Millennium-E, Owner'S Manual

The Olympia Millennium-E Owner's Manual is a comprehensive guide for users of this innovative product. Easily download the manual for free from our website, providing you with detailed instructions, troubleshooting tips, and useful information to ensure a seamless experience with your Olympia Millennium-E.

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GP 25 

 

 

Ersatzteilliste / Spare Parts list 

4699.770.019 

13 von / of 16 

Version B / 01.06.2010 

 

Abtriebsteile / Output Parts 

  

Benötigte Teilestückzahl / Required Number Of Pieces 

Pos.Nr. 

/ Pos. 

No. 

Bezeichnung  Name 

Bestellnummer 

/ Order 

Number 

4

6

9

9

 8

2

5

 0

1

3

 

4

6

9

9

 8

2

5

 0

1

4

 

4

6

9

9

 8

2

5

 0

1

6

 

4

6

9

9

 8

2

5

 0

1

7

 

4

6

9

9

 8

2

5

 0

1

8

 

4

6

9

9

 8

2

5

 0

1

9

 

4

6

9

9

 8

2

5

 0

2

0

 

4

6

9

9

 8

2

5

 0

2

1

 

4

6

9

9

 8

2

5

 0

2

2

 

4

6

9

9

 8

2

5

 0

2

4

 

4

6

9

9

 8

2

5

 0

2

5

 

4

6

9

9

 8

2

5

 0

2

6

 

4

6

9

9

 8

2

5

 0

2

7

 

4

6

9

9

 8

2

5

 0

2

8

 

4

6

9

9

 8

2

5

 0

2

9

 

4

6

9

9

 8

2

5

 0

3

0

 

4

6

9

9

 8

2

5

 0

3

1

 

4

6

9

9

 8

2

5

 0

3

2

 

4

6

9

9

 8

2

5

 0

3

3

 

4

6

9

9

 8

2

5

 0

3

7

 

4

6

9

9

 8

2

5

 0

3

8

 

4

6

9

9

 8

2

5

 0

3

9

 

4

6

9

9

 8

2

5

 0

4

2

 

4

6

9

9

 8

2

5

 0

4

8

 

4

6

9

9

 8

2

5

 0

4

9

 

103.500  Kit Hohlrad 

Ring Gear 

Kit 

4699 195 042 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

  

Hohlrad 

Internal 

gear 

  

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

  

Zahnscheibe 

Lock 

washer 

  

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

  

Ring 

Ring 

  

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

  

Torxschraube  Torx screw 

  

12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12  12 

103.600 

Kit Planeten-

radsatz 

Planet gear 

set 

4699 195 043 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

  

Planetenrad 

Planet gear 

  

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

  

Zylinderrolle

n-lager 

Cyl. roller 

bearing 

  

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

103.010  Radwelle 

Wheel 

shaft 

4699 303 126 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

103.020 

Planeten-

träger 

Planet 

carrier 

4699 303 127 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

103.070 

Ausgleich-

scheibe 

Shim 

4697 202 004 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

103.080  Radbolzen 

Wheel bolt 

4699 300 110 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

5 

103.090  Nutmutter 

Slotted nut 

4699 303 117 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

 
 

Summary of Contents for Millennium-E

Page 1: ...Owner s Manual ...

Page 2: ...d may be ordered on any model The illustrations and product information contained in this manual were current at the time of publication In order to continue Resurfice Corp s development of its ice resurfacing technology Resurfice Corp reserves the right to change designs models and specifications without notice and without liability for such changes The components in your OLYMPIA ice resurfacing ...

Page 3: ...ress Serial Numbers Ice Resurfacer Battery Charger Batteries Water Cart Controllers FL FR RL RR Auger Vertical Auger Horizontal Hydraulic Motors FL FR RL RR Auger Vertical Auger Horizontal Hydraulic Gear Boxes FL FR RL RR Conditioner Size Options ...

Page 4: ...ns of the User 9 1 8 Operator s Workplace 10 1 9 Safety Devices and Guards 10 1 10 Maintenance and Repair Regulations 14 1 11 Waste Disposal 15 1 12 Remaining Hazards 16 2 TECHNICAL DATA 2 1 Dimensions 20 2 2 Weights 20 2 3 Noise Emission 21 2 4 Filling Capacities 21 2 5 Electrical System 21 2 6 Brake Systems 22 2 7 Hydraulic System 22 2 8 Water System 22 2 9 Tires 23 2 10 Conditioner 23 2 10 1 Bl...

Page 5: ...N AND FUNCTION 4 1 Ice Resurfacer Design and Chassis 27 4 2 Snow Conveyor Auger 30 4 3 Hydraulic Components 30 5 CONTROLS 5 1 EMERGENCY Shut Off Switch 31 5 2 Top Control Panel 32 5 3 Bottom Control Panel 35 5 4 Ice Making Water Control Panel 41 5 5 Wash Water Control Panel 43 5 6 Foot Pedals and Parking Brake 45 5 7 Controls for the Water 47 5 7 1 Ice Making Water 47 5 8 Controls for the Hydrauli...

Page 6: ...nk Adjustment 65 6 5 Spreader Cloth Installation 67 6 6 Water Filling Procedure 67 6 6 1 Ice Making Water Filling Procedure 68 6 6 2 Wash Water Filling Procedure 69 6 7 Safety Circle Check 70 7 WORKING WITH THE OLYMPIA ICEBEAR 7 1 Driving 73 7 1 1 Starting 73 7 1 2 To move the Ice Resurfacer 73 7 1 3 Brakes 74 7 1 4 Shifting from Forward to Reverse 74 7 2 Ice Resurfacing 74 7 2 1 Working with the ...

Page 7: ...ed or Weekly 83 8 2 3 After 5 Hours 84 8 2 4 After 50 Hours 84 8 2 5 Monthly 85 8 2 6 Annually or Before Storage 86 8 2 7 Lubrication to be Done Whenever Necessary 87 8 2 8 Every 3 Years 89 9 SELF HELP AND TROUBLESHOOTING 9 1 Check the Carbon Brushes at the Motors 90 9 2 Edger Adjustment 90 9 3 Squeegee Replacement 90 9 4 Towel Replacement 90 9 5 Blade Replacement 90 10 Appendix 91 ...

Page 8: ...The Ultimate Ice Resurfacer ...

Page 9: ...arefully read this operating manual Pay particular attention to the safety instructions given throughout the manual and to Chapter 1 Safety This is a prerequisite for Safe handling and operation of the ice resurfacer Trouble free operation of the machine Always keep the operating manual in the vicinity of the ice resurfacer ...

Page 10: ... by law Copyright in acc with DIN 34 This manual must not be copied or passed on to third parties nor must its contents be used by nor imparted to third parties without express permission Failure to comply will result in claim for damages All rights with regard to the granting of a patent or design registration reserved Resurfice Corp 2012 Resurfice Corp 25 Oriole Pkwy E Elmira Ontario Canada N3B ...

Page 11: ...llowing pictograms Imminent danger that can result in death serious bodily injury or major material damage Warning about dangerous electrical voltage Warning about hazardous movements that can result in hand injuries Warning about blades sharp edges and similar that can result in cutting injuries Warning about potential explosion Application tips and other useful information ...

Page 12: ... are no people on the ice and no objects on the ice surface Sound the horn when you drive through areas in which pedestrians may be present where your view is restricted and when you drive onto the ice surface or leave the ice surface again No passengers are allowed on the ice resurfacer at any time Operating conditions vary greatly and Resurfice Corp cannot predict them Therefore it is the User s...

Page 13: ...mmediately if necessary e g push the emergency stop button and turn the key operated switch to the off position and remove the key Do not perform any procedures that are not described in this manual No liability will be accepted for any material damage or personal injury caused by failure to comply with the above directives or failure to follow the instructions given in this operating manual This ...

Page 14: ... safety devices Failure to comply with the on site directive posted by the User Driving on surfaces that have more than a 15 incline or 13 5 Carrying of passengers Operation without the duly trained driver Operation in inadequate light conditions Failure to comply with the instructions given in this documentation 1 5 Organizational Measures The operating manual must be kept in a place where it is ...

Page 15: ...e Corp before they operate or service the OLYMPIA Only the specially trained ice resurfacer operators may have access to the starter key and they must keep it under lock and key The necessary training and instruction will be given by Resurfice Corp or one of their authorized distributors upon delivery of the machine All operators must be trained by a qualified instructor All safety instructions mu...

Page 16: ... in association with the sharp components are pointed out in regularly held training courses The hazard avoidance measures must be explained The responsibilities of the personnel for operation setup and maintenance of the ice resurfacer must be clearly defined Make sure that only duly authorized personnel are allowed to work on and with the ice resurfacer The maintenance personnel must be duly cer...

Page 17: ...ations and that these are complied with Personal protection gear clothing is provided and is worn e g protective gloves warm clothing safety helmet and if necessary ear muffs steel toed safety boots and also non slip footwear for walking on the ice surface The operating manual is supplemented with facility internal instructions e g supervision and reporting duties to take account of facility speci...

Page 18: ...o prevent it from being switched back on again Turn the key switch to the OFF position and remove the key switch off the emergency stop switch and pull the battery plug 1 9 Safety Devices and Guards Operator Presence switch at the driver s seat There is an Operator Presence switch at the driver s seat on the OLYMPIA that must not be bypassed When the driver leaves the seat the ice resurfacer is st...

Page 19: ... it locks into place The normal switch on procedure must then be executed from the beginning section 7 1 1 Fig 1 1 Emergency Shut off switch on the OLYMPIA The Emergency Shut off switch turns off the whole ice resurfacer except for the battery discharge indicator The battery discharge indicator is mounted on the battery to save the stored data When the battery connector is disconnected the whole i...

Page 20: ...l power to the OLYMPIA is switched off The brake accumulator remains under pressure but can be depressurised by simply pressing the brake pedal several times The removal of guards or safety devices or rendering them inoperable while the ice resurfacer is in operation is prohibited Guards and safety devices may only be removed or put out of operation for repair or maintenance purposes after the mai...

Page 21: ...ted on the upper dash panel The horn sounds as soon as you press this button Fig 1 2 Horn button on the OLYMPIA Warning Signals Warning lamp indicating that there is not enough water in the water tank Warning signal indicating that the battery is low accumeter flashes ...

