Olympia Millennium-E Owner's Manual

Olympia Millennium-E is the latest ice resurfacing machine from Resurfice Corp. It is designed to deliver trouble-free performance and is backed by a two-year warranty. The Olympia Millennium-E is packed with features that make it the perfect choice for any ice rink. These features include an easy-to-use control panel, a powerful engine, and a durable construction. With the Olympia Millennium-E, you can be sure that your ice rink will always be in top condition.

PDF

Document

Owner’s Manual

Welcome to the OLYMPIA Advantage

The OLYMPIA MILLENNIUM – E has been designed and built to deliver trouble free performance.

Like all mechanical equipment however, trouble free operation is based on complete and ongoing maintenance procedures being adhered to in order to validate your Resurfice Corp. warranty.

We have included a maintenance log form at the back of this manual to assist you in maintaining a permanent record of your maintenance program. Please copy this form to provide additional pages as needed.

The operational and maintenance procedures outline a step by step process that should be followed precisely. A variety of safety and performance- enhancing options are available and 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 machine are warranted against defects in material and workmanship by Resurfice Corp., for two full years from the date of delivery.

For continued safe, economic operation and to validate the Resurfice Corp. warranty, the balance of your OLYMPIA ice resurfacing machine should be strictly maintained under the guidelines outlined in this manual.

ALL WARRANTY REPAIRS MUST FIRST BE AUTHORIZED BY

RESURFICE CORP. OR AN AUTHORIZED DEALER

The Ultimate Ice Resurfacer

No warranty on this machine will be honoured by Resurfice Corp. other than that stated above.

Owner´s Name:

Address:

...................................................................................

Serial Numbers:

Ice Resurfacer: ...................................................................................

Battery Charger:

Batteries.:

Water Cart.:

...................................................................................

Controllers.:

FL ................................... FR .......................................

RL ................................... RR .......................................

Auger Vertical ...................................................................................

Auger Horizontal ...................................................................................

Motors:

Gear Boxes:

Auger Vertical ...................................................................................

Auger Horizontal ...................................................................................

The Ultimate Ice Resurfacer

Conditioner Size:

Options:

...................................................................................

The Ultimate Ice Resurfacer

Foreword ......................................................................................................

Declaration of conformity ..................................................................................

1 SAFETY

1.1 Pictograms Used ........................................................................... 3

1.2

1.3

Generally Applicable Safety Instructions .............................................. 4

Proper Use .................................................................................. 6

1.4

1.5

1.6

1.7

Improper Use ............................................................................... 6

Organisational Measures ................................................................. 6

Personnel Qualifications .................................................................. 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 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

2.5

2.6

2.7

Filling Capacities ......................................................................... 21

Electrical System ......................................................................... 21

Brake Systems............................................................................. 22

Hydraulic System ......................................................................... 22

2.8 Water System ............................................................................. 22

2.9 Tires ........................................................................................ 23

2.10 Conditioner ................................................................................ 23

2.10.1 Blades ...................................................................................... 23

2.10.2 Conveyor System ......................................................................... 23

2.11 Materials Used ............................................................................ 24

2.12 Ice Edger ................................................................................... 24

The Ultimate Ice Resurfacer

3 ON-SITE CONDITIONS

3.1 Ground Conditions ....................................................................... 25

3.2

3.3

Room Ventilation ......................................................................... 25

Water Connections ....................................................................... 25

3.4

3.5

3.6

3.7

Water Quality ............................................................................. 25

Charger .................................................................................... 26

Garage Temperature ..................................................................... 26

Snow Dump ................................................................................ 26

4 DESIGN AND FUNCTION

4.1 Ice Resurfacer Design and Chassis ..................................................... 27

4.2

4.3

Snow Conveyor (Auger)

Hydraulic Components

.................................................................. 30

................................................................... 30

5 CONTROLS

5.1 EMERGENCY Shut Off Switch ............................................................ 31

5.2

5.3

Top Control Panel ........................................................................ 32

Bottom Control Panel .................................................................... 35

5.4

5.5

5.6

5.7

Ice Making Water Control Panel

Wash Water Control Panel

........................................................ 41

.............................................................. 43

Foot Pedals and Parking Brake ......................................................... 45

Controls for the Water ................................................................... 47

5.7.1 Ice Making Water ......................................................................... 47

5.8 Controls for the Hydraulic System ..................................................... 48

The Ultimate Ice Resurfacer

6 START UP OF THE OLYMPIA ICEBEAR

6.1 Charge the Batteries ..................................................................... 49

6.2

6.3

Installation of the Squeegee ............................................................ 52

Blade Installation ......................................................................... 53

6.3.1 Blade Level Adjustment ................................................................. 57

6.4 Horizontal and Vertical Augers ......................................................... 60

6.4.1 Horizontal Auger Adjustment ........................................................... 60

6.4.2 Auger Drive Chain Adjustment ......................................................... 62

6.4.3 Down Pressure Check

6.6

.................................................................... 63

6.4.4 Down Pressure Adjustment.............................................................. 64

6.4.5 Top Link Adjustment ..................................................................... 65

6.5 Spreader Cloth Installation ............................................................. 67

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 Edger ................................................................. 75

7.2.2 Driving with the Board Brush ........................................................... 76

7.2.3 Water Application ........................................................................ 76

7.3 Resurfacing Procedure ................................................................... 78

7.3.1 Cleaning the Ice Resurfacer after an Ice Resurfacing Operation .................. 80

The Ultimate Ice Resurfacer

8 CLEANING AND MAINTENANCE

8.1 Cleaning and Maintenance Safety Instructions ...................................... 81

8.2 Maintenance Checks ..................................................................... 83

8.2.1 Daily ........................................................................................ 83

8.2.2 Every Time the Blade is changed 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

9.3

Edger Adjustment ........................................................................ 90

Squeegee Replacement .................................................................. 90

9.4 Towel Replacement ...................................................................... 90

9.5 Blade Replacement ...................................................................... 90

10 Appendix .................................................................................................

The Ultimate Ice Resurfacer

Dear User!

Before you put your OLYMPIA Ice Resurfacer into operation, please take the 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 operation of the ice resurfacer,

• Trouble-free operation of the machine.

Always keep the operating manual in the vicinity of the ice resurfacer.

The Ultimate Ice Resurfacer

Note:

We reserve the right to make changes in content. Resurfice Corp. accepts no liability for any errors, omissions and or misinterpretations of the material in this documentation. Liability for indirect damages arising from the supply and use of this documentation is excluded, unless required 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.

25 Oriole Pkwy E, Elmira, Ontario Canada N3B 3A9

The Ultimate Ice Resurfacer

1 SAFETY

1.1 Pictograms Used

Throughout the texts in this manual and in part, on the ice resurfacer itself, you will find, among other things, the 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 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.

The Ultimate Ice Resurfacer

1.2 Generally Applicable Safety Instructions

• Please study the operating manual with due attention before starting the first resurfacing operation. Always remember that you are responsible for an ice resurfacer that weighs several tons.

• The ice resurfacer has been built and designed in compliance with Canadian and international safety standards, so that it can be used without risk.

• To operate the ice resurfacer safely, you must follow the safety instructions.

• The OLYMPIA may only be operated when there 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 responsibility to select the appropriate settings for operation of the OLYMPIA.

• Wherever necessary, safety circuits and safety devices are installed and are active.

Therefore, no modifications and conversions may be undertaken on the ice resurfacer, nor must the safety circuits and devices be modified in any way, or rendered inoperable.

• The OLYMPIA must be inspected at least once a day for visible signs of damage! Any changes, including changes in the operating behaviour must be reported to the responsible department or person immediately! The ice resurfacer must be switched off and 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 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 also applies for damage caused as a result of improper or unauthorized use of the machine.

The Ultimate Ice Resurfacer 5

1.3 Proper Use

The OLYMPIA ice resurfacer has been manufactured exclusively for the resurfacing of ice surfaces. Do not use the OLYMPIA for any other purpose.

Only duly authorized and trained drivers may operate the OLYMPIA.

All information and instructions given in this documentation must be adhered to without fail.

The Ultimate Ice Resurfacer

1.4 Improper Use

The following are deemed to be improper use:

• Operation 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 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 readily accessible to the operators and maintenance personnel!

• The personnel employed to work with and on the ice resurfacer must have read the operating manual before starting any work. This applies in particular for personnel who

only work occasionally on the machinery, e.g. for setup or maintenance purposes.

• Maintenance personnel must tie back long hair, and must not wear loose clothing or jewellery, including rings, when working on the machine. There is a risk of injury, e.g. by getting caught on or pulled into the machinery.

• The prescribed schedules, or those specified in the operating manual for periodic checks/ inspections must be adhered to!

• Local safety standards must be adhered to as well as recommendations in this document.

The Ultimate Ice Resurfacer

1.6 Personnel Qualifications

• Every OLYMPIA has a variety of built-in safety functions. To prevent accidents from occurring, everyone 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.

• 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 must be strictly followed when operating, maintaining and shutting down the ice resurfacer. Failure to adhere to the instructions can lead to accidents resulting in personal injury and material damage.

• The personnel are instructed both verbally and in writing, the emergency shut off switch must be switched off before disconnecting the battery connector (to avoid sparking). The emergency shut off switch must be switched on after connecting the battery charger.

• The driver is instructed both verbally and in writing, that he must wear the seatbelt if equipped at all times when operating OLYMPIA.

The Ultimate Ice Resurfacer

• Resurfice Corp. recommends that the user holds regular training courses, in which special emphasis must be placed on the hazards and safety measures. The service personnel must be instructed about the specific hazards in association with the maintenance and repair of the ice resurfacer. This instruction must be repeated at regular intervals, at least once a year.

• The employees must wear protective gloves when doing maintenance and repair work. 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 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 certified in accordance with the following charts.

Person

Job

Operation

Troubleshooting

Mechanical fault rectification

Electrical fault rectification

Maintenance

Repair

Instructed persons

Qualified technicians

Qualified electricians

Authorized Service personnel

The Ultimate Ice Resurfacer

1.7 Obligations of the User

The User must ensure that…

• The ice resurfacer is only used in the proper manner,

• The ice resurfacer is only operated when it is in perfect working order,

• The integrated safety devices are regularly maintained and checked for proper function,

• The operating manual is supplemented with all generally applicable, statutory and other binding accident prevention and environmental protection 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 boots, and also nonslip 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-specific particulars, such as work organization, operational procedures, employed personnel, etc.

• It is checked, regularly, that the personnel are working in a safe and hazard-conscious manner and are adhering to the instructions given in the operating manual!

The Ultimate Ice Resurfacer

1.8 Operator’s Workplace

Operation of the ice resurfacer is done solely from the driver’s seat on the driver’s platform.

Before doing any jobs of longer duration on moving parts, switch off the power and depressurise the systems at the vehicle and take suitable measures to 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 stopped after a delay of 8 seconds, so that the OLYMPIA cannot be operated without the driver in the seat.

EMERGENCY STOP

The EMERGENCY shut off button can be used to shut down the whole ice resurfacer in an emergency. The EMERGENCY shut off button is located at the front left, in front of the steering wheel.

Switch-Off: Depress the knob on the switch to shut off the power (disconnect the circuit).

Switch-On: To switch the ice resurfacer back on again, pull out the knob until 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 ice resurfacer is switched off too, with the exception of the battery discharge indicator.

The Ultimate Ice Resurfacer

Limitation: The (+) contact of the EMERGENCY STOP switch still carries the potential of the

(+)Ub port of the battery!

The Ultimate Ice Resurfacer

Charging of the battery is also interrupted when the Emergency shut off switch is pressed. If the charger is not working, please first check whether the Emergency shut off switch has been pressed.

Caution!

Do not attempt to operate the ice resurfacer until the reason for the shut down has been discovered and corrected.

If the EMERGENCY STOP circuit is activated, all 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 main switch has been turned off and measures taken to prevent it from being switched back on again, and after the ice resurfacer has been depressurised.

Tools are needed to open all covers and panels.

The Ultimate Ice Resurfacer

Horn Button

The horn button is located 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)

The Ultimate Ice Resurfacer

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.

• Never open the control cabinet and/or any electrical components while power is being supplied to the machinery.

• The battery connector must be disconnected before doing any work 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 snow dump tank. Carry the key on your person. Put up a notice on the ice resurfacer that says, DO NOT START.

• 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.

The Ultimate Ice Resurfacer

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 more tools or other parts in the vehicle.

• 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.

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.H.A. manual or Directive

91/157/EEC or to your local battery disposal regulations).

For more information, please contact your local waste disposal authorities.

The Ultimate Ice Resurfacer

1.12 Remaining Hazards

Risk of Injury!

The ice resurfacer operator must be in possession of all his mental and physical faculties to ensure that nobody gets run over (i.e. he must not have consumed alcohol, taken pills or other medication, or taken drugs).

Risk of Falling and Risk of Injury!

The carrying of passengers on the ice resurfacer is strictly prohibited, as they could fall off the machine and sustain injury.

Risk 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 blade. Because the blade is extremely sharp, for your own safety and to protect the sharp edge of the blade, always use the magnetic guard.

NEVER leave the OLYMPIA unattended when filling it with water, because hot water could leak out and injure someone.

The Ultimate Ice Resurfacer

Risk of Injury!

Make sure that there are no people or objects in the work and driving area.

Danger!

Do not spray the machine with a water hose to clean it, because this can lead to electrical faults.

Risk of Explosion!

Ensure proper ventilation during the charging process. Escaping hydrogen gas could lead to an explosion.

Risk of Short Circuiting!

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 the handbrake and the ice resurfacer will not move.

Failure to follow this procedure will result in the ice resurfacer rolling down the incline when the handbrake is released.

The Ultimate Ice Resurfacer

Risk of Injury!

Before switching on the OLYMPIA , it is necessary to make a complete circle check of the ice resurfacer.

Always use extreme caution when driving the OLYMPIA from the service area onto the ice surface (and vice-versa), as there could be people on the connecting routes.

The OLYMPIA may only be operated on the ice surface when it is completely clear of persons and debris.

The ice resurfacer operator 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 hazardous situation, depress the emergency shut off switch immediately, if any other controls fail for any reason.

