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The Ultimate Ice Resurfacer

MILLENNIUM

1.10 Maintenance and Repair Regulations

In terms of this manual, maintenance work means all …

• maintenance jobs that have to be done periodically on the OLYMPIA.

• lubrication.

• cleaning.

•

setup and retooling, changing of components / sub-assemblies.

•

Adjustments/setting of the electrical equipment, mechanical parts and hydraulic systems.

•

Before starting the work, cordon off the area in which the maintenance work is to be
done with a red/white safety chain and put up notices that read MAINTENANCE WORK IN
PROGRESS! UNAUTHORIZED ACCESS PROHIBITED. RISK OF INJURY.

After completing the maintenance jobs and before switching on the ice resurfacer, make sure that:

• There is nobody in the danger zone.

•

There are no tools or other parts in the vehicle or on the floor.

•

All safety devices/guards have been duly re-installed and are in proper working order.

•

Adhere to the safety regulations that are specified in the descriptions of the individual

maintenance jobs.

Содержание MILLENNIUM H

Страница 1: ...MILLENNIUM H Owner s Manual...

Страница 2: ...The Ultimate Ice Resurfacer...

Страница 3: ...of its ice resurfacing technology Resurfice Corp reserves the right to change designs models and specifications without notice and without liability for such changes Resufice Corp will not be liable...

Страница 4: ...The Ultimate Ice Resurfacer...

Страница 5: ...efects in material and workmanship In particular repairs and service adjustments that are necessary as a result of negligence misuse collision alteration or lack of reasonable and proper maintenance a...

Страница 6: ...The Ultimate Ice Resurfacer...

Страница 7: ...ation Owner s Name Address Serial Number Frame Number Type of Engine Engine Serial Number ECM Engine Serial Number ECM Transmission Serial Number Wheel Drives FL FR RL RR Fuel System Trans Drive Aux P...

Страница 8: ...asures 6 1 6 Personnel Qualifications 7 1 7 Obligations 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 Fuel Safety 15 1 12 W...

Страница 9: ...ESIGN 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 Contr...

Страница 10: ...oth Installation 60 6 5 Water Filling Procedure 60 6 5 1 Ice Making Water Filling Procedure 61 6 5 2 Wash Water Filling Procedure 62 6 6 Safety Circle Check 63 7 WORKING WITH THE OLYMPIA MILLENNIUM H...

Страница 11: ...r 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 90 9 SELF HELP AND TROUBLESHOOTING 9 1...

Страница 12: ...The Ultimate Ice Resurfacer...

Страница 13: ...time to carefully 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 opera...

Страница 14: ...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 co...

Страница 15: ...he following 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 re...

Страница 16: ...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...

Страница 17: ...nd secured immediately 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 t...

Страница 18: ...tion without the 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 th...

Страница 19: ...e that deals with the operation and maintenance of the machine must carefully read the instruction manuals provided by Resurfice Corp before they operate or service the OLYMPIA Millennium H Only the s...

Страница 20: ...rk The hazards 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 ope...

Страница 21: ...regulations 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 bo...

Страница 22: ...vent it from being switched back on again Turn the key switch to the OFF position and remove the key switch off the battery disconnect switch if equipped 1 9 Safety Devices and Guards Operator Present...

Страница 23: ...ERGENCY STOP In the case of an emergency remove your foot from the accelerator and shift gear into the Neutral position and then into the Park position Turn off the water valves and lift conditioner i...

Страница 24: ...he reason for the shut down has been discovered and corrected The removal of guards or safety devices or rendering them inoperable while the ice resurfacer is in operation is prohibited Guards and saf...

Страница 25: ...The Ultimate Ice Resurfacer 13 MILLENNIUM H Horn Button The horn button is located in the center of the steering wheel hub and will sound when pressed down Fig 1 2 Horn button on the OLYMPIA...

Страница 26: ...on off the area in which the maintenance work is to be done with a red white safety chain and put up notices that read MAINTENANCE WORK IN PROGRESS UNAUTHORIZED ACCESS PROHIBITED RISK OF INJURY After...

Страница 27: ...nce the engine has run out of fuel turn off the engine ignition switch get down from the OLYMPIA H using the three point contact dismount procedure While wearing your PPE disconnect the empty fuel cyl...

Страница 28: ...ition of the new tank start the engine to make sure the propane is flowing At this point if no problems are detected you are ready to use the OLYMPIA SAFETY NOTE We recommend performing at least one i...