Page 22: ...rk on the ice resurfacer including changing the blades The proper way to do this is to check to make sure the snow dump tank is empty then raise the tank to the fully open position Remove the starter key and properly dismount the resurfacer and install the snow dump safety supports Disconnect the battery by separating the main power plug located directly infront of the operators platform under the...

Page 23: ... in the descriptions of the individual maintenance jobs 1 11 Waste Disposal Hazardous waste must not be disposed of with general household waste Each local community generally has drop off locations for the proper disposal of hazardous waste The battery must be disposed of in the proper manner Contact your battery supplier for proper disposal of your batteries refer to the regulations in your O S ...

Page 24: ...k of Injury Before starting any maintenance job make sure that you secure the snow dump tank with the safety supports to prevent it from dropping down because there is a considerable hazard potential here Risk of Injury Always place blocks under the conditioner when performing maintenance work and blade changes Risk of Sustaining Cutting Injuries Always wear protective gloves when handling the bla...

Page 25: ...ng The batteries must not come into contact with water Never place anything on top of the batteries otherwise short circuiting could occur Risk of Injury If your ice resurfacer is parked on an incline before releasing the handbrake turn the start key to the ON position Make sure the gear selector is in neutral Depress and release the accelerator pedal Now you can depress the brake pedal release th...

Page 26: ...perator must stop the ice resurfacer and secure it to prevent it from rolling away before leaving the seat on the ice resurfacer s platform This is done by setting the key operated switch starter switch to the STOP position and applying the parking brake The driver s seat has a timed operator presence switch that stops all movements eight seconds after the driver leaves the seat Caution In a hazar...

Page 27: ... the snow dump tank the safety supports must be secured if the work is to be done with the tank open Risk of Injury When driving the OLYMPIA always proceed with caution When driving in areas with a restricted view or in narrow spaces drive with a reduced speed When driving off ice the vehicle lighting must be switched on The OLYMPIA must not be driven on public roads as it is not licensed for use ...

Page 28: ...ch Conditioner 100 254cm Length 162 411cm Height 77 195cm With snow bin open Length 228 579cm Height 142 360cm Blade width On 84 inch Conditioner 84 213cm On 96 inch Conditioner 96 243cm Turning radius 180 457cm 2 2 Weights Net weight total incl 770 Ah batteries 10 648 lbs 4 830 kg Front axle 3 792 lbs 1 720 kg Rear axle 6 944 lbs 3 150 kg ...

Page 29: ...ly 63 dB A Driving noise with elevator turned off 73 dB A Driving noise with elevator turned on 74 dB A At a distance of 25m away with elevator turned off 63 dB A At a distance of 50m away with elevator turned on 62 dB A 2 4 Filling Capacities Capacity of snow bin 103 ft 2 9 m Capacity of wash water tank 45 Imp gal 204 l Capacity of flood water tank 184 5 Imp gal 838 8 l Hydraulic oil quantity 5 I...

Page 30: ... years Oil filter Exchangeable filter 20 Micron Oil cooling Convection cooling at the oil tank Oil temperature Max 80 C normal approx 30 C Hyd Pump Motor driven Tandem gear pump 1 gpm 4 55 lpm steering 6 gpm 27 2 lpm auxillary Emergency hand pump Piston pump 0 15 in 2 5 cm stroke Steering Load sensing hydraulic 2 8 Water System Water Pumps Speed Related Water Impeller pump 26 9 Imp gal min 123 L m...

Page 31: ... T LT225 75R16 10 ply Tungsten tip studs Aluminium alloy wheels Tire pressure Front 85 psi 5 8 bar Back 85 psi 5 8 bar 2 10 Conditioner 2 10 1 Blades Ice shaver blade inlaid steel Length 84 96 213 244 cm Width 5 12 8cm Cutting angle 8 5 degrees Blade grind angle 27 degrees 2 10 2 Conveyor System Auger Vertical 8 20 3 cm Horizontal 12 30 5 cm ...

Page 32: ...Resurfacer 24 2 11 Materials Used Stainless Steel AISI 304L 316 Aluminium 5052H32 Steel Hot dip galvanized Electro zinc plating Hard chrome plating painted Plastics Glass fibre reinforced plastic Polyamide Polyurethane ...

Page 33: ...esigned such that natural ventilation is adequate see OSHA 1926 441 or VDE 510 3 3 Water Connections Ice making water on the left hand side of the ice resurfacer Wash water on the right hand side of the ice resurfacer The intake can be controlled with a solenoid valve The solenoid valve is controlled by the ice resurfacer Valve size is 1 3 4 Water Quality Clean water with low total grains of hardn...

Page 34: ...p tank directly in front of drivers platform It is possible to install longer cables from the charger 3 6 Garage Temperature Preferably above 15 C 59 F never below 0 C 32 F Charging can take considerably longer at temperatures below 15 59 F Freezing of a partially discharged battery can damage the battery The same applies for freezing of the water system 3 7 Snow Dump Pit Threshold A threshold at ...

Page 35: ...n hood Item 1 EMERGENCY SHUT OFF switch Item 2 Steering wheel Item 3 Driver s seat Item 4 Ice making water fill station Item 5 Conditioner Item 6 Step for climbing up to the driver s seat Item 7 Board brush Item 8 Front bumper wheel Item 9 Snow bin Item 10 Front headlights Item 11 Snow bin hood 1 2 3 4 6 5 7 10 9 11 8 ...

Page 36: ...3 Steering wheel Item 4 Top control panel Item 5 Manual Ice Making Water tap handle Item 6 Electrical control cabinet door Item 7 Tail lights Item 8 Drive motor for the horizontal auger Item 9 Automatic towel lift Item 10 Ice making water fill station Item 11 Spreader cloth Item 12 Conditioner bumper wheel Item 13 Reverse Light 3 1 2 4 10 13 7 12 11 5 6 7 8 9 9 ...

Page 37: ... for the conditioner the brush and other parts are part of the chassis The control cabinet the snow bin cover all parts of the hydraulic system power supply water supply and panelling are bolted to the chassis The front axle The front axle is of structural tube steel construction It holds the front drive units gear with motor and the hydraulic steering components The drive units are supported in s...

Page 38: ... ON on the dashboard Directional Control Switch for the elevator This switch has three possible positions Turning the switch to the left turns the elevator FORWARD self locking The middle position is OFF Turning the switch to the right turns the elevator REVERSE turn and hold switch 4 3 Hydraulic Components A tandem hydraulic pump supplies the hydraulic system with oil Control valves supply the ic...

Page 39: ...itch The ice resurfacer is equipped with an EMERGENCY SHUT OFF SWITCH that is installed above the steering wheel at the left To get power from the batteries to the ice resurfacer pull the red knob up To disconnect the batteries from the ice resurfacer depress the red knob ...

Page 40: ...Top Control Panel Fig 5 2 Top control panel Item 1 Horn Button Press this button to sound the horn Item 2 Lights This button turns the headlights and tail lights on and off Push and release to turn on repeat to turn off 1 3 3 4 5 6 4 3 2 ...

Page 41: ...0 litres of water in the tank Item 4 Wash Water Indicator When the tank is full the blue light will come on If equipped simultaneously the auto water fill valve will shut off the flow of water filling the tank The red light will come on when the wash water tank is empty Simultaneously turning off the wash water pump and valve Item 5 Accumeter The accumeter is equipped with a digital LCD display Th...

Page 42: ...h as service intervals operating hours counter and the customer information field Item 4 Battery discharge status indicator Indicates the discharge status of the battery Item 5 Fault indicator Indicates the status of the drive and pump controllers If there is a fault the relevant fault message appears instead of OK For more information please refer to the documentation provided by the manufacturer...

Page 43: ...The Ultimate Ice Resurfacer 35 5 3 Bottom Control Panel Fig 5 3 Bottom control panel 8 7 9 10 11 15 16 14 13 12 ...

Page 44: ...tioner push and hold the switch UP until the conditioner is in the full up position To lower the conditioner push and hold the switch DOWN until the conditioner is in the full down position Item 8 Elevator Off On Turn both augers ON horizontal and vertical auger by pushing the switch down Turn both augers OFF by lifting the switch to the off position If the ice resurfacer is switched off with the ...

Page 45: ... Water On Off To turn the wash water system on push the switch down To turn the wash water off lift the switch up to the off position When switched on the water from the tank will flow for approximately 8 seconds before the wash water pump turns on When switched off both the pump and the water flow stop at the same time Item 11 Speed Water To turn on the speed related water system push the button ...

Page 46: ...the snow dump tank is completely closed Before closing the snow dump tank make absolutely sure that there are no obstructions of any type that could get crushed between the tank and the chassis of the ice resurfacer It is recommended that if possible the snow dump tank should be left fully open after each ice cleaning operation with the safety bars down and locked so that any residual snow or wate...

Page 47: ...hen you turn the ignition key to the ON position the power on light will illuminate indicating the ice resurfacer is turned on Turn the ignition key to the OFF position to switch off the ice resurfacer the power light will turn off Item 16 Elevator Forward Reverse Left switch position Snow is transported from the conditioner into the snow bin by the horizontal and vertical augers Centre position N...

Page 48: ...atform If the lever is not in the neutral position when the ignition key is turned on the drive control will be disabled until the gear shift selector is switched back to the centre position Make sure the ice resurfacer comes to a complete stop before changing gears Item 18 Ignition Key Turn the ignition key to the right or ON position to switch on the ice resurfacer and put it into operation Turn...

Page 49: ...nted and wired The water hose down stream from the solenoid valve should not be too big in relation to the water pressure and pipe size because a pressure difference of 0 5 bar 7 psi is needed to close the solenoid valve The solenoid valve plug of the water supply pipe is connected at the Ice Making Water Control Panel and the water level for the water tank is set there At the left of the selector...

Page 50: ...ll or half full When the preselected water level is reached the solenoid valve automatically turns off Always be sure to insert the fill hose into the ice resurfacer first Disconnection of the Ice Making Water Line Proceed in the following order to disconnect the water hose from the ice resurfacer 1 Turn the selector switch to the neutral position 2 Pull the plug out of the socket 3 Disconnect the...