Risk of Getting Crushed!

There must not be any people in the vicinity of the OLYMPIA when the ice shavings are being unloaded.

The Ultimate Ice Resurfacer

Risk of Getting Crushed!

If other people enter the area during the unloading process, the ice resurfacer movements must be stopped and may only be resumed after these people have left the area again.

Risk of Falling!

Proceed with extreme caution when moving the ice resurfacer around or near the stationary snow dump area.

Risk of Getting Crushed!

When doing maintenance or repair work in the area under 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 on public roads and highways.

Risk of Getting Crushed!

There is an increased risk of accident when doing maintenance and repair work, because safety devices may have to be put out of action, while performing any diagnostics or repairs.

The Ultimate Ice Resurfacer

2 TECHNICAL DATA

2.1 Dimensions

With snow bin closed:

Width with 84 inch Conditioner ........................................................

88” / 224cm

Width with 96 inch 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

The Ultimate Ice Resurfacer

Gross weight (incl. 770 Ah batteries and full water tanks) .............

12,853 lbs / 5,830 kg

Front axle .........................................................................

4,828 lbs / 2,190 kg

Rear axle ..........................................................................

8,025 lbs / 3,640 kg

2.3 Noise Emission

Note: Ambient noise level 56 dB (A)

Readings taken on ice with dasher gates closed

Standing noise (hydraulic pump running only) ...........................................

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 ft³ / 2.9 m³

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 Imp gal / 22.75 l

2.5 Electrical System

Battery voltage ..................................................................................... 80 V

Battery capacity ......................................................................... up to 770 Ah

Total power ..................................................................................... 17.4 kW

The Ultimate Ice Resurfacer

2.6 Brake Systems

Operating principle: ................................................ Full disk brake at each wheel

Brake pads: .............................................................................. asbestos-free

Application:

Main brake: ....................................................................................Hydraulic

Parking brake: ...............................................................................Mechanical

2.7 Hydraulic System

Hydraulic fluid: ........................................................................ATF 55 F-30589

Oil change interval: ...........................................................Approx. every 3 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 in³ / 2.5 cm³/stroke

Steering: .......................................................................Load sensing hydraulic

2.8 Water System

Water Pumps:

Speed Related Water: ................................................................. Impeller pump

26.9 Imp gal/min (123 L/min) at 2,450 rpm

Tire wash pump: ....................................................................... Impeller pump

8.7 Imp gal/min (40 L/min)

The Ultimate Ice Resurfacer

Wash water: ............................................................................ Impeller pump

51.3 Imp gal/min (234 L/min) at 1,750 rpm

2.9 Tires

Tire size:

Tubeless: ....................................................................

HANKOOK DYNAPRO M/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

The Ultimate Ice Resurfacer

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

3 ON-SITE CONDITIONS

3.1 Ground Conditions

Level, solid floor covering, preferably with spike-friendly overlay.

Maximum permitted incline: 15 %

3.2 Room Ventilation

In accordance with OSHA (North America), VDE (Europe) and local codes, the battery rooms should be designed 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”.

The Ultimate Ice Resurfacer

3.4 Water Quality

• Clean water with low total grains of hardness.

• Ice making water temperature as hot as local codes will allow.

• Wash water: cold only.

The Ultimate Ice Resurfacer

3.5 Charger

Mains connection:

North America: 208, 480, 550, 600 volt, 3 phase fused disconnect.

Europe: Wall socket : 400 V/3~+N+PE 32 A 5-pol. CEE-Norm.

Charger cable:

15’ (4.5m) long, battery connection plug is located under snow dump 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 the snow dump pit must not be more than 23” (58.5cm)

4 DESIGN AND FUNCTION

4.1 Ice Resurfacer Design and Chassis

1 2 3

The Ultimate Ice Resurfacer

Fig. 4.1: Front view with open 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

The Ultimate Ice Resurfacer

2 3 4 5

Fig. 4.2: Rear view of the OLYMPIA ICEBEAR

Item 1

Item 2

Item 3

Item 4

Item 5

Item 6

Item 7

Item 8

Handle for climbing up to the driver’s seat

EMERGENCY SHUT OFF switch

Steering wheel

Top control panel

Manual Ice Making Water tap handle

Electrical control cabinet door

Tail lights

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

The OLYMPIA is available in either mainly structural stainless steel, or structural black steel chassis design. This applies to the chassis, the conditioner, the snow dump tank, the frame of the snow tank cover, the steel structure of the driver’s platform and all metal parts that, for technical reasons, should not be manufactured from any other material.

The electrical control cabinet is made of aluminium.

Self-supporting chassis

The chassis consists of 5/16” thick structural steel tube. It is supported on the front and rear axles. The front axle is designed as a floating axle. The rear axle is designed as part of the main chassis welded directly to the main frame rails. As well the battery holders, the driver’s platform and the mountings 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 Ultimate Ice Resurfacer

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 spindles attached via upper and lower king pins. They absorb all radial forces. The vertical forces are absorbed by a bearing ring. This extends the serviceable life of the bearing assembly.

Coupling of the front drives consists of two solid, adjustable steering links, which are connected to the gears via link fittings.

Steering is controlled by a hydraulic cylinder that is mounted between the steering links of the front wheels at the axle. In conjunction with a hydraulic orbit control and the hydraulic pump, this arrangement ensures smooth and low-maintenance steering.

The Ultimate Ice Resurfacer

Body Panels

All panels are made of glass fibre-reinforced plastic (GRP).

4.2 Snow Conveyor (Auger)

The horizontal auger in the conditioner transports the snow that has been scraped off the ice by the blade to the centre of the conditioner, where it is picked up by a vertical auger and is transported into the OLYMPIA’S snow dump tank. To switch on the horizontal and vertical augers, press the switch ELEVATOR 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 ice resurfacer with oil for the operation of a series of control valves for movement control, and control of the flow of hydraulic fluid to the various components as needed. The hydraulic system must only be serviced by qualified personnel.

5 CONTROLS

The Ultimate Ice Resurfacer

Fig. 5.1: EMERGENCY Shut Off Switch

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.

5.2 Top Control Panel

1 3 3 4 5 6

The Ultimate Ice Resurfacer

2 3

Fig. 5.2: Top control panel

Item 1 Horn Button

Press this button to sound the horn.

This button turns the headlights and tail lights on and off.

Push and release to turn on, repeat to turn off.

Item 3

Item 4

Ice Making Water Indicator

When the tank is full the green light will come on. If equipped, simultaneously the auto water fill valve will shut off the flow of water filling the tank. The yellow light will stay on until ½ of the tank capacity is used. Again if equipped simultaneously the auto water fill valve will shut off the flow of water filling the resurfacer, if the ½ full selection was used during the filling procedure. The red light will come on when the ice making water tank is empty. Simultaneously it will turn off the speed related water pump. When the red light first comes on there is approximately 100 litres of water in the tank.

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.

The Ultimate Ice Resurfacer

The accumeter is equipped with a digital LCD display. This will display the remaining capacity of the batteries. By pushing the white button it will change to operating hours. By pushing the white button a second time it will display hours until the next service is needed. A third push of the button will display operating temperature. A slashing red light in the right corner will indicate low electrolyte level.

For more information, please refer to the documentation provided by the manufacturer,

Elektron.

The Ultimate Ice Resurfacer

Item 6 Dashboard Display

Item 1

Item 2

Item 3

Item 4

Item 5

Display field for display of the speed.

Operating hours counter: can be activated using the display buttons.

Soft keys to set functions such as service intervals, operating hours counter and the customer information field.

Battery discharge status indicator

Indicates the discharge status of the battery.

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, DMC.

The Ultimate Ice Resurfacer

5.3 Bottom Control Panel

7 8 9 10 11

Fig. 5.3: Bottom control panel

13 14 15 16

The Ultimate Ice Resurfacer

The bottom control panel has been configured that the top row of switches is on ice and in a specific order to maintain the proper sequence of engagement. From Left to right.

Item 7

Item 8

Conditioner Up/Down

Raises and lowers the conditioner

To raise the conditioner, 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.

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 ignition key or with the EMERGENCY SHUT OFF switch, the augers must be restarted again.

The Ultimate Ice Resurfacer

Item 9 Board Brush

Raises and lowers the board brush.

To lower the board brush push the switch down.

When the brush is lowered, it will automatically start to rotate.

To raise the board brush lift and hold the switch in the up position until the board brush is fully raised.

When the board brush is raised, it will automatically stop rotating.

Item 10

Item 11

Wash 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.

Speed Water

To turn on the speed related water system push the button in, the button will light up green indicating the pump and valve have been energized.

To turn off push the button again and the green light as well as the pump and valve will turn off.

The Ultimate Ice Resurfacer

Item 12 Snow Bin Up/Down

Opens and closes the snow dump tank.

To open the snow dump, lift and hold the switch up until the snow dump tank is fully open.

Before opening the snow dump tank make sure there is sufficient clearance as the snow dump tank will move forward and up.

To close the snow dump tank hold down the down switch until 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 water can drain from the tank.

Item 13 Tire Wash

Push the button in and hold to activate the tire washing system.

Let the button out to deactivate the tire washing system.

The Ultimate Ice Resurfacer

Item 14 Snowbreaker Override

Is a backup system which allows for the manual operation of the snowbreaker.

Pushing the switch down will move the snow breaker down.

Lifting the switch up will raise the snow breaker.

Item 15 Power On Light

When 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: Neither auger turns

Hold in right switch position: Both augers reverse

The Ultimate Ice Resurfacer

Item 17 Gear Shift Lever

Unless moving the ice resurfacer, always make sure the gear shift selector is in the neutral position. To move the ice resurfacer forward move the gear shift selector to the forward position. To reverse the ice resurfacer, move the gear shift selector to the reverse position.

F = Forwards

N = Neutral

R = Reverse

Always move the gearshift selector to the centre position (neutral position) before you leave the driver’s platform.

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 the ignition key to the left or OFF position to switch it off again.

The ice resurfacer can be switched off with the EMERGENCY SHUT OFF

(Fig. 5.1) at any time.

When the ice resurfacer is switched off, all functions are shut down, except for the automatic water fill stations.

5.4 Ice Making Water Control Panel Optional

19 20 21

Fig. 5.4: Ice Making Water control panel

Item 19 Indicator lamp for water tank level HALF FULL

Item 20 Selector switch

Item 21 Indicator lamp for water tank level FULL

This panel controls how much hot water can be put into the ice resurfacer.

The ice resurfacer is supplied with an electric water valve, to be mounted onto the water supply line in the building. Power for this valve is supplied from the ice resurfacer. Once mounted 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 Ultimate Ice Resurfacer

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 switch there is a yellow indicator lamp (Fig. 5.4, Item 19) for half filling the water tank. At the right there is a green indicator lamp (Fig. 5.4, Item 21) for completely filling the water tank. To select the desired fill level, turn the selector switch (Fig. 5.4, Item 20) in the appropriate direction.

The Ultimate Ice Resurfacer

The filling process can be interrupted or stopped at any time by turning the selector switch to the centre 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 Ice Making Water Line

First connect the water line to the water fill pipe on the side of the dash and then connect the solenoid valve to the supply socket on the panel. Turn the fill level selector switch to the desired setting (full 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:

Turn the selector switch to the neutral position.

Pull the plug out of the socket.

Disconnect the hose from the ice resurfacer.

This procedure prevents the solenoid valve from opening before the water hose is connected to the ice resurfacer when the next fill takes place, thus preventing water from pouring out in an uncontrolled manner.

When the ½ or full mark is reached, the solenoid valve shuts off the supply of water.

When the solenoid valve is open, a pressure difference of at least 0.5 bar (7 psi) 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 larger water hose therefore works better than a large valve in a small pipe at low pressure!

5.5 Wash Water Control Panel

The Ultimate Ice Resurfacer

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 Ultimate Ice Resurfacer

The water hose behind 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 of the cold water supply line is connected at the Wash Water panel. To switch the wash water supply ON or OFF, turn the switch (Fig. 5.5, Item 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 to the supply socket on the panel. When the water tank is full, the solenoid valve automatically turns off the water.

Always be sure to insert the fill hose into the ice resurfacer first.

The Ultimate Ice Resurfacer

Disconnection of the Wash Water Line

Proceed in the following order to disconnect the water hose from the ice resurfacer:

1. Turn the selector switch to the OFF position.

Pull the plug out of the socket.

Disconnect the hose from the ice resurface.

This procedure prevents the solenoid valve from opening before the water hose is connected to the machine when the next fill takes place, thus preventing water from pouring out in an uncontrolled manner.

When the solenoid valve is open, a 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 area of the ice resurfacer:

Accelerator Pedal

The right foot pedal is the accelerator pedal and is used to control the driving speed of the machine.

Initially press the foot pedal just a little to switch on the hydraulic motor for the power steering. The more you press down on the pedal, the faster the OLYMPIA travels.

The Ultimate Ice Resurfacer

The accelerator pedal must not be pressed when you turn on the ice resurfacer, otherwise the controller will assume there is a fault and will not turn on.

Before pressing the accelerator pedal, it is essential that you first turn on the ignition with the key. And when ready select the direction in which you want to travel.

Brake Pedal

The left foot pedal 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 wheels. If movement of the ice resurfacer is started while the parking brake is applied, the controller switches to CREEP MODE (very low speed) to keep from damaging the wheel drive motors.

5.7 Controls for the Water

There must always be enough wash water available to be vacuumed up. The pump must not be allowed to run dry, because the impeller and shaft seal assembly is water-lubricated.

The wash water is sprayed directly out of the water tank onto the ice by a spray pipe on the back inside wall of the conditioner. When the wash water system is started, cold water is distributed in the conditioner over the whole width of the conditioner, creating slush.

The squeegee then forces the slush into the cuts on the ice. Any excess water and debris is vacuumed back into the wash water tank.

5.7.1 Ice Making Water

The flow of flood water is controlled either by the speed-related pump, or by the ball valve at the base of the conditioner (Manual Water Valve). 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 of cut to achieve a smooth surface. Which in turn, results in minimal ice build-up.

This means less time spent on ice maintenance and less wear and tear on the resurfacing equipment.