Страница 29: ...red an asphyxiate it is lighter than air it is a flammable gas and colorless and odourless in it s natural state it has an odorant added to it Never park the OLYMPIA H directly in the vicinity of a he...

Страница 30: ...enerally 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 refe...

Страница 31: ...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...

Страница 32: ...nnecting routes The OLYMPIA may only be operated on the ice surface when it is completely clear of persons equipment and debris The ice resurfacer operator must stop the ice resurfacer and secure it t...

Страница 33: ...with the tank open Risk of Injury When driving the OLYMPIA Millennium H always proceed with caution When driving in areas with a restricted view or in narrow spaces use horn and drive with a reduced s...

Страница 34: ...cron Oil filter change interval every year at start of season Oil cooling Inline fan assisted oil cooler Oil temperature Max 80 C normal approx 30 C 86 F Emergency hand pump Piston pump 0 15 in 2 5 cm...

Страница 35: ...tip studs Aluminium alloy wheels Tire pressure Front 65 psi 448 16 bar Back 65 psi 448 16 bar 2 5 Conditioner 2 5 1 Blades Ice shaver blade inlaid steel Length 80 96 203 2 243 8cm Width 5 12 8cm Cutt...

Страница 36: ...Resurfacer 24 2 6 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 Polya...

Страница 37: ...mum permitted incline 15 3 2 Room Ventilation Adhere to local standards 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...

Страница 38: ...ce Resurfacer 26 3 5 Garage Temperature Preferably above 15 C 59 F never below 0 C 32 F 3 6 Snow Dump Pit Threshold A threshold at the snow dump pit must adhere to local standards and not exceed 23 58...

Страница 39: ...1 Auxilliary Hydraulic Drive Reservoir Item 2 Wash Water Fill Item 3 Steering wheel Item 4 Driver s seat Item 5 Mounting handles Item 6 Ice Making Water Fill Item 7 Step for climbing up to the driver...

Страница 40: ...nel Item 4 Manual Ice Making Water tap handle Item 5 Wash water tap Item 6 Vertical auger drive motor Item 7 Tail lights Item 8 Horizontal auger drive motor Item 9 Wash Water pump motor Item 10 Spread...

Страница 41: ...platform and the mountings for the conditioner the brush and other parts are part of the chassis The snowbin cover all parts of the hydraulic systems engine transmission water supply and paneling are...

Страница 42: ...e blade to the centre of the conditioner where it is picked up by a vertical auger and is transported into the resurfacer s snow dump tank 4 3 Hydraulic Components A variable flow piston pump supplies...

Страница 43: ...The Ultimate Ice Resurfacer 31 MILLENNIUM H 5 CONTROLS...

Страница 44: ...The Ultimate Ice Resurfacer 32 5 2 Top Control Panel Fig 5 2 Top control panel Item 1 Tachomete Hour meter Item 2 Battery Gauge 1 2 3 5 4 6...

Страница 45: ...The Ultimate Ice Resurfacer 33 MILLENNIUM H Item 3 Oil Gauge Item 4 Service Engine Soon Indicator Item 5 Temperature Gauge Item 6 Low Fuel Indicator...

Страница 46: ...aintain the proper sequence of engagement From Left to right Item 7 Conditioner Up Down Raises and lowers the conditioner To raise the conditioner push and hold the switch UP until the conditioner is...

Страница 47: ...is fully raised When the board brush is raised it will automatically stop rotating Item 10 Wash Water On Off To turn the wash water system on push the bottom of the switch to the down position To turn...

Страница 48: ...ump tank is fully open 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 T...

Страница 49: ...Push the bottom of the switch to turn on push the top of the switch to turn off Item 15 Elevator Reverse To turn the Elevator in reverse push and hold the elevator reverse switch down Item 16 Engine...

Страница 50: ...gearshift lever to the Park position before you leave the driver s platform Prior to starting the OLYMPIA make sure the gear shift lever is in the park position Make sure the ice resurfacer comes to...

Страница 51: ...faster the OLYMPIA Millennium H will go DO NOT press down on the accelerator pedal when starting the engine The hydrostatic drive system automatically stops the 4 drive wheels when pressure on the acc...

Страница 52: ...pump switch mounted under the drivers seat The hand pump on the left enables the raising of the conditioner and snow dump in the case that the engine will not start The hand pump on the right enables...

Страница 53: ...into the N neutral position then insert the hand pump handle into the hand pump labelled brakes and commence pumping that hand pump until you feel a slight resistance on the pump At this point you wi...