Page 51: ...er hose therefore works better than a large valve in a small pipe at low pressure 5 5 Wash Water Control Panel Fig 5 5 Wash Water control panel Item 22 Selector switch illuminated This panel controls how much cold water can be put into the ice resurfacers wash water tank The ice resurfacer is supplied with an electric water valve to be mounted onto the water supply line in the building Power for t...

Page 52: ...m 22 in the appropriate direction The filling procedure can be interrupted or stopped at any time by turning the selector switch to the OFF position The control panel function can be used even when the ignition key is turned off provided the battery connector is plugged in Connection of the Wash Water Line First connect the water line to the water filling inlet and then connect the solenoid valve ...

Page 53: ... pressure difference of at least 0 5 bar must prevail at the valve to ensure safe and speedy switching of the pilot controlled solenoid A smaller valve on a low pressure supply pipe with a bigger cross section therefore works better than a large valve in a small pipe at low pressure 5 6 Foot Pedals and Parking Brake Another three controls that you will work with a lot are located in the foot well ...

Page 54: ...dal is the main brake pedal The foot brake acts simultaneously on all four drive wheels ABS is not installed The OLYMPIA braking system has a pressure accumulator so that the brakes can be applied at least another two times after the hydraulic system has been switched off Parking Brake Lever The parking brake lever hand brake is located at the right of the driver s seat It acts on the two rear whe...

Page 55: ...alve For the best resurfacing results the ice making water should have a temperature NO HIGHER than local codes will allow The hot water melts some of the surface of the ice thus achieving the best possible bond with the existing ice Hot water also holds less oxygen than cold water and therefore produces a denser harder ice Harder ice does not get damaged as easily and therefore needs less depth o...

Page 56: ...tem Switching the Hydraulic Pump Motor On and Off There are two ways of switching on the hydraulic pump motor 1 By pressing the accelerator pedal 2 By pressing the appropriate function switch However the ice resurfacer must be turned on at the ignition switch before the motor can be started up The hydraulic pump motor is switched off either by turning off the ignition switch or automatically appro...

Page 57: ... the snow dump tank fully and install the safety support bars 2 The battery charger will indicate connect battery 3 Push down the EMERGENCY SHUT OFF switch 4 Carefully disconnect the power supply coupling located directly in front of the operators platform above the rear wheel Now plug the cable from charger into the power supply coupling Battery gassing does occur in the final stages of charging ...

Page 58: ...lug 8 Reconnect the OLYMPIA s internal power supply cables 9 Pull the EMERGENCY SHUT OFF switch The batteries must not come into contact with water as this could cause them to short out When working with acid batteries avoid all contact of the acid with the skin or clothing Always wear proper safety clothing equipment when working on or near batteries Always use only distilled water to fill batter...

Page 59: ...flow indicator in the hose will stop spinning when the tray is full This process must be repeated on both battery trays The optimal charging cycle for a maximum life expectancy of the battery is as follows 1 Discharge until the battery is as close to 0 on the accumeter charge indicator as possible 2 Recharge uninterrupted for 7 8 hours 3 If at all possible do not attempt to charge the battery betw...

Page 60: ...that it fits tightly against the runners of the conditioner as in the picture Squeegee Trimming Snow that is pushed by the squeegee must stay within the area between the squeegee and the runners and must not be pushed out from there as this would cause ridges to be produced on the ice Squeege Clamp Conditioner Squeege Fig 6 1 Installation of the squeegee Item 1 Conditioner Item 2 Squeegee Item 3 S...

Page 61: ... wood sheath and install the magnetic protector supplied with the tool kit 3 Using the blade hook lift and slide the blade underneath the conditioner and lift against the bladeholder until the attachment holes line up 4 Tighten the blade hook thumb screws 2 so that the slide bracket 1 sits on top of the conditioner 2 1 3 4 Fig 6 2 Installing the blade Item 1 Bracket Item 2 Thumb screw Item 3 Blade...

Page 62: ... closest to the cutting edge The second row of holes should be used when the blade has been ground down to 4 inch approx 10 16 cm overall width The Order is Important Following the diagrams below begin to install the blade bolts Finger tighten the bolts DO NOT use lock washers as they will damage the blade holder ...

Page 63: ...onsecutively across the blade to the opposite end Remove the blade hooks and insert the remaining two blade bolts and tighten Blade Bolt Sequence B Sequence B starting in the middle tighten the bolts from the centre to one end then return to the centre and tighten the bolts to the other end in order Remove the blade hooks and insert the remaining two blade bolts and tighten ...

Page 64: ...warped blade and uneven ice The blade holder is feathered by 1 16 approx 1 6 mm over the last 6 to 7 15 2 to 17 78 cm at each end This prevents ridges from forming on the ice Removal of the blade is done in reverse order to that in which it was installed Blade Holder Tapered 1 16 to 0 Over 6 0 Both ends 6 0 1 16 View A A Blade Blade Holder 1 16 0 16 cm 7 17 78 cm ...

Page 65: ...or arm completely fills the sight hole at the side of the conditioner as shown below Fig 6 3 Blade height adjustment If the sight hole is filled but the blade is too low or high go to the rear of the conditioner and using a 1 1 8 wrench first loosen the top nut of the blade level adjusters located on each side of the rear of the conditioner shown below 1 2 3 4 5 Item 1 Sight hole Item 2 Indicator ...

Page 66: ...nds of the blade are flush with the runners the majority of the blade will extend 1 16 1 6mm below the runners which is an excessive cut To check the level of the blade slide a large coin along the runners of the conditioner from back to front until you feel it pass over the edge of the blade Safety Note Be careful when doing the coin check Make sure you are wearing gloves and that you move the co...

Page 67: ... the blade edge Blade Coin check Fig 6 4 Place a coin underneath Item 1 Blade Item 2 Coin Item 3 Runner At this point go back to the blade adjustment crank and turn it counter clockwise 2 turns to raise the blade Please Note It is important that the blade holder and the blade surface be free of foreign material and lightly coated with oil to prevent rust 1 2 3 ...

Page 68: ...set any change in the cutting depth will alter the indicator arm position in the sight hole but blade angle tolerances will accommodate such adjustment and further adjustment of the blade angle will not be necessary 6 4 Horizontal and Vertical Augers The horizontal auger in the conditioner carries the snow scraped off the ice by the blade into the centre of the conditioner where a vertical auger p...

Page 69: ...tring between the runners and observing the distance between the string and the auger Pry the auger to the proper position After the adjustment has been completed re tighten the four outer bolts on the bearing adjustment plate If the auger is set too low diagonal lines may be found where the auger touches the ice If the auger is set too high excessive amounts of snow will be left on the ice surfac...

Page 70: ...t all times If too loose the sprockets and chain will wear out prematurely If too tight the sprockets chain and auger bearings will also wear out prematurely To adjust the chain tension loosen the motor mount plate bolts and adjust the motor mount until you get the proper tension Allow to inch Play Allow 1 4 to 1 2 inch 048cm to 196cm play ...

Page 71: ... and holding the CONDITIONER UP DOWN switch down until the lift arms are against the down pressure stops Before operating the OLYMPIA you should check to see if the runners are sitting level on the ice surface We recommend that you drive around the ice surface with the conditioner down for 2 or 3 laps to cool the runners To do this the conditioner should be lowered so the runners are sitting on th...

Page 72: ... you have three tire lugs or 5 12 7mm of the tire touching the ice Shut off the OLYMPIA and dismount Turn the down pressure stop bolts until they are tight against the down stops under the conditioner arms Now tighten the jam nuts Too much down pressure will lift the rear wheels off the ice resulting in a loss of control Too little down pressure will result in rippled ice and gouging in the corner...

Page 73: ...uts on both top links Now loosen both top links by turning them counter clockwise until there is no tension Remount the OLYMPIA and drive forward six feet 2 meters stop turn off the OLYMPIA and dismount Now simultaneously re tighten the top links by turning them clockwise making sure to extend the top link to hand tight only Secure the top links by tightening the lock nuts Check to make sure the f...

Page 74: ...The Ultimate Ice Resurfacer 66 Proper Top Link Adjustment Top Link too long Top Link too short ...

Page 75: ...he nuts are on the towel side of the towel bar 2 Place the towel bar assembly onto the towel lift guides 3 Attach towel lift chains between the towel bar and towel lift arm 6 6 Water Filling Procedure Always fill the ice making water tank with hot water always fill the wash water tank with cold water Never leave the OLYMPIA unattended during the water filling procedure ...

Page 76: ...lenoid valve plug into the socket on the Ice making water fill station Item 2 3 Select whether you want to half fill or completely fill the tank 4 When the switch is turned the water begins to flow until the previously selected water level is reached and the system shuts itself off automatically 5 Return the switch to the OFF position pull out the solenoid valve plug and remove the hose from the f...

Page 77: ...resurfacer Plug the solenoid valve plug into the socket on the Wash water fill station Item 2 on the exterior right hand side of the OLYMPIA s control cabinet 2 Turn the switch to the ON position the water then begins to flow 3 The filling procedure ends automatically when the tank is full 4 Turn the switch to the OFF position pull out the solenoid valve plug and remove the hose from the filling i...

Page 78: ... lug nuts and tire pressure and general condition of tire and studs on right front wheel 13 Make sure both tank drains are closed 14 Check lug nuts and tire pressure and general condition of tire and studs on right rear wheel 15 Check the condition of the blade in relationship to the runners To avoid being cut by the blade always start at the rear of the conditioner and slide your hand towards the...

Page 79: ...n 25 Check the bottom of the runners again for burrs or nicks 26 If your OLYMPIA is equipped with the optional edger on the conditioner check the cutting tips for damage and make sure the plate is securely attached 27 Check all the hydraulic hose connections on the edger and make sure there are no fluid leaks 28 Check the electrical connections 29 Check lug nuts and tire pressure and general condi...

Page 80: ...e board brush by pushing the board brush switch down to lower the board brush and then up to raise the board brush 40 Depress the brake pedal to check the brake lights 41 Check the blade adjustment hand crank wheel Make sure it turns freely 42 Visually inspect snow breaker and cylinder to make sure all fasteners are tight 43 Turn on the tire wash to make sure the pump works 44 At least once a mont...