The Ultimate Ice Resurfacer

Speed Related Water

The automatic flow of water depends primarily on the speed at which the ice resurfacer is being driven, and secondarily on the internal water valve setting. The lowest quantity of water flows when the ice resurfacer is at a standstill, the highest quantity when the ice resurfacer is driving at full speed. This automatic function reduces the flow of water in the curves to an adjustable minimum.

The Ultimate Ice Resurfacer

Manual Ice Making Water Flow

The manual water function allows water to be applied to the ice at a constant rate, regardless of the speed at which the ice resurfacer is travelling. It can also be used to supplement the speed related water.

5.8 Controls for the Hydraulic System

Switching the Hydraulic Pump Motor On and Off

There are two ways of switching on the hydraulic pump motor:

By pressing the accelerator pedal.

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 approx. 20 seconds after the accelerator pedal was last pressed, or as soon as you let go of a function switch.

The Ultimate Ice Resurfacer

6 START UP OF THE OLYMPIA MILLENNIUM - E

6.1 Charge the Batteries

Before you can start work with the OLYMPIA, you must charge the battery. A battery charger is supplied with the ice resurfacer for this purpose. This charger is designed to fully recharge a battery that has been drained as close to 0% on the accumeter as possible.

Raise the snow dump tank fully and install the safety support bars.

The battery charger will indicate connect battery.

Push down the EMERGENCY SHUT OFF switch.

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. Gassing emits dangerous hydrogen gas.

5. Pull up the EMERGENCY SHUT OFF switch.

The EMERGENCY SHUT OFF switch must be pulled up, otherwise charging will not take place.

The Ultimate Ice Resurfacer

6. In North America the charger will automatically start. For other countries it may be necessary to manually start the charger.

The battery charger switches off automatically when the battery is fully charged.

7. When recharging is complete, depress the EMERGENCY SHUT OFF switch, disconnect and store the charger cable from the ice resurfacer’s power supply connection.

If the charging operation has to be interrupted for any reason, turn off the charger before disconnecting the charger plug.

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 batteries.

Check the electrolyte level in the batteries once a week immediately after recharging. Top it up, if necessary.

The battery water level is correct when all of the cell floats are visible. Periodically check the specific gravity with a hydrometer. In the log supplied, record water filling and specific gravity reading.

The Ultimate Ice Resurfacer

Watering The Batteries:

A battery watering cart is supplied with each ice resurfacer.

1. Connect the hose coupling to the respective battery trays.

Turn on the pump in the cart.

The batteries are automatically filled with distilled water until the float valve at the individual battery cells stop the filling process. The water 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.

Recharge uninterrupted for 7-8 hours.

If at all possible do not attempt to charge the battery between resurfacings

(opportunity charge).

Opportunity charging, although sometimes may be necessary should be avoided as it decreases the overall life of the battery.

6.2 Installation of the Squeegee

Mount the squeegee on the inside of the conditioner with the bolts and nuts provided. .

If not already trimmed, 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 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

Squeege

The Ultimate Ice Resurfacer

Fig. 6.1:

Conditioner

Installation of the squeegee

Item 1

Item 2

Item 3

Conditioner

Squeegee

Squeegee clamp bar

The Ultimate Ice Resurfacer

6.3 Blade Installation

Insert safety blocks under the conditioner before attempting to work under it.

Place the blade on small wood blocks(4) at the rear of the conditioner, remove it from the wood sheath and install the magnetic protector supplied with the tool kit.

Using the blade hook, lift and slide the blade underneath the conditioner and lift against the bladeholder until the attachment holes line up.

Tighten the blade hook thumb screws(2) so that the slide bracket(1) sits on top of the conditioner.

1 -

Fig. 6.2: Installing the blade

Item 1

Item 2

Item 3

Item 4

Bracket

Thumb screw

Blade hook

Wooden blocks

The Ultimate Ice Resurfacer

Install the blade bolts and finger tighten remembering to utilize the row of holes 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.

The Ultimate Ice Resurfacer

There are two ways of properly tightening the blade bolts:

Blade Bolt Sequence “A”

Sequence A – starting at one end of the blade, tighten the bolts consecutively 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.

Wrong Sequence

Please note: Tightening the bolts in any other order, such as from the end to the middle or at random will result in a warped blade and uneven ice.

The Ultimate Ice Resurfacer

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.

Blade Holder

Blade

6.0

Blade Holder Tapered 1/16” to 0

1/16" (0.16 cm)

1/16

6.3.1 Blade Level Adjustment

The next step is to adjust the angle of the blade. The blade adjustment crank, located on the tower to the right of the operator, raises and lowers the blade. The adjustment crank is turned until the indicator arm completely fills the sight hole at the side of the conditioner as shown below.

The Ultimate Ice Resurfacer

5 - 1

Item 1

Item 2

Item 3

Item 4

Item 5

Sight hole

Indicator arm

Blade holder

Blade

Blade level adjuster

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.

The Ultimate Ice Resurfacer

Then turn the nuts to raise or lower the blade into the proper 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 adjuster nuts.

When the ends 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 coin from back to front as the blades are extremely sharp.

The sharp tip of the blade should be flush with the runners on both sides. If the blade is flush the coin will slide smoothly over the blade edge.

Blade/ Coin check

The Ultimate Ice Resurfacer

3 2 1

Fig. 6.4: Place a coin underneath

Item 1

Item 2

Item 3

Blade

Coin

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.

Test drive the OLYMPIA doing a dry cut. If the blade is properly set up you will see a feathered edge on the ice surface on both sides of the conditioner. If the feathered edge on both sides of the conditioner is not an equal distance from the runners on both sides of the conditioner, stop, dismount, and adjust the driver’s side , up or down, until the feathered edge is equal distance from the runners on both sides of the conditioner.

After the blade angle and level are 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.

Feathered Edge

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 picks it up and transports it to the snow bin in the front of the OLYMPIA.

The Ultimate Ice Resurfacer

6.4.1 Horizontal Auger Adjustment

The horizontal auger should be approximately 1/8th” (3mm) above the bottom of the runners to maximize snow pick up while at the same time preventing any marking of the ice surface.

The Ultimate Ice Resurfacer

Auger Height Adjustment

The horizontal auger is adjusted by loosening the four outer bolts on the bearing adjustment plate on each end of the auger and the four bolts for the auger motor mount. This can be checked by running a piece of string 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 surface at the end of the resurfacing.

6.4.2 Auger Drive Chain Adjustment

The horizontal auger drive chain should be kept at a reasonable tension 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 motor mount plate bolts and adjust the motor mount until you get the proper tension.

The Ultimate Ice Resurfacer 62

The Ultimate Ice Resurfacer

Vertical Auger

There is only one adjustment to be made on the vertical auger, look into the inspection plate where the auger connects to the motor, the space between the coupling halves should be no more than 1/6th” (1.5mm).

Generally if the space is more than that it might be necessary to replace the bushing in the bottom of the vertical auger.

6.4.3 Down Pressure Check

Raise the blade to above the runners by turning the adjustment crank counter clockwise.

With the conditioner in the UP position, drive the OLYMPIA onto the ice surface.

Lower the conditioner to the ice surface by pushing 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 the ice surface and the conditioner lift arms are against the down pressure stops.

For proper traction and control the rear tires of the OLYMPIA should be in full contact with the ice surface, the entire width and 5” (12.7cm) of the circumference of the tire should be flat on the ice.

It is important to have the correct tire pressure 85 psi (5.8bar) in the tires prior to checking and adjusting the conditioner down pressure.

6.4.4 Down Pressure Adjustment

To adjust the down pressure, stop the OLYMPIA, place it in park and lower the conditioner until it is almost touching the ice surface.

Properly dismount and turn the down pressure stop bolts in (clockwise) 5 full turns.

Remount the OLYMPIA, lower the conditioner until 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 corners.

The Ultimate Ice Resurfacer

Down Pressure

Adjustment Bolt

Please Note: Every time you reset the down pressure you have to reset the top link adjustment.

The Ultimate Ice Resurfacer

6.4.5 Top Link Adjustment

Check to make sure the entire lenght of the runners are still on the ice surface.

Drive the OLYMPIA once around the rink.

When the top link is adjusted properly the rear tires should leave a full tread pattern on the ice.

Please Note: It is essential for proper operation that rear tire pressure be maintained at 85 psi

(5.8 bar).

To test the top linkage, first loosen the lock nuts 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 front of the runners are still on the ice surface. When properly adjusted the runners will not leave any marks on the ice surface.

Please Note: It is essential that you adjust both top links at the same time, and in the same direction.

The Ultimate Ice Resurfacer

Proper Top Link Adjustment

Top Link too short

Top Link too long

6.5 Spreader Cloth Installation

1. Install the towel on the backside of the towel bar with the 3/8” hex head bolts and locknuts, making sure the nuts are on the towel side of the towel bar.

Place the towel bar assembly onto the towel lift guides.

Attach towel lift chains between the towel bar and towel lift arm.

The Ultimate Ice Resurfacer

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.

The Ultimate Ice Resurfacer

6.6.1 Ice Making Water Filling Procedure

To fill the ice making water tank, insert the hot water hose into the filling inlet (Item 1) on the left hand side of the OLYMPIA.

Plug the solenoid valve plug into the socket on the Ice making water fill station (Item 2).

Select whether you want to half-fill or completely fill the tank.

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.

Return the switch to the OFF position, pull out the solenoid valve plug and remove the hose from the filling inlet.

The Ultimate Ice Resurfacer

6.6.2 Wash Water Filling Procedure

Always fill the wash water tank with cold water only.

1. Insert the cold water hose into the filling inlet (Item 1) on the right side of the ice 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.

Turn the switch to the ON position, the water then begins to flow.

The filling procedure ends automatically when the tank is full.

Turn the switch to the OFF position, pull out the solenoid valve plug and remove the hose from the filling inlet.

The Ultimate Ice Resurfacer

6.7 Safety Circle Check

Do a smell check

Turn on the lights

Be sure battery charge is complete. Check to make sure battery charger is turned off.

Remove the ignition key.

Depress Emergency Shut Off switch.

Disconnect the battery cables and store.

Reconnect the internal power supply cables.

Make sure the front bumper wheel spins freely.

Check lug nuts and tire pressure and general condition of tire and studs on left front wheel.

10. At front of ice resurfacer check the body for damage

11. Look under ice resurfacer for any leaking fluids, debris and make sure no one is working under the ice resurfacer.

12. Check 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 front of the conditioner.

16. Check the runners for burrs that would leave scratches on the ice surface. Make sure you go the full length of the runner. The runner should have no nicks or scratches on it and the blade should be flush or slightly above the bottom of the runner.

17. Remove the conditioner cover on the right hand side and check that the horizontal auger turns freely in both directions.

18. Make sure there is no up, down or side to side movement.

The Ultimate Ice Resurfacer

19. Check the tension on the conditioner chain. There should be between a quarter and half- inch play (6,5-12,7mm).

20. Check the auger for up and down and side to side movement.

21. Check electrical connection for conditioner (horizontal auger) motor.

22. Check the blade holder pivot bolts to make sure they are tight. Replace the conditioner cover plate and install the locking pin. Go to the back of the ice resurfacer and flip up the towel.

23. Check the squeegee making sure it fits tightly from end to end and there are no nicks or cuts.

24. Examine the bottom side of the towel. Make sure it is clean, debris free and that the loops of the towel are in good condition.

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 condition of tire and studs on left rear wheel.

30. Check the board brush. Make sure that no debris is caught in the brush and that there is no free play.

31. Move the snow dump tank safety support bars to the stored position and lock in place.

32. Using a three point mount, step onto the ice resurfacer and sit down.

33. Turn the start key to the ON position.

34. Check the horn and the lights.

35. Make sure the conditioner is all the way up by pushing and holding the conditioner UP switch on the dash.

The Ultimate Ice Resurfacer

36. Test the elevator system. First, make sure the toggle switch is in the FORWARD position, then push the ON OFF switch for the elevator. While it is still running turn the toggle switch to the REVERSE position. The augers should come to a stop and then reverse direction. Then switch back to the forward position and shut off by lifting the

ON OFF switch.

37. While the elevator is running check the snow breaker`s manual override by pushing the manual override switch down and then up to make sure the snow breaker cycles.

38. If the wash water tank is full turn on the wash water only long enough to make sure the wash water valve opens and you have an unobstructed water flow on both sides of the conditioner. Note (The augers must be turned on and the gear selector in the drive position to perform this check).

39. Check the 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 month lower the conditioner almost to the floor, insert the hand pump handle into the emergency hand pump located under the seat, push the switch under the seat to the HAND PUMP position and proceed to pump the conditioner up. After this is complete be sure to return the switch to the DRIVE position. Remove the hand pump handle and restow it.

45. Remove all hoses and cables from the ice resurfacer.

46. Complete the log book entry that you have performed the circle check.

47. You have now completed the safety check and are ready to proceed onto the ice surface and begin the resurfacing process. Make sure you use the horn when crossing any pedestrian areas.

The Ultimate Ice Resurfacer

7 WORKING WITH THE OLYMPIA MILLENNIUM-E

7.1 Driving

7.1.1 Starting

To start the OLYMPIA you must be seated in the driver`s seat. The red EMERGENCY SHUT OFF switch must be in the UP position. Turn the ignition key to the right and you will hear the switches turn on inside the electrical panel.

7.1.2 To move the ice resurfacer

Depress the accelerator pedal to start the 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 all the electrical motor controllers. Restart the ice resurfacer. If a fault code persists a pictogram will appear showing the fault code on the lower left hand corner of the DMC gauge on the dashboard.

The Ultimate Ice Resurfacer

7.1.3 Brakes

To stop the OLYMPIA, take your foot off the accelerator pedal and carefully press the brake pedal.

Always apply the hand brake (parking brake), set the gear lever to neutral and turn the ignition switch to the off position before 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 working with the OLYMPIA, there must not be any other person on the ice.

The Ultimate Ice Resurfacer

Operation and start-up must only take place from the driver’s seat!

Before driving onto the ice surface make sure pedestrian doors in the dasher boards are closed.

Before leaving the driver’s seat, always turn off all functions!