Страница 54: ...ice Any excess water and debris is vacuumed back into the wash water tank 5 6 2 Ice Making Water The flow of flood water is controlled by the ball valve at the base of the conditioner Manual Water Val...

Страница 55: ...lever to the right of the operator s seat either right or left to either decrease or increase the flow of flood water 5 7 Blade Level Adjustment The blade adjustment hand wheel located on the tower to...

Страница 56: ...d carefully trim the ends of the squeegee so 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 ar...

Страница 57: ...dling the blade For operator safety and to protect the edge of the blade always use the magnetic blade protector when handling the blade as it is extremely sharp For shipping and storage blades should...

Страница 58: ...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 attachme...

Страница 59: ...e second row of holes should be used when the blade has been ground down to 4 inch approx 10 16 cm overall width Remove the blade hooks and insert the remaining two blade bolts and tighten The Order i...

Страница 60: ...nsecutively 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 f...

Страница 61: ...in a 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...

Страница 62: ...tor arm completely fills the sight hole on the right 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...

Страница 63: ...position which is exactly level with the bottom of the runner Once the blade is at the proper level tighten the nuts on the blade level adjusters Safety Note Be careful when doing the coin check Make...

Страница 64: ...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 Pl...

Страница 65: ...ing 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 Distance A...

Страница 66: ...ring 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...

Страница 67: ...at 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 m...

Страница 68: ...ng 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...

Страница 69: ...ave 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...

Страница 70: ...n both top links Now loosen both top links by turning them counter clockwise until there is no tension Remount the OLYMPIA Millennium H and drive forward six feet 2 meters stop turn off the OLYMPIA Mi...

Страница 71: ...The Ultimate Ice Resurfacer 59 MILLENNIUM H Proper Top Link Adjustment Top Link too long Top Link too short...

Страница 72: ...e towel side of the towel bar or use plastic ties 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 5 Water Filling Proced...

Страница 73: ...d turn on the hot water Warning NEVER leave the resurfacer unattended during the hot water filling procedure Once the water level gauge on the left side of the resurfacer reaches the half way point fo...

Страница 74: ...only 1 Insert the cold water hose into the filling inlet Item 1 on the right side of the ice resurfacer 2 Turn on the cold water and fill until the gauge reaches the fill mark on the gauge on the righ...

Страница 75: ...studs to make sure they are tight and secure in the tire Inspect the lug nuts to ensure tightness and check the tire pressure for proper in ation 1 Inspect the valve block area for leaks Inspect all v...

Страница 76: ...rpentine belt for proper placement and damage 22 Inspect the hydraulic tank sight gauge on the right hand side for proper level and colour of liquid 2 3 3 4 full and bright red in colour 23 Inspect th...

Страница 77: ...he tank for damage as well as the o ring in the tank connection for proper placement ALWAYS WEAR YOUR PPE WHEN CHANGING A LPG TANK 45 Dress the straps of the tanks to ensure the tanks are secure 46 Tu...

Страница 78: ...The bearing should have no play 61 Run your hand on the bottom of the left hand side runner of the conditioner from BACK TO FRONT check for burrs on the runner and note the blade position If there are...

Страница 79: ...r a few minutes to ensure proper operation 78 When operating the LPG crossover make sure to turn it slowly as to not trip the excess ow valve 79 Dial back the RPM Controller until the OLYMPIA is at an...

Страница 80: ...nt to arrange for servicing 7 1 2 To move the ice resurfacer To move the OLYMPIA Millennium H first adjust the engine rpm knob on the top right corner of the dash until the rpm gauge reads between 150...

Страница 81: ...the park brake set the gear lever to park position and turn the ignition switch to the off position before dismounting the OLYMPIA Millennium H 7 1 4 Shifting from Forward to Reverse Always come to a...

Страница 82: ...before moving Next adjust the engines RPM by turning the RPM control clockwise until the engine reaches approximately 1200 RPM Sound the horn to let anyone in the area know you are about to move the O...

Страница 83: ...edure move the OLYMPIA H to the desired parking place in your building IDLE down the engine place the gear selector in the P park position and turn off the engine Be sure to remove the ignition key an...

Страница 84: ...er s seat always turn off all hydraulic functions 7 3 1 Driving with the Board Brush Normally the board brush is used for the first lap around the boards at the beginning of each ice cleaning process...

Страница 85: ...or from the Blue line to the goal line Next turn on the wash water pump by pressing down the wash water switch on the dash To properly turn off the wash water 3 4 of the way from the end of the last...