Page 81: ... hydraulic pump Release the parking brake and select forward or reverse gear Press down the accelerator pedal and carefully start driving When you are on the ice surface carefully check the distance to the boards In the event of electrical drive faults depress the EMERGENCY SHUT OFF switch on the dashboard Wait for approximately 10 seconds and lift up the EMERGENCY SHUT OFF switch This will reset ...

Page 82: ...ore dismounting the OLYMPIA 7 1 4 Shifting from Forward to Reverse Always come to a complete stop before changing the direction of travel Never drive in reverse when the board brush is out When lowering the conditioner make sure that the OLYMPIA continuously moves forwards 7 2 Ice Resurfacing Only lower the conditioner while the OLYMPIA is moving forward otherwise it could sustain damage When work...

Page 83: ...ces a clean snow free board area right up to the edges In connection with the edger and the automatic water function the use of the brush reliably prevents a build up of ice at the boards Drive with the brush in the same way as you would without the brush but always travel in a clockwise direction around the boards Never drive backwards while the brush is extended The brush can yield to the boards...

Page 84: ...l Ice making water will then be pumped out according to how fast or slow you are driving After each resurfacing it is recommended to drain any excess water left in the tank This will reduce scale build up inside the ice making water tank Wash Water Procedure The wash water system sprays water from both sides of the conditioner into the centre in front of the squeegee thus creating slush Excess wat...

Page 85: ...ater flow and the pump turn off at the same time By turning the wash water off of the lap before completion any water trapped between the blade squeegee and runners will be used up and this will prevent pooling of any water at the gate once the conditioner is raised The filter basket for the wash water is located in the top of the wash water tank to the right of the driver and can be easily access...

Page 86: ...s by pushing the top of the elevator on button Turn on the ice making water with either the Speed Related Water button or the manually operated water valve Turn on the Wash Water button Now engage the board brush Drive slowly ahead keeping the board brush close to the boards This will clean the snow on the kick plate and edges of the ice surface into the conditioner Upon completion of a full circu...

Page 87: ... surface Turn off the horizontal and vertical augers Lift the conditioner Do not move the ice resurfacer until the conditioner is in the fully raised position Proceed carefully to the snow dumping area Prior to dumping check to ensure there is sufficient overhead clearance Raise the snow dump tank button until it is completely opened After dumping the snow lower the snow dump tank of after dismoun...

Page 88: ... The snow dumping area should meet the following safety requirements Red white cordons at the left and right of the unloading area with pictograms Yellow black threshold on the floor that is high enough to prevent the OLYMPIA from falling into the dump Guard at the front of the snow dump to prevent people from falling in 7 3 1 Cleaning the Ice Resurfacer after an Ice Resurfacing Operation The cond...

Page 89: ...arise in the event of a component failure Whenever working on the conditioner it is recommended that blocks be placed under it to prevent any possible injuries Maintenance and repair work must only be done by duly trained personnel Specialists are needed for some jobs e g electricians hydraulics technicians etc Before doing such jobs the whole ice resurfacer must be switched off To do this push do...

Page 90: ... the respective controls accordingly After completing the maintenance and repair jobs the responsible employee must ensure that the isolating guards are remounted and that there are no people in the danger zone After it has been ascertained that the ice resurfacer can be put back into operation without endangering people or facility equipment the responsible employee can restore the power to the i...

Page 91: ...cessary Inspect all safety switches If your ice resurfacer is equipped with an edger inspect all the components 8 2 2 Every Time the Blade is changed or Weekly The procedure for changing the blade is described in Chapter 6 3 Re grease the blade bolts Lubricate the horizontal auger drive chain Lightly oil bottom side of blade holder system Grease blade holder pivots Grease horizontal auger bearings...

Page 92: ... water Never spray an open jet of water into the ice resurfacer as electrical components will be damaged 8 2 3 After 5 Hours Check and torque the lug nuts to 140 Nm 103 25 ft lb 8 2 4 After 50 Hours Check all drive belts vee belts and re tension them if necessary Refer to Chapter 9 1 First oil change on the wheel drive gear boxes using Dexron III ...

Page 93: ...5 8 bar Check that all lug nuts are tight 140 Nm Check all traction drives for leaks Check that the parking brake cable runs smoothly re lubricate it with penetrating oil if necessary Check the hydraulic oil level in the hydraulic tank Check that the board guide roller runs smoothly Check the surface of the blade holder in the conditioner and lightly oil it Briefly test all functions Check the ten...

Page 94: ... holder on the conditioner Clean the ice resurfacer Wash the OLYMPIA with luke warm water and a mild soap Make sure that you rinse off the soap with cold water before it dries and causes streaking on the surface of the OLYMPIA Never spray an open jet of water onto the ice resurfacer as electrical components will be damaged Use a high quality automotive wax to preserve the high gloss finish of the ...

Page 95: ...The Ultimate Ice Resurfacer 87 8 2 7 Lubrication to be Done Weekly and Before Long Term Storage The lube points are shown on the separate lubrication chart in the appendix 1 2 3 3 4 5 6 7 ...

Page 96: ...The Ultimate Ice Resurfacer 88 8 9 10 11 12 13 14 18 15 16 17 ...

Page 97: ...icture 10 Upper and lower king pin right side Picture 11 Snow dump tank cover pivot left side Picture 12 Snow dump tank cover pivot right side Picture 13 Snow dump tank pivot left side Picture 14 Snow dump tank pivot right side Picture 15 Upper bearing blade adjustment handle Picture 16 Lower bearing blade adjustment wheel Picture 17 Universal joint blade adjustment crank Picture 18 Front bumper w...

Page 98: ...es of the conditioner Snow that is pushed by the squeegee is trapped between the squeegee and the runners and must not be able to escape to the outside as it would form a ridge on the ice 9 2 Towel Replacement Inspect the towel and replace it if necessary Attach the towel to the back of the towel holder with hex head bolts 3 8 x 1 and locknuts make sure that the nuts are on the towel side of the t...

Page 99: ...vided by the company DMC Controllers Documentation provided by the company Victron Documentation provided by the company Siemens Documentation provided by the company Safe T Alert Documentation provided by the company DMC Converter Electric Drawings Grease Plan Battery Information ...

Page 100: ...The Ultimate Ice Resurfacer 92 ...

Page 101: ...The Ultimate Ice Resurfacer 93 ...

Page 102: ...sure and viscosity 1 Measured at valve outlet at 87 PSI and 68 F 20ºC Opening pressure build up 0 to 90 Closing pressure relief 100 to 10 FM Technical data Orifice 1 2 2 DN 13 50 mm Body material Threaded port Flange Brass Grey cast iron Inner part valve Stainless steel brass Seal material NBR EPDM FKM Media NBR EPDM FKM Neutral media such as compressed air water Oil and fat free media Hot air oxy...

Page 103: ... 7 2 9 230 024 VDC 457 395 456 864 024 60 457 396 456 865 120 60 457 397 456 866 240 60 457 398 456 867 20 NPT 3 4 5 8 2 9 230 024 VDC 457 399 456 868 024 60 457 400 456 869 120 60 457 401 456 870 240 60 457 402 456 871 25 NPT 1 11 7 2 9 230 024 VDC 457 403 456 872 024 60 457 404 456 873 120 60 457 405 456 874 240 60 457 406 456 875 32 NPT 1 1 4 23 5 2 9 230 024 VDC 457 407 456 876 024 60 457 408 ...

Page 104: ...sealing Materials Ordering chart for accessory Cable plug Type 2508 according to DIN EN 175301 803 Form A Circuitry Voltage frequency Item no None standard 0 250 V AC DC 008 376 further versions see datasheet Type 2508 The delivery of a cable plug includes the flat seal and the fixing screw For other cable plug versions acc to DIN EN 175301 803 Form A previously DIN 43650 see separate datasheet Ty...

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Page 111: ...12 80 6 20 40 100 9 20 40 100 9 20 40 100 9 50 30 30 50 30 30 50 30 30 Type 1078 Timer unit Type 2511 ASI cable plug Type 8600 Dosing control Type 2508 Cable plug FM Technical data Orifice 7 16 2 DN 12 50 mm Body material Brass stainless steel 1 4581 Internal parts of valve See drawing on page 2 Seal material NBR FKM EPDM Media NBR FKM EPDM Neutral media compressed air water hydraulic oil Per solut...

Page 112: ...453 792 S 120 UR 453 792 S 120 UR 453 792 S 120 UR 453 792 S 120 UR 453 792 S UL 452 747 B UL 452 747 B UL 452 747 B UL 452 747 B UL 452 747 B UL 452 747 B UL 452 747 B UL 452 747 B 450 748 W 450 748 W 450 748 W 450 748 W 450 748 W 450 748 W 450 748 W 450 748 W 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 240 UL 456 119 S 25...

Page 113: ...50 NPT 2 211 0 115 24 72 126 0 164 0 Material Coil Epoxy Stopper 1 4105 Shading ring Brass version copper only AC version Stainless steel version silver Spring 1 4310 Magnetic core 1 4105 Guide tube 1 4303 O ring see ordering chart Seat seal see ordering chart Diaphragm support Brass version CuZn39983 disc Stainless steel version 1 4401 Diaphragm see ordering chart Pilot seat Brass version CuZn399...

Page 114: ...Page 4 4 0290 In case of special application conditions We reserve the right to make technical 0602 2_USen please consult for advice changes without notice ...

Page 115: ...I B 1561 Rev B Model ES3 EnForcer SCR Battery Charger Service Manual ...

Page 116: ...ield Calibration 20 Recharge Characteristics 20 Gassing Voltage Point Not Reached 20 Gassing Voltage Point Reached 20 Finish Current Mode Not Reached 20 Finish Current Mode Reached 20 Equalize Mode 20 Refresh Mode 20 Checking the Recharge Characteristics 20 Default Setting 20 TERMINATION METHODS 21 CHARGE PROFILES 22 DATA LOGGING 23 SCR TRANSFORMER TYPE BATTERY CHARGERS Watchdog Circuits If instal...

Page 117: ...nformation Replacement part numbers for chargers with such letter codes shall be referred to the charger s tables with code letter B SPECIALTY CHARGER OPTIONS LIST Suffix Description C6 6 of 10 AWG AC cord with 30 amp plug C10 10 of 10 AWG AC cord with 30 amp plug C12 12 of 10 AWG AC cord with 30 amp plug C8 8 of 10 AWG AC cord with 30 amp plug CF 10 of 8 AWG AC cord with 50 amp plug CF12 12 of 8 ...