7.2.1 Driving with the Board Brush

Normally the brush is used for the first lap around the boards at the beginning of each ice cleaning process.

This produces 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 in the forward direction of travel, however, when driving in reverse, the brush could swing into an opening and catch the boards, causing severe damage.

Retract thre board brush when approaching any ice level opening.

The Ultimate Ice Resurfacer

7.2.2 Water Application

Ice Making Water Procedure

1. Fill the tank with hot water through the fill pipe located on the driver`s side.

Note: A ½ full tank is more than sufficient for a single resurfacing.

Water flow can be turned on and off two ways.

A: Gravity flow regulates the flow of water by opening or closing the water tap mounted just in front of the blade adjustment hand wheel on the conditioner.

B: Turn on the speed related water on the bottom control panel. 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 water and slush are then vacuumed up, taking with it any dirt and debris from the ice surface. In addition, any snow left behind by the blade is turned into slush by the wash water and is pushed into any cracks in the ice by the squeegee. The water is filtered and then returned to the wash water tank.

The Ultimate Ice Resurfacer

Always use cold water in the wash water system.

To turn on the wash water system during the resurfacing operation, depress the Wash Water switch. The water begins to flow. After 10 seconds, the wash water pump begins to vacuum up the water.

¾ of the lap prior to completion of resurfacing, turn off the wash water, lift the Wash Water switch to the Off position. Both the water flow and the pump turn off at the same time.

By turning the wash water off ¾ 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 accessed.

Fill the water tanks with enough water to do a complete resurfacing job. Any water still remaining in the tanks at the end of the day should be drained completely, to prevent a build- up of scale.

The Ultimate Ice Resurfacer

7.3 Resurfacing Procedure

Once you have taken on sufficient water, before driving onto the ice surface, turn on the tire wash to rinse the tires of any debris. Now carefully drive onto the ice surface and carry out the normal ice making procedure as follows:

• Lower the conditioner to the ice surface until the conditioner lift arms are against the down pressure stops.

• Engage both the vertical and the horizontal augers 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 circuit of the rink, retract the board brush and follow the pattern shown below.

Use extreme caution with the board brush when passing open gates as the board brush could swing into the opening, causing damage to both the boards and/ or the ice resurfacer.

1 2

3 4

The Ultimate Ice Resurfacer

• ¾ of a lap prior to completion of the resurfacing, turn off the wash water. Just prior to finishing the resurfacing, turn off the ice making water. Bring the OLYMPIA to a complete stop while the rear wheels are still on the ice 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 dismounting install the snow dump safety supports.

The Ultimate Ice Resurfacer

• 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 the conditioner.

In order to maintain the recommended ice thickness of 1-1/4” (36mm), it is important that you cut the ice at a rate equal to the water you put down. Usually between ½ and ¾ a bin of snow will equal the amount of water put down on an 8 to 10 minute resurfacing.

Proceed with extreme caution when driving up to the snow dumping area!

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 conditioner should be rinsed out after each use. Do not hose down the whole ice resurfacer unnecessarily. The control cabinet, the hydraulic station, the battery panels and the driver’s platform may only be cleaned with a damp cloth, never with a direct jet of water.

Keep the humidity in the storage area as low as possible!

8 CLEANING AND MAINTENANCE

The Ultimate Ice Resurfacer

8.1 Cleaning and Maintenance Safety Instructions

To perform the maintenance program, park the OLYMPIA with the conditioner in the fully

UP position and shift the gear lever to the neutral position (N).

Fully raise the snow dump tank and install the safety support bars.

Turn off the ice resurfacer.

Before starting any maintenance jobs, remove the ignition key from the lock and keep it on your person. Put up a notice at the dashboard that says: DO NOT SWITCH ON! WORK IN

PROGRESS IN THE DANGER ZONE!

Dismount using the three-point 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 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 down the Emergency shut off switch and disconnect the batteries from the resurfacer as shown in section 6.1. Put up a warning notice there that says: DO NOT PLUG IN BATTERY CONNECTOR!

WORK IN PROGRESS IN THE DANGER ZONE!

Before starting the work, the OLYMPIA must also be secured with wheel chocks to prevent it from rolling away. The red/white plastic chains must be clearly visible at the sides of the machine. It is imperative that the wheel chocks are removed again before putting the

OLYMPIA back into operation (the red/white plastic chains serve as a reminder).

The Ultimate Ice Resurfacer

Only after the OLYMPIA has been secured in the described manner may any isolating guards be removed (if necessary).

Only duly authorized personnel are permitted to be in the vicinity of the machine when maintenance and repair work is being performed.

If mechanically driven movements are necessary on the OLYMPIA in the course of maintenance and repair work, these may only be executed on the instruction of the facility supervisor, and at a safe, reduced speed.

Before starting 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 back on.

Mechanically driven ice resurfacer movements can only be started in jog mode during maintenance and repair work by holding 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 ice resurfacer by plugging the battery connector back in again. The people working on the ice resurfacer must be informed in advance.

In an emergency, press the EMERGENCY SHUT OFF switch. Before reengaging the ice resurfacer, make sure that this can be done without endangering people or facility equipment.

Employees must wear protective gloves when doing maintenance and repair work. The hazards associated with the sharp components should be pointed out in regular training courses.

Any failure of, or damage to the safety devices or guards must be reported to the facility supervisor without delay. He will then decide how to proceed.

The Ultimate Ice Resurfacer

8.2 Maintenance Checks

Failure to carry out the basic maintenance checks can lead to damage and downtime as well as possible personal injury.

8.2.1 Daily

• Carry out circle check as described in section 5.8.

• Recharge the battery (if necessary).

• 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.

• Grease conditioner lift arms.

• Grease conditioner mounting pins.

The Ultimate Ice Resurfacer

• Clean the entire ice resurfacer thoroughly with a damp cloth.

• Water the batteries using only distilled or RO. treated 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).

The Ultimate Ice Resurfacer

8.2.5 Monthly

• Have the battery voltage measured and battery acid density checked by a battery specialist. Add distilled water, if necessary.

• Check whether the battery box is dry.

• Inspect the hydraulic system for any sign of leaks.

• Check the belt tension at all drive belts.

• Check the tire pressure (85 psi or 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 tension of the conditioner drive chain, it should not have more than ½ inch (1,27 cm) of play.

• Spray lubricant onto the conditioner drive chain.

8.2.6 Annually or Before Storage

• Spray all metal surfaces of the conditioner with a thin coating of penetrating oil.

• Lubricate all lube points on the OLYMPIA to eliminate moisture.

• The horizontal and the vertical auger and all moving parts of the conditioner must be coated with a thin coating of penetrating oil.

• Open the drains.

• Remove the 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.

• 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.

The Ultimate Ice Resurfacer

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 OLYMPIA.

• Disconnect the battery charger and leave the batteries unplugged. If storing for more than one month charge the batteries each month.

• Have a qualified technician tighten all connections in the control cabinet.

• Check the brake lines for leaks and wear.

• Grease the entire ice resurfacer.

• Change hydraulic oil filter.

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

The Ultimate Ice Resurfacer

12 13

The Ultimate Ice Resurfacer

Picture 1: Conditioner lift arm block left side

Picture 2: Conditioner lift arm block right side

Picture 3: Conditioner mount pins left and right sides

Picture 4: Board brush arm pivot and shaft

Picture 5: Blade holder pivot and horizontal auger bearing left side

Picture 6: Blade holder pivot and horizontal auger bearing right side

Picture 7: Blade adjustment screw,

Picture 8: Upper and lower king pin left side

Picture 9: Front axle center pivots

Picture 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 wheel

Picture 19: Parking brake linkage pivots on rear axle

The Ultimate Ice Resurfacer

8.2.8 Every 3 Years

• Change the wheel drive gear box oil (Dexron III)

• Change the hydraulic oil and filter

To put the OLYMPIA back into operation at the beginning of the season, perform the weekly maintenance procedure

The Ultimate Ice Resurfacer

9 SELF- HELP AND TROUBLESHOOTING

9.1 Squeegee Replacement

If the squeegee needs to be replaced, it should be mounted on the inside of the conditioner with hex head bolts (3/8” x 1-1/4”) and locknuts. Install the squeegee such that the ends fit tightly against the sides 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 towel holder.

9.3 Blade Replacement

Refer to Chapter 6.3, “Installation and Removal of the Blade“.

The Ultimate Ice Resurfacer

10 APPENDIX

Hydraulic Drawings

Documentation provided 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

The Ultimate Ice Resurfacer 92

The Ultimate Ice Resurfacer 93

5281

Type 5281 can be combined with...

2/2-way Solenoid Valve with servo-diaphragm

• Universal version up to 232 PSI

• NBR, EPDM or FKM servo-diaphragms

• Waterhammer-free, low noise

• NC circuit function

• Brass and stainless steel body

• Threaded port or flange connections

• Approvals:

Type 2508

Cable plug

Type 1078

Timer unit

Type 2511

ASI cable plug

Type 8600

Dosing control

Servo-assisted solenoid valve with servo- diaphragm for the control of liquid or gaseous media. A pressure difference of 2.9 PSI is required for a complete switchover.

Power consumption

Inrush

[VA]

Hold (hot coil)

[VA/W]

14/8

[W]

Technical data

Orifice

Body material

Threaded port

Flange

Inner part valve

Seal material

Media

NBR

EPDM

FKM

Media temperature

NBR

EPDM

FKM

Ambient temperature

Voltage tolerance

Duty cycle

Electrical connection

Protection class

Installation

1/2" - 2" (DN 13 - 50 mm)

Brass

Grey cast iron

Stainless steel, brass

NBR, EPDM, FKM

Neutral media, such as compressed air, water

Oil and fat-free media

Hot air, oxygen, per-solutions

14°F to 176°F (-10°C to +80°C)

-40°F to 248°F (-40°C to +120°C)

14°F to 248°F (-10°C to +120°C)

Max. 131°F

(+55°C)

±10 %

Continuous operation 100% ED

Tag connector acc. to DIN 43650 Form A for cable plugs Type 2508 (see Accessories)

IP 65 with cable plug

As required, preferably with actuator upright

Response times 1) 0.1 - 4 seconds

(depending on orifice, pressure 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% www.burkert–usa.com

p. /3

Dimensions [mm]

Threaded port version

5281

Type 2509 dimensions [mm]

0.71

2.32

1.10

M3 without circuitry

Torque 0.74 ft-lb

Threaded port

DN D B1 B1* E1

NPT 1/2

NPT 3/4

100.0

120.0

107.5

127.5

NPT 1 116.0

136.0

NPT 1 1/4 126.5

146.5

NPT 1 1/2

NPT 2

135.5

157.2

155.5

177.2

B1* Version with manual override, available on request

115

100

115

126

164

Ordering chart for valves (other versions on requests)

Circuit function A (Type 5281, normally closed), brass body, supplied with cable plug

A 2/2-way valve NC 13

NPT 1/2

NPT 3/4

NPT 1

NPT 1 1/4

NPT 1 1/2

NPT 2

4.7

5.8

11.7

23.5

47.1

2.9 – 230

120/60

240/60

024/VDC

024/60

120/60

240/60

024/VDC

024/60

120/60

240/60

024/VDC

024/60

120/60

240/60

024/VDC

024/60

120/60

240/60

024/VDC

024/60

120/60

240/60

024/VDC

024/60

Note: Versions with manual override available on request. FKM and EPDM seals are also available on request.

457 405

457 406

457 407

457 408

457 409

457 410

457 411

457 412

457 413

457 414

457 415

457 416

457 417

457 418

457 395

457 396

457 397

457 398

457 399

457 400

457 401

457 402

457 403

457 404

456 874

456 875

456 876

456 877

456 878

456 879

456 880

456 881

456 882

456 883

456 884

456 885

456 886

456 887

456 864

456 865

456 866

456 867

456 868

456 869

456 870

456 871

456 872

456 873 p. /3

5281

Materials i

Further versions on request

Approvals

UL/UR/CSA, ATEX-Ex, UL-fire protection, European gas approval

Voltage

110/50, other non-standard voltages

Port connection

NPT, Rc

Ordering chart for accessory

Cable plug Type 2508 according to DIN EN 175301-803 Form A

1 Coil:

2 Plunger:

Polyamide 1)

Epoxy 2)

1.4105

3 Plunger-seal:

4 O-rings:

5 Cover:

6 Spring:

7 Diaphragm:

8 Valve body:

NBR, EPDM, FKM

Brass

1.4310

NBR, EPDM, FKM

Brass

1) with NBR-sealing

2) with EPDM-, FPM-sealing

Fixing screw

Flat seal

None (standard) 0 - 250 V AC/DC further versions see datasheet Type 2508

008 376

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 Type 2508.

In case of special application conditions, please consult for advice.

We reserve the right to make technical changes without notice.

0290

2/2-way Solenoid Valve for gases and ﬂ uids

• Universal valve with coupled diaphragm system

• Switches without differential pressure

• For gases and liquids

• Brass and stainless steel bodies

• Seal material NBR, EPDM and FKM

• Approvals:

Type 2508

Cable plug

Type 1078

Timer unit

Pilot-controlled normally–closed valve with servo-diaphragm, forced valve lifting and coupled magnetic system. The valve switches without differential pressure from 0 bar with gases and liquids.

Power consumption

Orifice Inrush Hold

20 – 40 100

Type 2511

ASI cable plug

Technical data

Oriﬁ ce

Body material

Internal parts of valve

Seal material

Media

NBR

FKM

EPDM

Media temperature for NBR for FKM for EPDM

Ambient temperature

Voltage tolerance

Duty cycle

Electrical connection

Protection class

Installation

Type 8600

Dosing control

7/16” – 2” (DN 12 – 50 mm)

Brass, stainless steel 1.4581

See drawing on page 2

NBR, FKM, EPDM

Neutral media, compressed air, water, hydraulic oil

Per-solutions, hot oils, oxygen

Oil and fat-free media, e.g., hot water

14°F to 176°F (–10°C to +80°C)

32°F to 248°F (0°C to +120°C)

–22°F to 248°F (–30°C to +120°C)

Max. 131°F (+55°C)

±10%

100% continuous cycle

Cable plug for Ø 7 mm cable (supplied as standard)

IP 65 with cable plug

As required, preferably with actuator upright www.burkert–usa.com

Page 1/4

0290

Solenoid valves

Ordering chart for valves (other versions on request) – all valves with cable plugs, brass bodies and various diaphragm materials

A 2/2–way valve NC

For 50 mm orifice and UC (universal current), the cable plug has an integrated single–phase bridge.