Страница 86: ...e driver s side With the Ice Making Water tank filled with enough hot water to do a complete resurfacing plus 10 Now drive onto the ice surface and lower the conditioner all the way to the ice surface...

Страница 87: ...g the bottom of the elevator on switch Turn on the ice making water with the manually operated water valve Turn on the Wash Water following the previous instructions first the wash water hand valve an...

Страница 88: ...e board brush until you are all the way past the opening 2 Retract board brush by pushing and holding the board brush switch until it is fully retracted to the side of the OLYMPIA 3 Proceed along the...

Страница 89: ...fter dismounting install the snow dump safety supports Engage the parking brake and turn off the ice resurfacer After stepping down from the ice resurfacer be sure to remove cover plates and wash out...

Страница 90: ...cing The conditioner should be rinsed out after each use Do not hose down the whole ice resurfacer unnecessarily The control panels and the driver s platform may only be cleaned with a damp cloth neve...

Страница 91: ...a hand pump switch mounted under the drivers seat The hand pump on the left enables the raising of the conditioner and snow dump in the case that the engine will not start The hand pump on the right e...

Страница 92: ...he N neutral position then insert the hand pump handle into the hand pump labelled brakes and commence pumping that hand pump until you feel a slight resistance on the pump At this point you will be a...

Страница 93: ...t procedure When working on any of the other hydraulically operated components of the OLYMPIA also secure them with safety bolts or props so that a hazardous situation does not arise in the event of a...

Страница 94: ...tarting the work the employee responsible for doing the work must first ensure that this can be done without endangering people or facility equipment Only after he has done so may he switch the power...

Страница 95: ...f 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 th...

Страница 96: ...e resurfacer as electrical components will be damaged 8 2 3 After 5 Hours Check and torque the lug nuts to 140 Nm 100 ft lb 8 2 4 After 50 Hours Check all drive belts vee belts and re tension them if...

Страница 97: ...m Check the hydraulic oil level in both hydraulic tank Check that all the board guide rollers run smoothly Check the surface of the blade holder in the conditioner and lightly oil it Briefly test all...

Страница 98: ...filter basket from the wash water tank Using a wet vac vacuum out any debris left in the tank Remove the blade and properly store it Oil the blade holder on the conditioner Change the hydraulic filte...

Страница 99: ...The Ultimate Ice Resurfacer 87 MILLENNIUM H 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 4 5 6 7 8 3 1 2...

Страница 100: ...The Ultimate Ice Resurfacer 88 10 9 11 13 15 12 14 16...

Страница 101: ...The Ultimate Ice Resurfacer 89 MILLENNIUM H 20 21 18 19 17...

Страница 102: ...12 Right Side Conditioner Mount Pin Picture 13 Blade Adjustment Screw Bearing Picture 14 Blade Adjustment Nut Bearing Picture 15 Left Side Conditioner Mount Pin Picture 16 Left Side Horizontal Auger...

Страница 103: ...e 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 Replacemen...

Страница 104: ...high concentration of any of these contaminates can degrade machine performance and reduce component lifespan resulting in premature failure The onboard filters remove solid particulate only and are d...

Страница 105: ...ason Rexroth recommends that the hydraulic fluid has to be changed at least every 2 years or every 2000 operating hours or that it has to be analyzed by a laboratory Periodically check operation of th...

Страница 106: ...ced power Confirm the charge pressure temperatures sound levels and hours of service and communicate these and any other abnormalities to the machine manufacturer If the OLYMPIA Millennium H is not dr...

Страница 107: ...ary System Millennium HD Documentation provided by the company DMC Controllers Documentation provided by the company Victron Documentation provided by the company Siemens Documentation provided by the...

Страница 108: ...The Ultimate Ice Resurfacer 96...

Страница 109: ...The Ultimate Ice Resurfacer 97 MILLENNIUM H MILLENNIUM H...

Страница 110: ...els for any new damage Inspect the board brush making sure to check for any dirt or debris stuck in the brush Inspect the roller for free movement Physically grab the board brush arm making sure it is...

Страница 111: ...ter nuts on the valve block must be tight Inspect all hoses in the area for leaks damage and wear nspect the rear right tire and rim for damage nspect the studs to make sure they are tight and secure...

Страница 112: ...side auger bearing for proper operation Take hold of the centre of the auger shaft and move it to check for movement north south east and west The bearing should have no play Run your hand on the bott...

Страница 113: ...perating the LPG crossover make sure to turn it slowly as to not trip the excess ow valve Dial back the RPM Controller until the OLYMPIA is at an idle and turn the OLYMPIA off Fill the ood making wate...

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