Page 118: ...argeur de batteries industrielles Avant tout emploi il est fortement conseillé de lire l ensemble des instructions recommandations et avertissements concernant le chargeur et la batterie 2 Ce chargeur a été conçu pour la charge des batteries industrielles type plomb acide les batteries étanches 3 Lisez toutes les consignes d installation et d utilsation avant d employer le chargeur de batterie pou...

Page 119: ...all and 12 inches between the charger and any other equipment 2 Place the second charger on top of the first Align the bolt holes on each charger 3 Fasten both charger cabinets together securely using 3 8 bolts and nuts NOTE The two bolts toward the back of the charger may be omitted if an after market metal strap about 8 inches is used to secure both chargers Remove existing screws of the charger...

Page 120: ...f the AC fuse block BRANCH CIRCUIT PROTECTION The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing Even if the charger has an optional factory installed Disconnect Switch PLUG POLARITY The charging cable is connected to the DC output of the charger with the positive lead marked RED The output polarity o...

Page 121: ...up of 3 SCR Diode Blocks that converts AC to DC for charging The AC voltage of the secondary is connected directly to the SCR Diode Blocks For increased reliability there is a snubber assembly connected across each SCR Diode Block to limit the gate firing noise and high voltage spikes Each snubber assembly consists of an MOV Metal Oxide Varistor which is a device used to clamp positive or negative...

Page 122: ...art current setting 16 times battery AH rating 2 Constant Voltage control at the Gassing Voltage 80 point setting 3 Constant current at finish rate 4 Finish voltage will not exceed 2 53 VPC SEALED configuration only These modes of operation are determined by the recharge characteristics described in the following sections The control circuitry is connected to three small windings off the main tran...

Page 123: ...ze cycle is pending Light on during and after the actual equalize cycle Light is reset when battery is disconnected from charger BAR GRAPH Shows capacity returned to battery during charge cycle PUSHBUTTONS START STOP Stops a charge in progress or restarts a charge that has been stopped Can also force a charge cycle by pushing and holding for 5 seconds EQUALIZE Will activate the equalize function a...

Page 124: ...mation they wish to display REAL TIME CLOCK CALENDAR The ES3 features a real time clock and calendar The current time and date is displayed and the time date information can be used for charge cycle control A super capacitor enables the control board to retain the time and date information for up to one week during AC power outages AUTO CELL SIZING The ES3 can charge any battery from 1 to 40 cells...

Page 125: ... any time during the charge cycle will activate the equalize function Once pressed the EQUALIZE LED will begin to flash indicating that an equalize cycle will occur once the battery has completed a successful charge cycle The EQUALIZE button can again be pressed at any time during the normal charge cycle to stop the pending equalize cycle The charge counter is reset every time the charger complete...

Page 126: ...charger and no battery is connected the POWER LED will be lit Two alternating messages will appear on the front display Connect Battery 1 Where Battery is the selected battery settings 1 3 Tue Dec 11 2014 10 12 20 The current date time 2 During Idle Mode toggling the UP or DOWN pushbuttons will display the previous charge cycle parameters Toggle the UP or DOWN to display the total charge time Amp ...

Page 127: ... or all the above parameters will be displayed The default setting is for all parameters to be displayed CAUTION To prevent arcing and burning at the connector and possible battery explosion press the START STOP pushbutton first to stop the charge cycle before removing a battery that is currently on charge 4 When the battery reaches Gassing Voltage the yellow 80 LED will light and the charge curre...

Page 128: ...meter In the case of setting the real time clock toggle the Equalize button when Set Clock Calendar is displayed in order to enter the clock setting function Clock Minutes is now displayed Choose the Clock Minutes by toggling the Equalize button again To change Clock Minutes scroll with the UP or DOWN arrows Press Equalize again to set the value Scroll through the other real time clock value of ho...

Page 129: ...VICE PARAMETERS While in Idle Mode hold down the DOWN and EQUALIZE buttons until the display reads Service Parameters approximately 10 seconds Release the buttons and the display will read Charger Cell Size Range 1 40 Cells Toggle the UP or DOWN arrow keys to scroll through the available Service parameters To view the contents of the variable displayed toggle the EQUALIZE button The value of that ...

Page 130: ...r acknowledgement specifies a change 0 100 20 U p B a t t e r y D e t e c t Up Battery Time If battery reaches gassing voltage before this time in minutes has expired the charger will stop and go to complete Do not adjust unless order acknowledgement specifies a change 00 10 02 C a b l e L e n g t h Cable Length Length of battery cables in inches installed on the charger used in battery cable drop...

Page 131: ... 3 AGV Auto guided vehicle 4 I VVR 5 IE Floating mode 6 Opportunity This should be set to match the type of battery that the charger will be charging 1 6 1 S e a l e d F i n i s h V o l t s Sealed Finish Volts For sealed VRLA charge profiles the final voltage in volts per cell Do not adjust unless order acknowledgement specifies a change 1 000 3 000 2 530 S e a l e d F i n i s h T i m e Sealed Fin...

Page 132: ... a b l e B a t t e r y A H r Enable Battery Amp Hours in User Parameters 0 NO 1 YES Do not adjust unless order acknowledgement specifies a change 0 1 1 E n a b l e U s e r D i s p l a y Enable Display Adjustment in User Parameters 0 NO 1 YES Do not adjust unless order acknowledgement specifies a change 0 1 1 E n a b l e D e l a y S t a r t Enable Delay Start in User Parameters 0 NO 1 YES Do not ad...

Page 133: ...d 1 8 volts cell Call Service NO Bar Graph Steady On Can be reset if battery voltage is between 1 8 and 2 4 volts cell High Battery Voltage Check Battery Occurs when the battery is first connected and the voltage is above 2 4 volts cell Call Service NO Bar Graph Steady On Can be reset if battery voltage is between 1 8 and 2 4 volts cell Battery Temperature Decreasing Voltage Occurs when there is n...

Page 134: ...fault occurs resulting in charger shut down GASSING VOLTAGE POINT REACHED When the gassing voltage point is reached within the time to gassing period the charge cycle enters constant voltage or E mode During constant voltage mode the current tapers down to approximately 4 5 amps per 100 AH At this point the charger stops applying constant voltage and returns to applying constant current This const...

Page 135: ...ermination algorithm looks for a flattening of the battery voltage after the charge cycle enters into finish rate In particular when the battery voltage does not increase greater than 10 mV cell over a 30 minute period the dvdt requirements are satisfied The minimum time for dvdt termination is 50 minutes after gassing voltage is reached Please note that the above values are default charger values...

Page 136: ...2 53 V C reached Finish Rate 2 of Battery AH Charge Time Limit 14 Hours AGV Auto Guided Vehicle Automatic guided vehicle AGV is an IE profile with a two hour time after gassing time limit Charge cycle will terminate if the time after gassing limit is reached or if the charge current drops below finish rate If battery is disconnected from charger during the charge cycle no Open Battery fault will r...

Page 137: ...cycles greater than 1 hour 5 Total Charge Amp Hours 1000 Total Amp Hours the charger has put out in thousands of Amp Hours 6 Max Charger Temperature Future option 7 Current Charger Temperature Future option 8 Minimum Charger Temperature Future option 9 Maximum Charger DC Volt Max DC volt for this particular charge cycle 10 Minimum Charger DC Volt Min DC volt for this particular charge cycle 11 BID...

Page 138: ...ging and the main microcontroller does not shut off the output within second the Override Watchdog will operate Note that when the Override Watchdog operates the main processor may still attempt to start a charge cycle Since the SCRs are held off a DC fuse error will eventually result Continuous DC fuse faults are sometimes an indicator of an Override Watchdog operation FAULT RECOVERY The only way...

Page 139: ...ime out TESTING COMPONENTS The following information applies to all charger types unless otherwise noted TRANSFORMER Please follow these steps before testing the Transformer Disconnect the battery Remove the charger cover Connect the charger to AC power First Transformer Test You will be testing the transformer s windings with a good quality meter to check the transformer s voltages Your measureme...

Page 140: ...e current 100K ohms or less 1 Disconnect the gate leads from SCR Diode Blocks 2 Remove the transformer input connection to the SCR Diode Block anode 3 Using an ohmmeter set to its 1k scale check for continuity between each SCR diode Block anode input connection and bussbar The ohmmeter should read infinity 4 If continuity is shown replace the SCR diode Block 5 If infinity open is measured in both ...

Page 141: ...asures zero current for both directions polarities 10 The SCR Diode Block is open if the meter reads infinity for both directions polarities AC AND DC FUSES Please follow these steps before testing the fuses Disconnect the battery Disconnect the AC power You will be testing each fuse to see whether there is continuity across it 1 Using an ohmmeter set to its X1 scale test each fuse 2 If a fuse tes...

Page 142: ...nnect the battery Disconnect the AC power MAIN TRANSFORMER Use the wiring diagrams in the back of this manual to help identify wires connected to the transformer Removal To remove the transformer 1 Remove the AC input wires from the 3 terminal input blocks 2 Remove the transformer control voltage wires from the little glass fuse holder 3 Remove the secondary leads from the SCR Diode Blocks 4 In th...

Page 143: ...n the nut SCR Diode Block Mounting Torque in lb Buss Bar Mounting Torque in lb SCR Diode Block Size Bolt Size Max Bolt Size Max 104 Amp 10 32 X 1 25 19 0 5mm 31 162 Amp 10 32 X 1 25 19 0 6mm 65 250 Amp 10 32 X 1 25 19 0 8mm 132 285 Amp 10 32 x 1 25 19 0 8mm 132 Removal The SCR Diode Blocks cannot be removed until the buss bars are removed first These steps explain how to remove the heat sink 1 Rem...

Page 144: ...able to activate through the front decal Over tightening of the 11 32 nuts on the PCB will result in damage to the tactile pushbuttons 3 Attach the connectors to the replacement board Be careful to insert the connectors properly The connectors should be inserted so that the raised portion of the socket slips under the raised portion of the plug on the PCB 4 Enter USER SERVICE parameters Set all US...