UL 452 746 A

Page 2/4

Dimensions [mm]

Solenoid valves Dimensions [mm]

Threaded port

Material

Brass resp. 1.4581

0290

Dimensions [mm] according to DIN 2501

DN D B E

NPT 1/2

NPT 3/4

95.5

122.0

NPT 1

NPT 1 1/4

NPT 1 1/2

NPT 2

131.0

145.0

154.0

211.0

115

73.0

86.5

91.5

99.0

126.0

74.5

100.0

115.0

126.0

164.0

Coil:

Stopper:

Shading ring:

(only AC version)

Spring:

Magnetic core:

Guide tube

O– ring:

Seat seal

Diaphragm support disc

Diaphragm

Pilot seat

Body

Epoxy

1.4105

Brass version: copper

Stainless steel version: silver

1.4310

1.4105

1.4303

(see ordering chart)

Brass version: CuZn39983

Stainless steel version: 1.4401

(see ordering chart)

Brass version: CuZn39983

Stainless steel version: 1.4401

Brass or stainless steel

Page 3/4

0290

In case of special application conditions, please consult for advice.

We reserve the right to make technical changes without notice.

Page 4/4

0602/2_USen

Model: ES3

EnForcer™ SCR Battery Charger

Service Manual

I.B. 1561

Rev B

EnForcer™ SCR Service Manual I.B. 1561

TABLE OF CONTENTS

AC Line Voltage Letter Codes ............................. 3 DATA LOGGING ……………………………………….23

Specialty Charger Options List ............................ 3

Important Safety Instructions............................... 4

Installation ......................................................... 5

Location......................................................... 5

Stacking Multiple Chargers ........................... 5

SCR TRANSFORMER TYPE BATTERY CHARGERS

Watchdog Circuits (If installed) ...................................24

Operation of Reset Watchdog

And Override Watchdog ................................24

Electrical Connections................................... 5

Connecting Input Power................................ 6

Branch Circuit Protection .............................. 6

Plug Polarity .................................................. 6

Grounding the Charger ................................. 6

Theory of Operation............................................. 7

Introduction.................................................... 7

Override Watchdog ..............................................24

Normal Operation ..........................................24

Fault Indication...............................................24

Fault Conditions .............................................24

Fault Recovery...............................................24

Reset Watchdog...................................................24

Normal Operation ..........................................24

Printed Circuit Boards ................................... 7

Control Circuitry ............................................ 8

EnForcer™ SCR Features

Front Panel ......................................................... 9

LED ......................................................... 9

Pushbuttons .................................................. 9

Charger Features................................................. 10

General ......................................................... 10

Multiple Battery Select .................................. 10

Auto Start/Delayed Start ............................... 11

Auto Equalize Cycle ...................................... 11

Manual Equalize Cycle.................................. 11

AC Power Fail ............................................... 11

Refresh Cycle................................................ 11

Cool Down..................................................... 11

Parallel Charging (Optional).......................... 11

Fault Indication...............................................24

Fault Recovery...............................................25

Testing Components...................................................25

Transformer ...................................................25

SCR/Diode Block ...........................................26

Diode Test......................................................27

AC & DC Fuses..............................................27

Printed Circuit Board......................................27

Snubber Assembly.........................................28

Replacing Components ..............................................28

Introduction ....................................................28

Main Transformer ..........................................28

SCR/Diode Block ...........................................29

Contactor .......................................................29

Control Transformer.......................................30

Printed Circuit Board......................................30

Voltage Conversion .......................................30

AC Disconnect (Optional).............................. 12

AC Input Change Quick Tap™ (Optional)..... 12

ES3 CONTROL BOARD

Normal Operation …………………………………..12

User Parameter Configuration ............................. 14

Adjusting Settings ......................................... 14

Adjusting Battery Selection ........................... 14

With Multiple Battery Select Enabled ............ 14

With or Without Multiple Battery Select

Enabled................................................... 14

Service Parameter Configuration ........................ 15

Charger Faults ..................................................... 19

Field 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

AC Input Change (Standard) .........................30

AC Input Change (Quick Tap™)....................32

Maintenance .........................................................33

REPLACEMENT PARTS, SCHEMATICS, ASSEMBLY

DRAWINGS:

ES3: Replacement Parts, Schematics ................34

ES3: Assembly Drawings ....................................43

ES3 Large Cabinet Replacement Parts/Fuse Values,

Schematics ………………………………………….58

ES3 Large Cabinet: Assembly Drawings ............62

EnForcer™ SCR Service Manual I.B. 1561

AC LINE VOLTAGE LETTER CODES

The following table describes the code letters to be used in new charger part numbers to indicate the AC line voltage(s) and AC line frequency at which the charger can be operated.

Code

Letters

Voltages(s) (volts rms.)

Line Frequency

(Hz)

208/240/480

220/380/440

480/550/600

208

Comments

Applicable to all charger families; single or three phase chargers.

Use only for special designs; single or three phase chargers.

240

240/480

480

400

Use only for special designs; single or three phase chargers.

Use only for special designs. Contact the plant for further information.

S Special Voltages Unspecified Use only for special designs. Contact the plant for further information.

* 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

C10

C12

CF12

HD3

HD4

L10

L13

L15

L18

L20

L25

L30

6’ of #10 AWG AC cord with 30 amp plug*

10’ of #10 AWG AC cord with 30 amp plug*

12’ of #10 AWG AC cord with 30 amp plug*

8’ of #10 AWG AC cord with 30 amp plug*

10’ of #8 AWG AC cord with 50 amp plug*

12’ of #8 AWG AC cord with 50 amp plug*

Description

6’ of #10 AWG AC cord with 30 amp Plug and 30 amp receptacle. *

Charger with AC Disconnect Switch

Outlet receptacle option, GFCI type

6’ of #10 amp AC cord with 30 amp plug*

6’ of #10 AWG AC cord with 30 amp plug and receptacle*

10’ of DC cable

13’ of DC cable

15’ of DC cable

18’ of DC cable

20’ of DC cable

25’ of DC cable

30’ of DC cable

SCR charger with Load Management Control

No DC cable

Special configuration of a standard EPROM **

Parallel DC cables, standard size.

Charger Shipped on a Plastic Pallet

Voltage conversion Quick Tap

Series DC cables

Block out timer switch

Combination not listed

*When AC cord is installed at the factory only one input voltage is marked on the charger.

**Prior approval needed from Director of Engineering

EnForcer™ SCR Service Manual I.B. 1561

IMPORTANT SAFETY INSTRUCTIONS

1) This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, cautions , and warnings on the battery charger, the battery, and the product using the battery.

2) These chargers were designed to charge industrial batteries, flooded and sealed cell.

3) Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger.

4) Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock.

5) During charge, batteries produce hydrogen gas that can explode if ignited. Never smoke, use an open flame, or create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space.

6) Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arcing and burning of the connector resulting in charger damage or battery explosion.

7) Lead-acid batteries contain sulfuric acid that causes burns. Do not get in eyes, on skin, or on clothing. In cases of contact with eyes, flush immediately with clean water for 15 minutes. Seek medical attention immediately.

8) Only factory qualified personnel can service this equipment.

9) De-energize all AC and DC power connections before servicing the charger.

10) The charger is not for outdoor use.

11) Do not expose the charger to moisture. Operating conditions should be 0° to 104°F; 0 to 70% relative humidity.

12) Do not operate the charger if it has been dropped, received a sharp hit, or otherwise damaged in any way.

13) For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material such as stone, brick, or grounded metal.

WARNING: The shipping pallet must be removed for proper and safe operation.

INSTRUCTIONS DE SÉCURITÉ IMPORTANTES

1) Ce manuel contient des informations et des consignes importantes pour l’emploi et l’utilisation du chargeur 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 pour empêcher des dommages à la batterie et/ou au chargeur.

4) Ne pas être en contact avec les péces sous-tension non-isolées tels que la prise de charge ou des éléments de connexion de la batterie pour empêcher le choc électrique.

5) Pendant la charge, le dégagement d’hydrogène rend l’emploi de feu strictement interdit <<risque d’explosion>>.

Ne jamais fumer, employer une flamme nue, ou créez les étincelles à proximité de la batterie. Ventiler suffisamment pour éviter toute condensation de gaz dans un espace restreint.

6) Ne brancher ou débrancher la batterie que si le chargeur est à l’arrêt.

Faire ainsi risque d’endommager la prise de charge pouvant avoir pour conséquence des dommages du chargeur ou l’explosion de la batterie.

7) Les batteries d’ecide au plomb contiennent l’acide sulfurique, qui cause des brûlures. Eviter le contact avec les yeux, la peau, ou sur l’habilement. Dans le cas de contact avec les yeux, il faut nettoyer immédiatement avec de l’eau propre pendant 15 minutes et consulter un médecin immédiatement.

8) Seul le personnel qualifié par l’usine peut entretenir cet équipement. Pour le service, veuillez contacter la société

EnerSys ou l’un de ces représentant.

9) Avant toute intervention d’entretien ou de réparation il faut s’assurer que le chargeur est hors tension et la batterie est déconnectée.

10) Le chargeur n’est pas pour un usage extérieur.

11) Ne pas exposez le chargeur à l’humidité. Les conditions de fonctionnement devraient être –15° à 40°C; humidité relative de 0 à de 70%.

12) Ne pas mettre en fonctionnement le chargeur s’il a reçu un choc mécanique ou tout autre dommage de quelque façon.

13) Pour la protection permanente et pour réduire le risque du feu, installez les chargeurs sur un plancher ou un matériel non-combustible tel qu’un mur plein en beton, en brique, ou le acier.

EnForcer™ SCR Service Manual I.B. 1561

INSTALLATION

WARNING: The shipping pallet must be removed for proper and safe operation.

LOCATION

For maximum trouble-free service, choose a location that is free of excess moisture, dust, and corrosive fumes. Also, avoid locations where temperatures are high or where liquids will drip on the charger. Allow six (6) inches of clearance at rear and sides of the charger for air circulation. Do not obstruct the ventilating openings or the space under the charger.

STACKING MULTIPLE CHARGERS

These chargers can be stacked up to a maximum of 3 units high. Chargers are not designed to be stacked side by side due to ventilation requirements.

METAL STRAP

TWO STACKED CHARGERS, RIGHT SIDE VIEW

1) Position the first charger so that a minimum of 6 inches of space is between the charger and any wall, 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 ¼” screws of the charger sides and attach strap with screws. Refer to picture.

Hardware kit #X225-99-0-2 can be ordered to attach two chargers.

4) Repeat steps 2 and 3 for the third charger.

5) Stacked chargers must be fastened to the wall using devices suitable for the wall construction and the bolt holes at the top of the highest charger.

NOTE: Ambient temperature at all levels cannot exceed 104°F/40°C.

ELECTRICAL CONNECTIONS

To prevent failure of the charger, be sure it is connected to the correct line voltage.

ON THREE PHASE UNITS

Connect all the chargers as follows:

Phase A to L1 (fuse block)

Phase B to L2 (fuse block)

Phase C to L3 (fuse block)

EnForcer™ SCR Service Manual I.B. 1561

CONNECTING INPUT POWER

WARNING:

Make sure the disconnect is in the OFF position and the battery is disconnected before connecting the input power to the terminals of the charger.

Connect the input power to the appropriate terminals, including ground . Follow your local electrical or National Electric

Code in making these connections.

The figure that follows shows both the top and right side installation options for routing the incoming power.

IMPORTANT: When the AC Disconnect Switch is factory installed connect the input power to the Switch instead of 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 of the charger must be strictly observed when connecting to the battery (read warning above). Improper connection will open the DC fuse.

GROUNDING THE CHARGER

DANGER:

FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC

SHOCK. Follow National Electric Code for ground wire sizing.

Connect a grounding conductor to the lug provided on the horizontal support panel. This lug is marked as shown:

EnForcer™ SCR Service Manual I.B. 1561

THEORY OF OPERATION

INTRODUCTION

EnerSys™ EnForcer™ SCR Battery Chargers are three phase 50 or 60 Hz, and SCR/Diode Block-controlled. EnForcer™

SCR chargers use the control board known as “ES3”. See Replacement Parts Lists for complete part numbers.

SCR/Diode Blocks are used to control the output and yield tight regulation over the whole operating curve. Line variations of ±10% will have almost no effect on the operating curve.

All chargers are designed for convection cooling with no de-rating, up to an ambient temperature of 40°C, 104°F (if properly installed per the Installation and Operating Instructions manual).

All models have an Equalize cycle that can be started manually or automatically.

While charging, the information about the state of charge is provided through the control board LEDs and LCD display.

Batteries with cell size and amp hour ratings less than or equal to the charger nameplate values can be charged.

Charging batteries that have higher cell size and amp-hour ratings above of the charger nameplate is strongly discouraged.

Refer to the schematic diagrams in the back of this manual as you read the following description.

The 3-phase SCR-controlled battery chargers are available with several operating voltage ranges and come in 50 or 60

Hz models. The voltage, current, and frequency ratings are specified on the nameplate located on the lower-left corner in the front of the charger. It is important not to exceed any of these nameplate ratings.

The charger power circuitry contains a transformer that provides full isolation from the primary source to the secondary.

In the transformer secondary there is a 3-phase bridge rectifier made 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 voltage spikes at a given level and a capacitor (used to limit DV/DT of the SCR) in parallel.

The magnitude of the secondary AC voltage can be measured across the inputs of the SCR/Diode Blocks, and the values are listed in the troubleshooting section of this manual.

Each primary input line is individually fused, and in some cases, the charger may have been provided an optional AC fused Disconnect Switch. This switch, when it is on, prevents the front door from opening. The secondary DC cable is fused on the negative lead.

Chargers rated at 36 cells and higher will have a different style fuse designed to operate with higher voltages. This will typically be a FWA style semiconductor fuse.