Page 145: ...O B4 B1 TO B4 C3 TO C4 A2 B2 TO B5 B3 TO B6 A3 TO A4 A2 C1 TO C4 C1 TO C4 B3 TO B4 AS C2 TO C5 C3 TO C6 C3 TO C4 Replacement part numbers for chargers with letter codes T W X or Y shall be referred to the charger s tables with code letter B MODEL J 480 VOLT INPUT 550 VOLT INPUT 600 VOLT INPUT WIRE MARKER CONNECTION CONNECTION CONNECTION D2 F1 TO A1 F1 TO A1 F1 TO A1 D7 F1 TO C5 F1 TO C6 F1 TO C6 D...

Page 146: ... C4 A2 B3 TO B6 A2 TO A4 A3 TO A4 A2 C1 TO C4 B2 TO B4 B3 TO B4 A2 C3 TO C6 C2 TO C4 C3 TO C4 MODEL E 400 VOLT INPUT WIRE MARKER CONNECTION D2 F1 TO A1 D7 F1 TO C6 D3 F2 TO A6 D3 F2 TO B1 D4 F3 TO B6 D4 F3 TO C1 AC INPUT CHANGE WITH QUICK TAP CAUTION CONNECTOR IS KEYED AND PINS ARE FRAGILE 1 Change AC fuses to the value of the desired line voltage available for this charger AC fuse values can be f...

Page 147: ...The unit should be periodically cleaned with an air hose to prevent any excessive dirt build up on components Care should be taken not to bump or move any adjustments during cleaning Make sure that both the AC lines and the battery are disconnected before cleaning The frequency of this type of maintenance depends upon the environment in which this unit is ...

Page 148: ...EnForcer SCR Service Manual I B 1561 34 ES3 REPLACEMENT PARTS SCHEMATICS ...

Page 149: ... 6 DOOR LATCH X044 1 32 RIVET FOR DOOR LATCH 164 8 6 TERMINAL BOARD MAIN XFMR LEFT 256 99 12 TERMINAL BOARD MAIN XFMR RIGHT 256 99 13 DC CABLE CLAMP 2 1 0 2 0 3 0 CABLE 356 5 15 DC CABLE CLAMP 4 0 CABLE 356 5 16 FUSE REDUCER 70A FUSE INTO 100A FUSE BLOCK X014 17 6 FUSE REDUCER 40A FUSE INTO 60A FUSE BLOCK X014 17 5 GROUND LUG X012 7 24 PC BOARD FUSE X014 7 28 Base kits are required for base replac...

Page 150: ...CR MODULE PART NUMBER ES3 X B MODELS 6 550B X127 S06 680B R507 18 2 6 680B X127 S06 680B R507 18 2 6 850B X127 S06 850B R507 18 2 12 550B X127 S12 550B R507 18 2 12 680B X127 S12 680B R507 18 2 12 750B X127 S12 680B R507 18 2 12 850B X127 S12 850B R507 18 2 12 950B X127 S12 1050B R507 18 3 12 1050B X127 S12 1050B R507 18 3 12 1200B X127 S12 1200B R507 18 3 12 1500B X127 S12 1500B R507 18 4 18 550B...

Page 151: ...127 S40 550B R507 18 2 40 680B X127 S40 680B R507 18 2 40 850B X127 S40 850B R507 18 2 MODEL NUMBER TRANSFORMER PART NUMBER SCR MODULE PART NUMBER ES3 X D MODELS 12 550D X127 S12 550D R507 18 2 12 680D X127 S12 680D R507 18 2 12 850D X127 S12 850D R507 18 2 12 1050D X127 S12 1050D R507 18 3 18 550D X127 S18 680D R507 18 2 18 680D X127 S18 680D R507 18 2 18 750D X127 S18 850D R507 18 2 18 850D X127...

Page 152: ...127 S18 1700J R507 18 4 18 2000J X127 S18 1700J R507 18 4 24 550J X127 S24 681J R507 18 2 24 680J X127 S24 681J R507 18 2 24 750J S24 850J R507 18 2 24 850J X127 S24 850J R507 18 2 24 950J X127 S24 1050J R507 18 3 24 1050J X127 S24 1050J R507 18 3 24 1200J X127 S24 1200J R507 18 3 24 1500J X127 S24 1500J R507 18 4 24 1600J X127 S24 1500J R507 18 4 40 450J X127 S40 550J R507 18 2 40 550J X127 S40 5...

Page 153: ...99 35 10 15 X014 99 15 18 750 26 40 X014 99 40 22 35 X014 99 35 11 20 X014 99 20 18 850 29 45 X014 99 45 25 40 X014 99 40 13 20 X014 99 20 18 950 33 50 X014 99 50 28 45 X014 99 45 14 25 X014 99 25 18 1050 36 60 X014 99 60 31 50 X014 99 50 16 25 X014 99 25 18 1200 41 60 X014 99 60 36 60 X014 99 60 18 30 X014 99 30 18 1500 51 80 X014 99 80 44 70 X014 99 70 22 35 X014 99 35 18 1700 58 90 X014 99 90 5...

Page 154: ...9 25 15 25 X014 99 25 18 1500 22 40 X014 99 40 20 40 X014 99 40 18 35 X014 99 35 18 1600 24 40 X014 99 40 21 40 X014 99 40 19 35 X014 99 35 18 1700 25 40 X014 99 40 22 40 X014 99 40 20 35 X014 99 35 18 2000 30 50 X014 99 50 26 40 X014 99 40 24 40 X014 99 40 24 550 11 20 X014 99 20 10 15 X014 99 15 9 15 X014 99 15 24 680 14 25 X014 99 25 12 20 X014 99 20 11 20 X014 99 20 24 750 15 25 X014 99 25 13 ...

Page 155: ... 99 60 23 40 X014 99 40 20 35 X014 99 35 18 1500 48 70 X014 99 70 28 45 X014 99 45 24 40 X014 99 40 18 1600 52 80 X014 99 80 30 50 X014 99 50 26 40 X014 99 40 18 1700 55 80 X014 99 80 32 50 X014 99 50 28 45 X014 99 45 18 2000 64 100 X014 99 100 38 60 X014 99 60 32 50 X014 99 50 24 550 24 40 X014 99 40 14 25 X014 99 25 12 20 X014 99 20 24 680 30 50 X014 99 50 17 30 X014 99 30 15 25 X014 99 25 24 75...

Page 156: ...EnForcer SCR Service Manual I B 1561 42 SCHEMATIC DIAGRAM ES3 ...

Page 157: ...EnForcer SCR Service Manual I B 1561 43 ES3 ASSEMBLY DRAWING ...

Page 158: ...e 3 Cabinet Left side 4 Cabinet Top Back 5 Upright 6 Cross Member Main Transformers 7 Main Transformer 8 Heat Sink Assembly 9 SCR diode block 10 Buss bar 11 Cross Member Heat Sink 12 PC Board Fuses 13 Shunt 14 DC Fuse 15 Terminal Board Primary Main Transformer 15 Terminal Board Primary Main Transformer 16 Panel Sub assembly 17 AC Block Input Fuses 18 Door 19 Ground Lug 20 DC output cables and clam...

Page 159: ...EnForcer SCR Service Manual I B 1561 45 INTERIOR VIEWS ...

Page 160: ...EnForcer SCR Service Manual I B 1561 46 SINGLE EXTRUSION HEAT SINK ASSEMBLY ...

Page 161: ...EnForcer SCR Service Manual I B 1561 47 SINGLE EXTRUSION HEAT SINK ASSEMBLY HARDWARE STACK UP DETAILS TO BUSS BAR TO J4 BLACK TO BATT ...

Page 162: ...EnForcer SCR Service Manual I B 1561 48 THREE EXTRUSION HEAT SINK ASSEMBLY ...

Page 163: ...EnForcer SCR Service Manual I B 1561 49 THREE EXTRUSION HEAT SINK ASSEMBLY HARDWARE STACK UP DETAILS FROM BUSS BAR TO J4 BLACK TO BATT ...

Page 164: ...EnForcer SCR Service Manual I B 1561 50 SUB ASSEMBLY PANEL ASSEMBLY ...

Page 165: ...TO A6 B3 TO B4 A2 B1 TO B4 B1 TO B4 C3 TO C4 A2 B2 TO B5 B3 TO B6 A3 TO A4 A2 C1 TO C4 C1 TO C4 B3 TO B4 A2 C2 TO C5 C3 TO C6 C3 TO C4 MODEL D LOOSE WIRE MARKER COLOR CONNECTION G1 GREEN G1 TO DOOR WIRE MARKER 220 V CONNECTIONS 380 V CONNECTIONS 440 V CONNECTIONS D2 F1 TO A1 F1 TO A1 F1 TO A1 D7 F1 TO C6 F1 TO C5 F1 TO C6 D3 F2 TO A6 F2 TO A5 F2 TO A6 D3 F2 TO B1 F2 TO B1 F2 TO B1 D4 F3 TO B6 F3 T...

Page 166: ...TO A1 F1 TO A1 F1 TO A1 D7 F1 TO C5 F1 TO C6 F1 TO C6 D3 F2 TO A5 F2 TO A6 F2 TO A6 D3 F2 TO B1 F2 TO B1 F2 TO B1 D4 F3 TO B5 F3 TO B6 F3 TO B6 D4 F3 TO C1 F3 TO C1 F3 TO C1 A2 A2 to A4 A2 TO A4 A3 TO A4 A2 B2 TO B4 B2 TO B4 B3 TO B4 A2 C2 TO C4 C2 TO C4 C3 TO C4 INDICATES DOUBLE JUMPER MODEL E 400 V CONNECTIONS WIRE MARKER CONNECTIONS D2 F1 TO A1 D7 F1 TO C6 D3 F2 TO A6 D3 F2 TO B1 D4 F3 TO B6 D4...

Page 167: ...EnForcer SCR Service Manual I B 1561 53 DOOR ASSEMBLY ...

Page 168: ...EnForcer SCR Service Manual I B 1561 54 PARALLEL CABLES OPTIONAL ...

Page 169: ...EnForcer SCR Service Manual I B 1561 55 DISCONNECT SWITCH OPTIONAL ...

Page 170: ...EnForcer SCR Service Manual I B 1561 56 CABINET ASSEMBLY ...

Page 171: ...EnForcer SCR Service Manual I B 1561 57 CABINET ASSEMBLY EXPLODED VIEW ...

Page 172: ...el Number PCB Part Number Charger Model Number PCB Part Number ES3 30 1700YNC X1060 09 ES3 1 ES3 64 1250J X1060 09 ES3 2 COMMON PARTS TO ALL MODELS Description Part Number Door X054 99 3 19 Top Panel X057 99 3 23 Back Panel X057 99 3 3 Left Side Panel X057 99 3 13 Right Side Panel X057 99 3 22 Base 013 99 3 3 Cross Member Heat Sink Mtg X051 99 3 13 Cross Member Xfmr Mtg Front X051 99 3 14 Cross Me...

Page 173: ...ARTS FUSE VALUES FOR ES3 64 1250J Description Part Number Transformer X127 S64 1250J AC Fuse 480V Connection 100A X014 99 100 AC Fuse 550 600V Connection 90A X014 99 90 DC Fuse 250A X014 30 4 Shunt 300A X117 99 1 AC INPUT AND FUSES Special Models NOTE Special charger models might not be listed in these tables However AC input is listed on the charger nameplate AC Fuse Values are listed on a decal ...

Page 174: ...EnForcer SCR Service Manual I B 1561 60 SCHEMATIC DIAGRAM ...

Page 175: ...EnForcer SCR Service Manual I B 1561 62 ES3 LARGE CABINET ASSEMBLY DRAWINGS ...

Page 176: ...EnForcer SCR Service Manual I B 1561 63 CHARGER INTERIOR VIEW ...

Page 177: ...EnForcer SCR Service Manual I B 1561 64 TRANSFORMER CONNECTIONS ...

Page 178: ...EnForcer SCR Service Manual I B 1561 65 HEAT SINK ASSEMBLY ...

Page 179: ...EnForcer SCR Service Manual I B 1561 66 HEAT SINK ASSEMBLY CON T ...

Page 180: ...EnForcer SCR Service Manual I B 1561 67 SUB ASSEMBLY PANELS ...

Page 181: ...EnForcer SCR Service Manual I B 1561 68 CABINET ASSEMBLY ...

Page 182: ...EnForcer SCR Service Manual I B 1561 69 CABINET ASSEMBLY CON T ...

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Page 198: ...eschriebenen Produkts behält sich ZF Gotha GmbH das Recht vor Produktdokumentationen im Bedarfsfall zu ändern Technische Veränderungen sind im Sinne von Veränderungen in Produktion Verarbeitung und Erscheinungsform des Produktes zu sehen For possible technical modifications of the product described in this manual ZF Gotha GmbH reserve the right to change the product documentations if necessary Tec...

Page 199: ...3 3 Getriebe Identifizierung 4 4 Ersatzteile 5 4 1 Gehäuseteile 5 4 2 Bremsenteile 7 4 3 Eintriebsteile 10 4 4 Abtriebsteile 12 4 5 Anbauteile 15 1 Contents list 1 Contents list 2 2 Preface 3 3 Transmission Identification 4 4 Parts 5 4 1 Housing parts 5 4 2 Brake system parts 7 4 3 Input parts 10 4 4 Output parts 12 4 5 Attaching parts 15 ...

Page 200: ... der ZF Gotha GmbH Bestellungen richten Sie bitte an ZF Gotha GmbH Passauer Str 1 D 99867 Gotha Telefon 49 0 3621 311 4400 Telefax 49 0 3621 311 4419 E Mail Aftermarket zfgotha zf com 2 Preface This Spare Parts List is only valid for the type of transmission as shown at the front page You will find the transmission type on your transmission name plate Use only original ZF spare parts or spare part...

Page 201: ...ebssystems MDU identification Typenschild Type plate Pos Nr Item no Bezeichnung Description 1 Getriebetyp Transmission type 2 Seriennummer Serial number 3 Identnummer Parts list number Transmission Id No 4 Übersetzung Ratio 5 Kundenidentnummer optional Customer code number optinal Typenschild Type plate 3 2 4 5 1 ...

Page 202: ... 01 06 2010 4 Ersatzteile Parts 4 1 Gehäuseteile Housing parts Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen Illustrations may differ from actual design 101 020 101 030 8x 101 040 2x 101 090 101 060 101 010 101 050 101 060 101 050 101 050 101 070 ...

Page 203: ...699 301 146 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4699 301 168 1 101 020 Gehäuse deckel Housing cover 4699 309 083 1 4699 309 085 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 101 030 Zylinder schraube Cylindrical screw 0636 101 411 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 101 040 Zylinderstift Cylindrical pin 0631 302 212 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 101 050 Dichtr...

Page 204: ... 7 von of 16 Version B 01 06 2010 4 2 Bremsenteile Brake system parts Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen Illustrations may differ from actual design 109 090 109 110 109 000 109 070 3x 4x 3x 109 020 109 010 109 100 ...

Page 205: ...ake wearing parts 4699 195 039 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Axiallager Axial bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Zylinderstift Cylindrical pin 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Außen lamelle Outer clutch disc 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Innen lamelle Inner clutch disc 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 ...

Page 206: ...5 033 4699 825 037 4699 825 038 4699 825 039 4699 825 042 4699 825 048 4699 825 049 109 010 Axiallager Axial bearing 4699 309 054 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 109 020 Zylinderstift Cylindrical pin 0631 313 003 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 109 070 Druckfeder Pressure spring 0632 040 021 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 109 090 Dichtring Sea...

Page 207: ...0 019 10 von of 16 Version B 01 06 2010 4 3 Eintriebsteile Input parts Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen Illustrations may differ from actual design 102 070 102 040 102 010 102 060 102 050 102 000 102 030 6x ...

Page 208: ...1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Antriebsritzel Input pinion 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Kugellager Ball bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Sicherungs ring Circlip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 102 010 Antriebsritzel Input pinion 4699 302 037 1 1 1 1 1 4699 302 053 1 1 1 4699 302 055 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 469...

Page 209: ... Abtriebsteile Output parts Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen Illustrations may differ from actual design 103 500 103 600 3x 12x 3x 103 090 103 200 103 080 103 010 103 100 103 120 103 150 103 160 103 070 103 020 103 140 103 190 103 130 103 180 103 110 ...

Page 210: ...1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ring Ring 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Torxschraube Torx screw 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 103 600 Kit Planeten radsatz Planet gear set 4699 195 043 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Planetenrad Planet gear 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Zylinderrolle n...

Page 211: ...501 323 470 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 103 120 Nilosring NILOS ring 0501 325 596 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 103 130 Wellendicht ring Shaft seal 0634 301 781 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 103 140 Nadelhülse Needle ring 0635 303 037 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 103 150 Kegelrollen lager Ta...

Page 212: ...are Parts list 4699 770 019 15 von of 16 Version B 01 06 2010 4 5 Anbauteile Attaching Parts Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen Illustrations may differ from actual design 170 010 170 020 ...

Page 213: ...699 825 021 4699 825 022 4699 825 024 4699 825 025 4699 825 026 4699 825 027 4699 825 028 4699 825 029 4699 825 030 4699 825 031 4699 825 032 4699 825 033 4699 825 037 4699 825 038 4699 825 039 4699 825 042 4699 825 048 4699 825 049 170 010 Motor Motor 0501 213 927 1 1 1 0501 319 869 1 0501 007 341 1 1 1 1 0501 217 044 1 1 0501 214 992 1 0501 215 738 1 0501 215 832 1 0501 215 724 1 Motoreinheit Mo...

Page 214: ...boxes manholes excavations For pollution control and watering for dust control INSTALLATION Pump may be mounted in any position Intake and discharge ports are determined by the direction of shaft rotation refer to dimensional drawing Before installing energize clutch and turn pump shaft in direction of shaft rotation Drive pump with two A size belts or one B size belt Avoid dry running by using Va...

Page 215: ...aft to remove shaft from bearing ASSEMBLY Support inner race of bearing on arbor press platten Oil shaft insert drive end of shaft into bearing and press shaft through bearing until it bottoms firmly against shoulder Install shaft to bearing until it bottoms firmly against shoulder Install shaft to bearing retaining ring in groove of shaft Support impeller bore end of pump on arbor press platten L...

Page 216: ...ng Brg to Body 1 18724 0000 18712 0000 14 Retaining Ring Brg to Shaft 1 18713 0000 18711 0000 15 Shaft 1 11867 0000 11877 0000 16 Seal Shaft 1 96080 0080 6407 0010 17 Roll Pin Adaptor 2 93100 0160 18 Adaptor 1 11876 0000 19 Key Clutch Drive 1 91401 0100 91401 0100 20 Clutch Assy Complete 12 V 2 A Grooves 1 92300 0030 92300 0030 12 V 1 B Groove 18753 0493 18753 0493 24 V 2 A Grooves 92300 0061 9230...

Page 217: ...eet of meters of psi sq cm water water GPM LPM HP GPM LPM HP GPM LPM HP GPM LPM HP GPM LPM HP 4 3 0 3 10 3 0 6 0 22 7 1 4 14 8 56 0 1 3 23 3 88 2 3 4 32 5 123 0 1 34 8 131 7 1 1 2 11860 8 7 0 6 20 6 1 5 5 20 8 1 4 14 1 53 4 1 2 22 3 84 4 3 4 31 8 120 4 1 1 2 34 2 129 5 1 1 2 Series 17 3 1 2 40 12 2 4 0 15 1 1 4 12 0 45 4 1 2 19 5 73 8 3 4 28 5 107 9 1 1 2 32 5 123 0 2 26 0 1 8 60 18 3 8 8 33 3 3 4...

Page 218: ... 22 X2 Panel 2 1 2 3 4 5 6 7 8 9 1O X4 1 2 3 4 16 5 6 7 8 9 10 11 12 13 14 15 X23 Traction RR 1 2 3 4 16 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 X27 Contactor Coils 1 2 3 4 X34 CAN Hydro 1 2 3 4 X13 Pump TireWash BinWash 1 2 3 4 5 6 7 8 9 1O X6 Divers 1 2 3 4 16 5 6 7 8 9 10 11 12 13 14 15 X24 Hydro Pump 1 2 3 4 5 6 X7 1 2 3 4 X35 CAN ELV1 1 2 3 4 X12 DC DC 24V Switched 1 2 3 4 5 6 X3B IcemakingWa...