If the charger has been provided with optional parallel DC cables, each of the two negative leads will be individually fused with a size ½ of the rating of a single-cabled charger of similar rating.

PRINTED CIRCUIT BOARDS

All charger functions, features, and controls are handled by one printed circuit board (PC Board) under microprocessor control. Because of its flexible design, this PC board model is capable of being used on an entire range of chargers.

If changes are required on a board that is already installed, then all adjustments, calibrations, and settings are made through the front panel using the pushbuttons and the display. The specific operation of all adjustments through the front panel is described in detail in later parts of this manual. The adjustments are permanently stored in on-board FLASH

EnForcer™ SCR Service Manual I.B. 1561 memory. If AC power is lost during a charge cycle, the charge cycle will resume after a random delay when AC power is restored. This allows the charger to return to where it left off when power is restored. NOTE: There are no trimming potentiometers located in this charger.

Caution must be observed when handling or taking measurements on the PC board. The control common, or ground, is tied to the positive battery buss. This is especially important to consider when taking measurements on the board while it is operating.

CONTROL CIRCUITRY

The control circuitry measures current via the precision shunt located in the positive lead of the charger. DC Voltage is measured by means of a precision resistor circuit.

WARNING:

Under no circumstance should the starting current be adjusted to higher than the charger’s ampere-hour nameplate rating times 0.16, or overheating of the charger will occur.

The control circuitry has three phases of charge cycle. When set for SEALED it has four:

1) Constant-Current control at the start-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 transformer through connector J1. The value of these AC voltages can be found in the troubleshooting section of this manual. These windings serve several purposes:

1. Provide the signals that enable the control circuitry to synchronize and determine the proper phase angle to gate on each SCR.

2. Provide power to the control board. The controller will give an AC fault if any of the three phases becomes low or distorted, or if any of the three AC fuses clear.

Each SCR is gated with a DC pulse. The red lead of the SCR is tied to control common, and the white gate lead is tied to the gate-firing circuit on the control circuitry. The control will automatically balance SCR currents to within 10% at the beginning of each charging cycle.

Refer to later sections of the manual for specific measurements and values that can be expected for normal charger operation.

EnForcer™ SCR Service Manual

EnForcer™ SCR Features

Front Panel

I.B. 1561

START/STOP

POWER

CALL SERVICE

TIME LIMIT EXCEEDED

LED

Light on when control board powered

Light on when serious fault occurs during charge cycle, usually requiring field assistance.

Light on when charger time fault occurs

BATTERY DISCONNECTED Light on when battery disconnected during charge cycle before normal termination

Light on during charge cycle. Light is off when charger is stopped or charge cycle terminates

REFRESH

EQUALIZE

BAR GRAPH

Light on during refresh cycle

Light flashes when an equalize cycle is pending. Light on during and after the actual equalize cycle. Light is reset when battery is disconnected from charger.

Shows capacity returned to battery during charge cycle.

START/STOP

EQUALIZE

DOWN

PUSHBUTTONS

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.

Will activate the equalize function at any time during the charge cycle. The equalize button is also used for programming the charger.

Used to scroll through charge cycle data when charger is idle. Also used to scroll up through charger settings in programming mode.

Used to scroll through charge cycle data when charger is idle. Also used to scroll down through charger settings in programming mode.

EnForcer™ SCR Service Manual I.B. 1561

CHARGER FEATURES

GENERAL

The standard ES3 charger has a wide range of charging features for both flooded and sealed cell batteries. The ES3 is capable of charging various cell sizes and ampere-hour ratings as listed on the charger nameplate. Some of the basic features are described below.

DATA LOGGING

A new feature is the data logging of charge cycle parameters such as total charge time, amp hours returned, maximum charger voltage etc. Charge data is held in non-volatile memory for up to 1000 cycle incidents. After 1000 incidents, the charge counter rolls over.

CHARGE PROFILE OPTIONS

The ES3 is capable of charging sealed or flooded batteries under a variety of conditions. Multiple profiles, such as

Flooded, Sealed, Opportunity and Automatic Guided Vehicle are only some of the charge profiles the ES3 is capable of delivering to the battery. Multiple termination and finish selections will provide the customer with the perfect charge to fit their battery needs.

LCD DISPLAY

A bright, 2X20 large character LCD display provides large and easy to read text messages and data throughout the charging cycles. Multiple settings let the user choose their preferred contrast and type of information 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. Automatic cell sizing is limited to specific common cell sizes shown below. The range of battery cell sizes that an ES3 charger can automatically select is shown in the following table.

Charger Nameplate Automatic Battery Cell Select Range

Rating

40 cells

32 cells

24 cells

18 cells

12 cells

40,32,24,18,12,6

32,24,18,12,6

24,18,12,6

18,12,6

12,6

After detecting a battery, the ES3 will go into a two minute test charge phase, followed by a two minute rest period. The

ES3 then automatically determines the battery cell size based on the voltage response of the test charge.

MULTIPLE BATTERY SELECT

A total of 3 completely different battery profile selections can be stored and quickly selected for the customer that has multiple battery cell sizes and amp-hours. Used in conjunction with auto cell sizing, the ES3 charger can automatically choose between batteries with different cell sizes, amp-hours and profiles. The default for the charger is to have this feature shut off so that only a single battery selection can be made.

EnForcer™ SCR Service Manual I.B. 1561

AUTO START/DELAYED START

Auto Start enables the charger to start the charge cycle automatically after the battery is connected to the charger. A programmable delay can be programmed so that Auto Start will begin after a set time period. This delay can be set through the front panel display. Refer to Delayed Start in the USER parameter section. Auto start can be delayed anywhere from 0 up to 25 hours, in one minute intervals.

AUTO/MANUAL EQUALIZE CYCLE

An Equalize Cycle adds a predetermined amount of time to extend the battery’s charge cycle. The ES3 charger is equipped with an auto equalize function referred to as Equalize Count in USER parameters . This is a configurable parameter; consult your service representative for more information. The factory default setting for the auto equalize cycle is 3 hours of charge time for every fifth charge cycle. A charge cycle consists of at least one hour of continuous charging of the battery by the charger. Every time the battery completes a charge cycle, the charge counter is incremented. When the charge counter reaches the programmed Equalize Count value, an equalize cycle will occur immediately after the battery completes its normal charge cycle. When an equalize charge cycle is pending, the

EQUALIZE LED will flash. The equalize button can be pressed at any time during the normal charge cycle to stop the pending equalize cycle. Once the battery has completed a successful charge cycle, the CHARGE COMPLETE LED will light and the charger will immediately go into the equalize charge cycle. The EQUALIZE LED will then light steadily.

Pressing the EQUALIZE button during the equalize charge cycle will have no effect on the charger. When Equalize on

Day is chosen in the Service Parameters, the Equalize Count is automatically disabled.

The charger can also equalize a battery manually. Pressing the EQUALIZE button at 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 completes at least one (1) hour in Equalize charge.

NOTE : Since Equalize charging extends the recharge time; it is best to do this when additional cooling time is available

(example: on a weekend). Consult your factory representative to determine Equalize intervals that meet your needs.

AC POWER FAIL

AC power may fail with a battery connected to the charger during a charge cycle. When AC power returns with the battery connected, the charge cycle will resume the battery charging after a random delay. The charger will also detect an AC fuse open when the charger is charging a battery. This will result in a stopping of the charge cycle and an AC fault message displayed.

REFRESH CYCLE

If a battery remains connected to the charger for a predetermined amount of time after a charge cycle has been completed, a refresh charge cycle will be given to the battery. The factory default setting for the Refresh Cycle is to refresh for 20 minutes every 24 hours. This is a configurable parameter; consult your service representative for more information .

COOL DOWN

When a battery completes a charge cycle without error, it ideally should cool down before being used. The Cool Down period after a successful charge cycle is an idle period that allows a battery to cool off before use. Cool Down is a configurable parameter that can be set through the front panel display, refer to Cool Down in section User Parameter .

The factory default setting for the Cool Down is 1 hour.

PARALLEL CHARGING (OPTIONAL)

In parallel charging, batteries must have an equal number of cells and must match the charger nameplate’s ratings. Amp-

Hour rating of charger must be equal to the Amp-Hour of both batteries combined. Theoretically, charging current is

EnForcer™ SCR Service Manual I.B. 1561 equally divided between both batteries provided that batteries % of discharge and ages are equal. Make sure both batteries are connected before charge cycle starts.

The charger must be set for parallel cable and have Auto Cell sizing disabled in the service settings. Contact your sales/service representative.

AC DISCONNECT (OPTIONAL)

When an AC disconnect is installed, access to the charger through the front door is denied unless the AC disconnect is switched off. When the AC disconnect is in the off position, power is only present at the disconnect switch input terminals.

Make sure that main breaker is switched off before working on the charger.

AC INPUT CHANGE QUICK TAP™ (OPTIONAL)

Quick Tap™ is a feature to EnerSys chargers that allows the user to change AC input easily and quickly. See the heading VOLTAGE CONVERSION for more information.

ES3 Control Board

NORMAL OPERATION

1. Idle Mode : When AC input voltage is applied to the 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-hours delivered, highest voltage during the previous charge cycle, the number of charge cycles since the last equalize and the equalize count. Only the charge count and equalize count will be saved in non-volatile memory and can be recalled when AC power is restored after an outage. The other values will remain in volatile memory until the next charge cycle begins or if AC power is removed.

3. Plug the battery connector into the charger connector. The control board senses voltage. Once the battery is connected to the charger, the START/STOP LED will flash for approximately 5 seconds while the display shows this message:

Start

Battery Charger

850 Amp Hours*

Flooded Profile*

* Note that the Amp Hour value and battery type will vary.

Start in

3 Seconds

2 Seconds

1 Second

EnForcer™ SCR Service Manual I.B. 1561

Starting

Charger

Charging will begin. The START/STOP LED will light steadily. The ES3 will now enter the Auto Cell Sizing Test Charge indicated by the displayed text message on the LCD and the ‘bouncing ball’ on the bar graph. After two minutes in the test phase, the charger will shut off and enter the Auto Cell Selection phase. The display will show the count down from two minutes. The ES3 will then choose the appropriate battery cell size based on the voltage response of the battery.

Start Charge

18 Cell 1000 AH

Cell size is chosen

Flooded profile

Battery type displayed

The charge cycle starts and will reach steady state start current within a few seconds. The LED bar graph will indicate the percent charged status of the battery and the display will rotate through the following charge parameters.

Charger Current (Charger output current)

46.3

Amp Hours Returned (Amp-Hours returned to Battery)

268

Charge Time (Total Charge Time)

3:12

Battery Volts/Cell (Individual Cell Voltage)

2.56

These values are displayed in rotation for about 3 seconds each. The display settings can be changed so that one 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 current will begin to taper.

The charge cycle enters constant voltage or E mode.

5. After the current tapers to the finish-rate current, charging will continue until the battery voltage flattens or the time in taper equals 5 hours. If no Equalize charge is to be applied to the battery, the charger will stop and the display will show Cool Down . Cool Down is an idle time period that allows the battery to cool off before use. After a 1 hour Cool Down period (default), the display will show “Done” .

NOTE: If the battery is to receive an Auto Equalize charge, the charge cycle continues for 3 more hours at finish-rate current and then stops, displaying Cool Down .

7. When the battery is fully charged the green Charge Complete LED will light, the START/STOP LED will extinguish and the charger will shut off. At this time the battery is at full capacity and ready for use.

If Cool Down is not selected, the display will read “ Done” when the charge is complete.

EnForcer™ SCR Service Manual I.B. 1561

If Cool Down is selected, at the end of charge the display will read:

Cool Down

In: 00:59

For the duration of the cool down period. After the cool down period has expired, the display will read “ Done/Battery

Available” .

8. When the battery is disconnected, only the POWER LED remains lit and the display will return to “ Connect

Battery” / Time/ Date alternately. The charge counter is incremented by one for the completed charge cycle.

USER PARAMETER CONFIGURATION

ENTER USER PARAMETERS

The charger’s User parameters may only be configured while the charger is in idle mode with no battery connected.

Press Equalize button and hold for approximately 5 seconds. The display will show: “ User Parameters” . Release the

Equalize button and the first User parameter: “ Set Clock/Calendar?” is displayed.

ADJUSTING USER SETTINGS :

Toggle the UP or DOWN arrow keys to scroll through the available User Parameters. To view the contents of the variable displayed, toggle the Equalize button. The value of that setting will be displayed. To change the displayed value, toggle the UP or DOWN arrow keys to the desired value. If you press and hold the UP or DOWN pushbuttons for 3 seconds when adjusting the parameters, the options will scroll through at a rapid pace. Release the pushbutton to return to normal scrolling mode. Once the desired value is chosen for that parameter, toggle the Equalize button again to set it and to move on to the next parameter. 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 hours, days etc. by toggling the UP or DOWN arrow keys and set in a similar fashion. Press the Start/Stop key to save and exit the real time clock function.

To exit and save from User Parameters at any time, press the Start/Stop button. For a list of available user parameters and their definitions, see the table below.

Parameters Description Range Default

Battery

Selection

Set

Clock/Calendar

Battery Cell

Size

Battery Amp-

Hours

Select Battery 1-3

When Battery Select is enabled in Service Parameters , choose between 1,2 or 3 completely different battery and charge profiles.

NOTE: This parameter is displayed when Battery Select is enabled in Service Parameters.

Minute, Hours, Date etc.

Enter the set clock function to adjust the time/date.

This should be set to match current Date/Time

Battery Cell Size

Select the battery cell size to be charged. This value can be less than or equal to the Charger nameplate cell size.

Do not adjust unless order acknowledgement specifies a change.

Battery Amp Hour

Select the battery amp hour value. This value can be less than or equal to the Charger nameplate amp hour value.

Do not adjust unless order acknowledgement specifies a change.

1-3 various

1-Charger nameplate cell size

10 –

Charger nameplate amp hour

1 none

850

EnForcer™ SCR Service Manual

Contrast

Adjust

Display Mode

Delayed Start

Cooldown

Time

Equalize Count

Contrast Adjust

Select the LCD contrast between characters and background.