Page 219: ...pia Canada DMC GmbH Herten Germany www dmcde de A3 1 1 Friday September 03 2010 Title Size Document Number Rev Date Sheet of X4 4 IN_23 B29 Snow Dump Down X2 12 Tyre Wash H Power ON X2 16 Board Brush IN H Icemakingwater Half B2 2 Reverse drive X2 21 Elevator On X2 17 Snow Bin Up b6 1 Elevator Off 1 H31 WASHWATER EMPTY B18 Washwater On X1 10 Washwater Full 8 X1 2 80V Switched B28 Snow Dump Up X4 5 ...

Page 220: ...3 1 1 Friday September 03 2010 Title Size Document Number Rev Date Sheet of X5 12 Brakelight Y26 Board Brush IN 19 X17 1 Power Gnd 12 X8 2 Hydraulic pressure Conditioner X8 5 Edger Down E Blue 5 Y20 2 Snow Breaker Down D Yellow 6 Y24 Conditioner Up X5 13 Power 24V MY4 24V 4 B15 Footbrake Y Bypass Valve 12 Y28 Snow Bin Up P1 POT B9 Parkbrake 1 X8 13 Snow Bin Down 18 X5 15 Washwater clutch 10 X5 1 G...

Page 221: ...1 Horn K40 1 Icemaking watervalve X18 8 AD8 X6 6 Icemaking watervalve X13 1 Power Gnd X18 9 AD9 2X3B3 IceMakingWater 1 2 X6 7 Washwatervalve 2X3A2 WashWater Full X6 5 Icemaking waterclutch B11B IceMakingWater Empty 2X3A5 Logic Gnd 2X3A6 Washwater Empty X18 3 IN_37 2X3B5 Logic Gnd X6 4 Power 24V X6 1 Logic Gnd 2X3B4 NC D1 1N5404 X18 5 IN_35 2X3A4 Nc B13A WashWater Full 2X3B6 IceMakingWater Empty X6...

Page 222: ...GmbH Herten Germany www dmcde de A3 1 1 Friday September 03 2010 Title Size Document Number Rev Date Sheet of L1 Valve L3 GND X14 4 NC D30 1N5406 H10b1 Green X15 2 24V X16 2 24V H10b2 Blue L2 X3A 2 24V continu B10b1 Icemaking watertank 1 2 Full X3B 6 Pwr Gnd X16 1 Power Gnd X3A 6 Pwr Gnd D10B1 1N4007 X3B 1 24V 8R2 X3A 5 Nc k35B1 X15 1 Power Gnd k35a1 X3B 4 IceMakingWater 1 2 X3A 4 NC X3A 1 24V 8R2...

Page 223: ...eat X27 11 X30 2 Can H X20 15 10V X19 2 X20 15 10V X20 7 Handbrake X20 6 Spd2 X27 20 X30 2 Can H X20 2 Rev X27 17 X30 2 Can H X20 8 Footbrake K0 Line Main X20 15 10V X30 4 Gnd K5 Line Hydraulic motor X20 14 Aux2 contactor X20 7 Handbrake X20 12 Line contactor X27 8 Backup Alarm X30 2 Can H X20 14 Aux2 contactor X20 12 Line contactor X30 2 Can H X20 13 Aux1 contactor X30 4 Gnd X20 1 Speed 1 X20 11 ...

Page 224: ... www dmcde de A3 1 1 Thursday September 02 2010 Title Size Document Number Rev Date Sheet of 18 X8 7 Snow Breaker Down X8 3 Power 24V 9 6 X8 14 Bypass Valve 13 7 1 X17 1 Power Gnd 4 X8 5 Edger Down X8 10 Board Brush IN 17 X8 12 Snow Bin Up 20 D36 1N4007 2 10 16 X8 6 Snow Breaker Up Omron MY4 24V 19 X8 13 Snow Bin Down X8 11 Board Brush OUT 3 X8 8 Conditioner Up X17 2 24V CO 11 X8 1 Logic Gnd 5 X8 ...

Page 225: ...WG 16 red AWG 16 black BLACK tubing RED tubing RED tubing RED tubing RED tubing RED tubing BLACK tubing BLACK tubing 80 V 15 A fuse A B C to Accumeter on small panel BiCAT II connector at battery 17 ORANGE Pin 6 AWG 2 0 60 cm only for North American machines RED tubing Black tubing Main DC plug female ...

Page 226: ...ions 2 0 Main Panel AWG 2 0 270 cm AWG 2 0 420 cm AWG 2 0 190 cm E Stop Main DC plug male Use 3 4 NPT SKINTOP connector 72 WH RD 71 RD WH 41 in main panel Handle use 5 16 hole lugs use 5 16 hole lug use 3 8 hole lug ...

Page 227: ...eat Connects to Main Harness 28 cm d3 8 37 cm d3 8 10 cm d1 4 50 cm d1 4 5 cm d1 4 16 cm d1 4 60 BU WH 49 BK BLACK BLACK 50 GY 57 PK 59 YL BK 54 BK 55 BR WH 56 RD YL 58 YL BK 57 PK A B A B 1 3 2 3 1 2 1 3 2 4 5 none none none P E D connector Use male pins on AMP connector yellow seal Switch located under the seat Use insulated spade lugs harness side P E D connector Use male pins on harness side ...

Page 228: ...8 BR 39 GY 40 BK WH 42 PK 3 WIRES TO KEYSWITCH 1 RD WH 2 RD 3 WH BK 3 WIRES TO DIRECTION SWITCH 4 BK 5 WH 6 YL 15 WIRES TO LARGE PLUG UNDER CHAIR 49 BK 50 GY 54 BK 55 BR WH 56 RD YL 57 PK1 57 PK2 58 YL BK 59 YL BK 60 BU WH 62 OR BK 63 GN 64 YL 65 BK WH 66 BK 3 WIRES TO PARKBRAKE 3 pole connector 49 BK 51 PU 52 PK 4 WIRES TO COMSYS 5 pole connector 45 RD 46 GN 47 BK 48 BU 3 WIRES TO FOOTBRAKE 3 pol...

Page 229: ...in conduit runs for JBs Horn R Light L Light Pump Icemaking watertank empty Icemaking watertank half Icemaking watertank full 98 RD YL 97 BK 96 YL 94 BK 95 GRN 94 BK 85 GRAY 81 PINK 86 PINK 87 BRN 88 BK 89 ORNG 86 PINK 87 BRN 94 BK 86 PINK 87 BRN 94 BK 94 BK 87 BRN 87 BRN 86 PINK 86 PINK 23920 9313 Use male pins on harness side where applicable ...

Page 230: ... 23 BK 23 BK 23 BK 23 BK 36 PU WH 35 PU 40 BK WH 39 GY 24 GN BK 25 GN WH 34 OR 38 BR 37 BR WH 31 YL BK 30 YL RD 29 BU 28 BU WH 42 PK 32 GN RD 32 GN RD 27 YL BU 26 WH BU 42 PK CONDITIONER SNOW BIN ELEVATOR TIRE WASH BOARD BRUSH SNOW BREAKER WASH WATER POWER LIGHT SPEED WATER ELEVATOR FWD REV LARGE DASHBOARD PK BK BLACK 3 1 2 50cm 50cm Wrap in 1 4 tubing ...

Page 231: ...G 16 RED 340 cm AWG 8 RED 340 cm AWG 8 BLUE 340 cm AWG 8 WHITE 340 cm 4 CONDUCTOR SHIELDED CABLE 620 cm AWG 16 BLACK 620 cm AWG 16 RED 620 cm AWG 8 RED 620 cm AWG 8 BLUE 620 cm AWG 8 WHITE 620 cm AWG 16 PINK 340 cm M2 Motor RTD M0 Motor RTD M0 Motion control M2 Motion control M0 Motor leads M2 Motor leads Icemaking watervalve SHIELD BROWN WHITE YELLOW GREEN SHIELD BROWN WHITE YELLOW GREEN SHIELD B...

Page 232: ... control 4 COND SHLD CABLE 210 cm AWG 16 BLACK 210 cm AWG 16 RED 210 cm 4 COND SHLD CABLE 195 cm AWG 16 BLACK 195 cm AWG 16 RED 195 cm AWG 8 RED 195 cm AWG 8 BLUE 195 cm AWG 8 WHITE 195 cm AWG 8 RED 210 cm AWG 8 BLUE 210 cm AWG 8 WHITE 210 cm M1 leads RTD and motion control wires go continues through PBM1 Pump Motion control M3 Motion control M1 Motion control SHIELD BROWN WHITE YELLOW GREEN SHIEL...

Page 233: ...U RD WH BU RD 2 x AWG 8 43cm RD 2 x AWG 8 46cm BL 2 x AWG 8 49cm WH 4 Cond cable shielded 58 cm 4 Cond cable shielded 105 cm AWG 8 105cm WH AWG 8 100cm BL AWG 8 95cm RD M3 M2 M1 WH BU RD M3 M2 M1 WH RD BU M1 M2 M3 RD BU WH M1 M2 M3 BU RD WH M3 M2 M1 WH RD BU M 1 M 0 M 2 M 3 Vert Horz Pump MOTOR CONNECTIONS use 4 AWG 1 4 lug use 4 AWG 1 4 lug use 4 AWG 1 4 lug use female connectors on panel side us...

Page 234: ... BK jumper A B C 52 PK 49 BK 51 PU Large connector under seat A 49 BK R B 50 GY Q H 58 YL BK K 62 OR BK I 59 YL BK J 60 BU WH S O 66 BK T N 65 BK WH V U P L 63 GN C 54 BK G 57 PK D 55 BR WH E 56 RD YL F 57 PK M 64 YL Part of Main Harness gasketed side w female pins Jumper Part of Main Harness male pins Part of Main Harness male pins Part of Main Harness male pins ...

Page 235: ...X2 X1 X1 2 4 6 9 3 5 8 7 BK 17 OR 16 RD 8 BR 8 BR 10 PK 7 BK 7 BK 10 PK 10 PK 10 PK 12 YL BK 10 PK 15 YL 14 GN 10 PK 11 BU WH 13 RD BU 9 GY 5 8 7 6 22 WH 21 PU 20 BU 19 GN DMC Display use female pins on harness side use female insulated spade lugs 16AWG ...

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