Do not adjust unless order acknowledgement specifies a change.

Display mode

The following selection determines the parameters that are displayed during the charge cycle.

3 = displays current, A-H retuned, charge time and battery voltage

2 = displays current and voltage only

1 = displays current only

0 = displays voltage only

Do not adjust unless order acknowledgement specifies a change.

Delayed start

Amount of time delay after a battery is connected to the charger, before charging proceeds. Increments in 1 minute intervals.

Do not adjust unless order acknowledgement specifies a change.

Cool Down Time

Amount of time after a complete charge cycle that a battery needs to cool down before being utilized.

Do not adjust unless order acknowledgement specifies a change.

Equalize Counts

Total amount of charge cycles that need to occur before an automatic equalize charge cycle will take place. Charge cycle must be 1 hour minimum duration.

(0 indicates that no Equalize charge will occur)

Do not adjust unless order acknowledgement specifies a change.

SERVICE PARAMETERS

10-1100

0-3

0 min – 25 hr

0 hr – 12 hr

0(OFF)

1-20 charge cycles

100

.00

1.00 hr

5 charge cycles

I.B. 1561

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 setting will be displayed. To change the displayed value, toggle the UP or DOWN arrow keys to the desired value. If you press and hold the UP or DOWN pushbuttons for 3 seconds when adjusting the parameters, the options will scroll through at a rapid pace. Release the pushbutton to return to normal scrolling mode. Once the desired value is chosen for that parameter, toggle the EQUALIZE button again to set it and to move on to the next parameter. To save and exit from Service parameters at any time, press the START/STOP button.

The table below shows a list of the available Service parameters, their meanings, and allowed values. The table shows the

Service parameters in the order that they appear.

Parameter

C h a r g e r C e l l

S i z e

C h a r g e r

A m p - H o u r s

Description

Charger Cell Size

This is the maximum number of cells that the charger is designed to charge.

This should be set to match the cell size rating on the charger nameplate.

Charger Amp-Hours

This is the maximum amp-hour rating of the charger.

This should be set to match the amp-hour rating on the charger nameplate

Range

1 - 40

10 – 2500

Default

850

EnForcer™ SCR

T i m e t o

G a s s i n g

C h a r g e T i m e

L i m i t

R e f r e s h

T i m e

R e f r e s h

I n t e r v a l

E q u a l i z e

D u r a t i o n

G a s s i n g

V o l t a g e

- d v d t ( v o l t a g e

/ t i m e )

U p B a t t e r y

D e t e c t

C a b l e

L e n g t h

C a b l e T y p e

C a b l e

C o n f i g u r a t i o n

T e r m i n a t i o n

M e t h o d

A m p - H o u r s

R e m o v e d

E x t e n d e d d v d t

Service Manual

Time to Gassing Limit

If the battery does not reach the gassing voltage within this time (in hours and minutes), the charger will shut off.

Do not adjust unless order acknowledgement specifies a change.

Charge Time Limit

If the charge is not complete within this time (in hours and minutes), the charger will shut off and indicate fault.

Do not adjust unless order acknowledgement specifies a change.

Refresh Charge Time

Length of refresh charge, in hours and minutes.

Do not adjust unless order acknowledgement specifies a change.

Refresh Interval

Length of time between refresh charges, in hours and minutes.

Do not adjust unless order acknowledgement specifies a change.

Equalize Time

Length of time to run in equalize, in hours and minutes.

Do not adjust unless order acknowledgement specifies a change.

Gassing Voltage

Set point for gassing (80% point) voltage, in volts per cell.

Do not adjust unless order acknowledgement specifies a change.

Negative dV/dt Voltage

Set point for negative dV/dt voltage, in millivolts per cell. Used for hot battery or bad cell detection.

Do not adjust unless order acknowledgement specifies a change.

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.

Cable Length

Length of battery cables, in inches, installed on the charger – used in battery cable drop compensation calculations.

This should be set to match the length of the cables installed on the charger.

Cable Type

Size of battery cable:

1 = 4/0 cable

2 = 3/0 cable

3 = 2/0 cable

4 = 1/0 cable

5 = #2 cable

This should be set to match the type of cable installed on the charger.

Cable Configuration

This parameter configures the controls to the configuration of the battery cables for the purposes of calculating the battery cable drop compensation:

0 = Cable drop compensation disabled.

1 = Standard cable

2 = Parallel cable

This should be set to match the configuration of the cables installed on the charger.

Termination Method

Method used to finish charge:

1 = dV/dt

2 = time-voltage

3 = both dV/dt and time-voltage (whichever occurs first)

4 = proportional

5 = amp-hour

Amp Hours Removed

If Amp-Hours Termination Method is chosen above. This parameter sets the Amp-hours removed.

Do not adjust unless order acknowledgement specifies a change.

Extended dV/dt

Adds a specified time to the dV/dt termination method if dv/dt termination is

:01 – 12:00

:01 – 18:00

:00 – 1:00

2:00 – 99:00

:06 – 10:00

1.00 – 3.00

0 - 100

:00 - :10

0 - 2400

1 - 5

0 - 2

1 – 5

10-2500

0:00 – 4:00

6:00

14:00

:20

24:00

3:00

2.370

:02

120

850

0:00

I.B. 1561

EnForcer™ SCR

D e l t a

V o l t a g e d v / d t

T i m e a f t e r

G a s s i n g

P r o p o r t i o n a l

F a c t o r

F i n i s h

C u r r e n t

S t a r t

C u r r e n t

C h a r g e

P r o f i l e

S e a l e d

F i n i s h V o l t s

S e a l e d

F i n i s h T i m e

E q u a l i z e o n

D a y 1

E q u a l i z e o n

D a y 2

B l o c k O u t t i m e S t a r t

B l o c k O u t t i m e S t o p

E n a b l e

F o r c e d S t a r t

Service Manual chosen above.

Do not adjust unless order acknowledgement specifies a change.

Delta Voltage- dv/dt

The change in battery voltage over time limit that the charger monitors, in order to determine charge completion. Units are in mV/cell. High values correspond to a shorter charge cycle.

Do not adjust unless order acknowledgement specifies a change.

Time after Gassing Voltage

Time limit for time-voltage and Both termination modes (see above).

Do not adjust unless order acknowledgement specifies a change.

Proportional Factor

For proportional termination mode, this parameter specifies the percentage of start rate time to continue charging after reaching gassing voltage.

Do not adjust unless order acknowledgement specifies a change.

Finish Current

Setting for finish rate current in amps. This is automatically set to 4.5% of battery amp-hours when either battery amp-hours or charger amp-hours is set. If Sealed profile is chosen (VRLA), then this value is set to 2.5% of battery amp-hours. The maximum setting is 16% of charger nameplate amp-hours.

Do not adjust unless order acknowledgement specifies a change.

Start Current

Setting for start rate current in amps. This is automatically set to 16% of battery amp-hours when either battery amp-hours or charger amp-hours is set. The maximum setting is 16% of charger nameplate amp-hours.

Do not adjust unless order acknowledgement specifies a change.

Charge Profile

1 = IEI (flooded)

2 = IEIE (sealed- VRLA)

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.

Sealed Finish Volts

For sealed (VRLA) charge profiles, the final voltage, in volts per cell.

Do not adjust unless order acknowledgement specifies a change.

Sealed Finish Time

For sealed (VRLA) charge profiles, the maximum time to stay in the final voltage stage.

Do not adjust unless order acknowledgement specifies a change.

Equalize on Day 1

Equalize on a particular day of the week after charge cycle completes. Set from Sunday – Saturday or OFF. Used in conjunction with the real-timeclock. Will disable Equalize by Count in USER Parameters when ON.

Do not adjust unless order acknowledgement specifies a change.

Equalize on Day 2

Second day equalize setting similar to above. Equalize on a particular day of the week after charge cycle completes. Set from Sunday – Saturday or

OFF. Used in conjunction with the real-time-clock. Will disable Equalize by

Count in User Parameters when ON.

Do not adjust unless order acknowledgement specifies a change.

Block out Start Time

Start time for charger block out period. Setting 00:00 is OFF.

Do not adjust unless order acknowledgement specifies a change.

Block out Stop Time

Stop time for charger block out period. Setting 00:00 is OFF.

Do not adjust unless order acknowledgement specifies a change.

Enable Forced Start

Enable/Disable the charger control forced start function.

Do not adjust unless order acknowledgement specifies a change.

0-50

0:00 – 10:00

0 – 100

3 – 200

3 – 400

1 – 6

1.000 –

3.000

0:00 – 12:00

Sunday-

Saturday or

OFF

Sunday-

Saturday or

OFF

00:00(OFF)

00:01-23:59

00:00(OFF)

00:01-23:59

0(OFF)

1(ON)

5:00

136

2.530

2:00

OFF

00:00

I.B. 1561

EnForcer™ SCR Service Manual

A u t o C e l l

S i z i n g

E n a b l e

B a t t e r y

S e l e c t

E n a b l e

R a n d o m

D e l a y

E n a b l e

C l o c k

S e t t i n g

E n a b l e

B a t t e r y C e l l

E n a b l e

B a t t e r y A - H r

E n a b l e U s e r

D i s p l a y

E n a b l e

D e l a y S t a r t

E n a b l e C o o l

D o w n

E n a b l e

E q u a l i z e

C o u n t

C h a r g e r

C o u n t e r

T o t a l

C h a r g e

C y c l e s

Auto Cell Enable

Enable/Disable automatic cell sizing routine.

Do not adjust unless order acknowledgement specifies a change.

Enable Battery Select

Enable/Disable automatic battery select routine.

0 = OFF

1 = ON

Do not adjust unless order acknowledgement specifies a change.

Random Delay Enable

Enable/Disable random delay after AC power outage.

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Real Time Clock Setting Enable in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Battery Cell Selection in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Battery Amp-Hours in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Display Adjustment in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Delay Start in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Cooldown in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Enable Equalize Count in User Parameters

0 = NO

1 = YES

Do not adjust unless order acknowledgement specifies a change.

Charge Cycle Odometer

Changeable Charger Cycle counter for short time testing.

Do not adjust unless order acknowledgement specifies a change.

Total Charges

Total Charge Cycle count of the number of charger cycles that terminated normally. This parameter is not adjustable.

0(NO)

1(YES)

0 – 1

0-1

0-200

0 – 64000

I.B. 1561

EnForcer™ SCR Service Manual

CHARGER FAULTS

The charger control circuitry constantly monitors for several fault conditions. If a fault should occur, the charge in progress is interrupted, and a fault message is displayed on the LCD. A list of the faults and their descriptions follow.

Displayed Fault Description Fault LED Fault Clearing

No DC Current

Check DC Fuse

Battery

Disconnected

While

Charging!

Time To Gassing

Limit Exceeded

Occurs when the DC fuse opens or no DC output current.

Occurs when a charging battery is disconnected from the charger without first stopping the charge cycle.

Occurs when the time limit to gassing voltage is exceeded.

Call Service – Yes

Bar Graph - Flashes

Battery Disconnect -

YES

Bar Graph – Steady On

I.B. 1561

Can be reset by disconnecting the battery from charger. Replace fuse or trouble shoot.

Can be reset by connecting a battery to the charger.

Overall Charge

Time Limit

Exceeded

Time After

Gassing Limit

Exceeded

Low Battery

Voltage/ Check

Battery

High Battery

Voltage/ Check

Battery

Occurs when the overall charge cycle time limit is exceeded

Occurs when the time limit after gassing is exceeded

Occurs when the battery is first connected and the voltage is between 1.0 and 1.8 volts/cell*

Occurs when the battery is first connected and the voltage is above 2.4 volts/cell.

Battery

Temperature/

Decreasing

Voltage

Occurs when there is negative change in battery voltage

High Amp-Hours Occurs when more than 150% of battery

Amp-Hours are returned during the charge cycle

AC Voltage Fault Occurs when input AC voltage quality is poor or distorted. Note that this condition may be temporary. The charger will attempt to re-start after 3 minutes. If unsuccessful, will attempt a total of 4 times before a permanent fault condition occurs.

AC fuse blown

Or lost phase

Occurs when AC fuse is blown or a phase of

AC power is interrupted when the charger is charging a battery. Note that this condition may be temporary. The charger will attempt to re-start after 3 minutes. If unsuccessful, will attempt a total of 4 times before a permanent fault condition occurs.

Time Limit Exceeded -

YES

Bar Graph – Steady On

Time Limit Exceeded -

YES

Bar Graph – Steady On

Time Limit Exceeded -

YES

Bar Graph – Steady On

Call Service – NO

Bar Graph – Steady On

Call Service – NO

Bar Graph – Steady On

Call Service – NO

Bar Graph – Steady On

Call Service – NO

Bar Graph – Steady On

Call Service – NO, ON when fault is permanent.

Bar Graph – Steady

ON, Flashes when fault is permanent

Call Service – NO

Bar Graph – Steady

ON, Flashes when fault is permanent

Can be reset by disconnecting the battery from the charger

Can be reset if battery voltage is between 1.8 and

2.4 volts/cell

Can be reset if battery voltage is between 1.8 and

2.4 volts/cell

Can be reset by disconnecting the battery from the charger

Can be reset by disconnecting battery from the charger

Can be reset by

Disconnecting and reconnecting battery to the charger. Disconnect AC power & check AC source.

Can be reset by

Disconnecting and reconnecting battery to the charger. Disconnect AC power & check AC source.

EnForcer™ SCR Service Manual I.B. 1561

DEFAULT SETTINGS

To set the control board to the default control board settings, perform the following actions. Note that default values will not necessarily match the charger nameplate values. Entering Service Parameters and resetting selected parameters may be necessary.

1. Remove power to the control board.

2. Before applying power to the board, hold down the UP and DOWN pushbuttons.

3. Reapply power. Hold down the UP and DOWN pushbuttons, for approximately five seconds, until the display reads Default Parameters .

4. Release the UP and DOWN pushbuttons.

5. All battery profile settings will now be reset to the original default settings.

FIELD CALIBRATION

No field calibration is necessary. All control boards are factory calibrated. No pots or adjustments are available.

Return all failed or defective boards to the factory.

RECHARGE CHARACTERISTICS

When a charge cycle begins, constant current is applied to the battery (start current mode). This constant current is called start rate current. When the gassing voltage point (80% charge voltage of 2.37 volts/cell) is reached, the charger stops applying constant current, and starts applying constant voltage (Constant Voltage mode).

GASSING VOLTAGE POINT NOT REACHED

If the gassing voltage point is not reached during the time allotted (which is factory set for 6 hrs), a time-to-gassing 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 constant current is called finish rate current.

FINISH CURRENT MODE REACHED

If charger current drops below finish rate, the cycle will continue charging until termination time or a flattening of the battery voltage(dvdt) is achieved

EQUALIZE MODE

If this is an Equalize charge cycle, once the charger completes the normal cycle, it will enter Equalize mode where it will equalize all the cells in the battery. It is recommended that every fifth or sixth charge cycle be an equalize cycle (check with Service representative).

During Equalize mode the charger applies constant current at the same rate as the current in finish current mode. The

Equalize mode adds 3 hours to a daily charge cycle.

REFRESH MODE

Refresh mode will be entered after the charge cycle has completed, if the battery is left connected to the charger for the period of time specified. The refresh wait period is factory set for 24 hours. A refresh charge assures that the battery is fully charged.

During Refresh mode, the charger applies constant current at finish rate. The time spent in Refresh mode is adjustable.

Refresh Charging time is defaulted to 20 minutes.

CHECKING THE RECHARGE CHARACTERISTICS

EnForcer™ SCR Service Manual I.B. 1561

You can check the battery voltage during start rate on a discharged battery. The battery voltage should gradually increase to 2.37 volts/cell (v/c) with the charging current at 16% of the charger nameplate rating. Example: If you are using a 550 AH charger, the charging current during start current mode will be 16% of 550, which is 88 amperes.

The output voltage at the battery terminals can be checked during constant voltage mode. The battery voltage should be steady at 2.37 v/c ± 1%, and the charge current should gradually decrease.

The battery voltage can be checked during finish current mode. The battery voltage should measure at least 2.37 v/c at a constant current of 4.5% of the charger nameplate rating.

Termination Methods

There are five choices for termination methods. These termination methods apply mainly tor flooded batteries with the IEI charge profile.

1. dvdt

2. Time-voltage

3. Both dvdt or time-voltage (whatever occurs first)

4. Proportional

5. amp-hour dvdt

The dvdt termination 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 and can be adjusted by modifying the service parameters extended dvdt and delta voltage dvdt .

Time-Voltage

A set time-after-gassing voltage period that charge cycle terminates. The default value in service parameters is 5 hours.

Both

Charge cycle completes when either time -voltage or dvdt termination methods, as described above, occurs.

Proportional

Charge cycle completes when the time after gassing reaches a set percentage of the start rate time before gassing. The default setting in service parameters is 40%. As an example, the charge cycle will terminate when the time after gassing is 40% of the start rate time.

Amp Hour

Charge cycle completes after set amount of amp-hours returned are reached. Note that an amp-hour return of greater than 150% of charger nameplate amp-hours will result in a high amp-hour fault.

EnForcer™ SCR Service Manual I.B. 1561

Charge Profiles

There are six choices for charge profiles. These profiles have default time and level settings that are detailed below. The profile’s settings can also be modified various ways in Service Parameters for custom applications to satisfy a customer’s needs.

IEI (Flooded)

IEI is the standard flooded profile. The first stage of the charge cycle

(the first I in IEI) is current mode at start rate current which is defaulted to 16% of the amp-hour rating. Start rate current is maintained as the battery voltage increases until gassing voltage is reached. Gassing voltage is set normally at the default rating of 2.37 volts/cell. Once gassing voltage is reached, the charger goes into the E mode where the charger voltage is held constant at gassing while the charge current tapers off. Once the charge current reaches the finish rate of

4.5% of the amp-hour rating (default), the charger enters the final I mode of the charge cycle. Charge termination will occur once the battery voltage flattens out in finish I mode (dvdt) or if the time period after the gassing voltage is reached is 5 hours (time-voltage), whichever comes first. This result occurs if the charge termination is the default “Both dvdt or time-voltage” setting.

Defaults:

Start Rate Current 16% of Battery AH

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

2.37 V/C

Both dvdt or Time Voltage

5 Hours

4.5% of Battery AH

14 Hours

IEIE (Sealed)

IEIE profile is more commonly referred to as sealed or VRLA. This profile is similar to IEI except that the finish rate constant current is 2% of the amp-hour rating of the battery. Also, there is an added voltage mode (E) in the profile that will hold the battery voltage to 2.53volts/cell

(default) until the charge cycle finishes. Dvdt termination does not apply in the sealed profile. Charge termination will occur when the time-after gassing reaches 4 hours if the battery voltage does not reach 2.53 volts/cell. If the battery voltage reaches 2.53 volts/cell before the 4 hour time limit, an added 2 hours in constant voltage E mode is added to the charge cycle.

AGV (Auto Guided Vehicle)

Automatic guided vehicle. AGV is an IE profile with a two hour timeafter-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 result.

I (VVR)

Constant current mode throughout entire charge cycle. Charge current is limited to finish rate (default).Charge time limit defaults to 32 hours.

IE (Floating)

Also known as floating mode. Constant start rate current until gassing voltage then constant voltage (E) mode. Gassing voltage default is

2.35 volts/cell. While in constant voltage mode, display indicates

‘floating charge’. Note that there is no charge time limit in this profile.

Charge cycle will continue indefinitely while battery is connected.

Charge current may fall to zero with no Open Battery fault while charger is in floating (E) mode. Disconnecting the battery while in float mode will not result in a fault. However, disconnecting the battery while charging in start rate (I mode) or in equalize will cause an Open

Battery fault. In case of a hot battery, charge current is limited to finish

Opportunity

IE profile with a default of 10 hours time-after-gassing, settable up to

32 hours. Overall charge time limit default is 32 hours. When charge cycle is in constant voltage (E) mode, the charger is ‘floating’ and disconnecting the battery will not result in an Open Battery fault.

Defaults:

Start Rate Current

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

Defaults:

Start Rate Current

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

Defaults:

Start Rate Current

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

16% of Battery AH

2.37 V/C

Time Voltage or Charge Current falls below Finish Rate

2 Hours

4.5% of Battery AH

14 Hours rate in floating mode. If charge current rises above finish rate, charge cycle will terminate as Charge Complete.

Defaults:

Start Rate Current 16% of Battery AH

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

2.35 V/C

Floating indefinitely

Indefinite

Floating (Does not apply)

Indefinite

Defaults:

Start Rate Current

Gassing Voltage

Termination Method

Time after gassing limit

Finish Rate

Charge Time Limit

16% of Battery AH

2.37 V/C

Time Voltage

4 Hours if under 2.53 V/C

2 Hours if 2.53 V/C reached

2% of Battery AH

14 Hours

4.5% of Battery AH

Does not apply

32 Hours

16% of Battery AH

2.37 V/C

Time Voltage

10 Hours

Floating (Does not apply)

32 Hours

EnForcer™ SCR Service Manual I.B. 1561

Data Logging

While in Idle Mode or Done mode, hold down the DOWN and UP buttons (approximately 10 seconds) until the display reads Data

Logging Selections.

Release the buttons and the display will read “ Number of Records:”.

Toggle the EQUALIZE button and the display will read Display a Record? The last record number will be shown at the bottom right of the display.

Toggle the DOWN arrow keys to scroll through the available records. To view the contents of the individual record, toggle the

EQUALIZE button. The Log Date will be displayed. To view the log data, toggle the UP or DOWN buttons. The log time, charge parameters for that log can be read. To exit a particular log, press the EQUALIZE button. You can then continue to scroll through different Data Logs with the UP and DOWN buttons. Select a new log again by pressing the EQUALIZE button. In order to exit

Data Logging at any time, press the START/STOP button.

The table below shows a list of the available Data Log parameters. The table shows the data in the order that it appears.

1. Log Date/Time

2. Log Store Code

3. Total Charge Cycles

4. Total Equ. Cycles

5. Total Charge Amp-Hours/1000

Date and time of log event

1 = Daily charge Complete. 2 = Daily Charge Incomplete. 3 =

Equalize Charge Complete. 4 = Equalize Charge Incomplete.

Total Charge cycles greater than 1 hour

Total Equalize cycles greater than 1 hour

Total Amp- Hours the charger has put out in thousands of Amp-

Hours.

6. Max. Charger Temperature *

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

11. BID Serial Number **

12. Battery Amp-Hour Rating

13. Battery Start Temperature *

Min. DC volt for this particular charge cycle

Future option

Battery Amp-hour setting from USER parameters

Future option

14. Battery End Temperature *

15. Battery Cell Size

16. Equalize Count

17. DC volts at Start

18. DC volts at End

19. Amp-Hours Returned

20. DC Amps at Start

21. DC Amps at End

22. Pre 80% Charge Time

23. Total Charge Time

24. Charge Profile Used

25. Fault Code

Future option

Battery Cell size from USER parameters

Equalize count setting from USER Parameters

DC volts at beginning of charge cycle

DC volts at end of charge cycle

Amp hours returned for this particular charge cycle

DC amps at beginning of charge cycle

DC amps at end of charge cycle

Charge Profile 1-6 from Service Parameters.

1 = DC fuse, 2 = Open Battery, 3 = Time to gassing, 4 = Low

Battery, 5 = Overall Time Limit, 6 = Hot Battery, 7 = High Battery

Voltage, 8 = Time After Gassing, 9 = High Amp-Hours, 10 = AC power distortion, 11 = AC fuse or single phase

*Note that all the temperature features are future features.

** Note the BID serial Number is a future feature

A total of 1000 events can be logged before data logger rolls over and overwrites previous data.

EnForcer™ SCR Service Manual I.B. 1561

CAUTION: To prevent arcing and burning at the connector or a possible battery explosion, press the

START/STOP pushbutton first to stop the charge cycle before removing a battery that is currently on charge.

WATCHDOG CIRCUITS

There are two watchdog circuits on the Enforcer SCR control board – the Override Watchdog and the Reset Watchdog.

Each has an associated orange LED, located on the bottom half of the right edge of the board. The LEDs can be readily observed by opening the door and looking at the board edge on. The status of the Override Watchdog is indicated by

LED1 – the upper LED; the status of the Rest Watchdog is indicated by LED2 – the lower LED.

OPERATION OF RESET WATCHDOG AND OVERRIDE WATCHDOG

OVERRIDE WATCHDOG

The Override Watchdog monitors the operation of the charge cycle and the Start/Stop pushbuttons and overrides the main microprocessor if a fault condition is detected. The SCRs are turned off and held off when an override occurs.

NORMAL OPERATION

LED1 flashes once a second to indicate that the microprocessor is operating correctly.

FAULT INDICATION

LED1 flashes at 6-8 times per second to indicate that a fault has been detected.

CONDITIONS THAT CAUSE FAULTS

Total charge time: If the charge time exceeds 19 hours (this includes successive refresh cycles), the Override Watchdog will operate.

Start / Stop button: If the Start/Stop button is pressed while the charger is charging and the main microcontroller does not shut off the output within ½ 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 to recover from any override watchdog fault is to cycle control board power.

Please note: If a battery has been connected to a charger for a long period after the charge cycle has completed, the successive refresh cycles may cause the 19 hour charge time limit to expire. The Override Watchdog will operate and prevent the main processor from starting a charge cycle. A “DC fuse” fault will result.

RESET WATCHDOG

The Reset Watchdog will reset the main processor in the event of a processor fail or lock-up.

NORMAL OPERATION

LED2 flashes every second for 2 minutes after control board power up. The Reset Watchdog is not enabled during this 2 minute start-up. After two minutes, LED2 stays on steady. The Reset Watchdog is now monitoring the main processor.

For normal operation, LED2 will remain on steady.

FAULT INDICATION

If the main processor locks-up or does not operate as expected, the Reset Watchdog will reset the main processor after an 8 second delay. The control board will re-boot and resume normal operation. If a battery is connected to the charger, the control board will go into random delay before starting the charge cycle. LED2 will flash every 4 seconds indicating a

Reset has occurred since the last control board power up.

EnForcer™ SCR Service Manual

SUBSEQUENT FAULT INDICATION

If the main processor locks-up again before the next control board power-down, LED2 will flash as shown below.

LED2 state

ON steady

Main Processor

No lock-ups or failures since last power-up.

Flash every 4 seconds

Flash every 2 seconds

Flash every 1 second

Flash every ½ second

1 lock-up since last power-up.

2 lock-ups since last power-up.

3 lock-ups since last power-up

4 or more lock-ups since last power-up.

I.B. 1561

If the main processor locks-up more than four (4) times, LED2 will remain flashing every ½ second.

FAULT RECOVERY

The Reset Watchdog is reset by cycling power to the control board. After power-up, the Reset Watchdog will resume normal operation and will light steadily after the two minute time-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 measurements should be within 10% of what is listed on the nameplate.

Second Transformer Test (120V Test)

Be sure to disconnect the transformer from SCR/Diode Block, PC board, and control transformer primary. You will need to have the transformer isolated for this test.

1) Use a line cord with a 3 to 5 amp slow-blow fuse in an in-line fuse holder.

2) Power each section separately. Power from TB #1 and #6, and jumper leads 3 and 4.

3) If a fuse has opened, there might be a winding problem in the transformer. Perform all other tests in this section before replacing the transformer.

EnForcer™ SCR

SCR/DIODE BLOCK

Service Manual I.B. 1561

WARNING: Faulty SCR/Diode Blocks may cause voltage to be present at the DC cables.

Physical Test

If you do not have a clamp-on meter to check for current in the 3 SCR/Diode Blocks, you can perform the following to locate a fault in the secondary phase:

1) Start the charger, and run it for 5 minutes with a battery connected.

2) Turn off the charger and disconnect the battery.

3) Within 1 minute, check the temperature of the SCR/Diode Blocks. If an SCR/Diode Block is cold, then it is defective.

WARNING: Heatsink and SCR/Diode Blocks may be very warm. Please exercise caution.

First SCR/Diode Block Test

Please follow these steps before testing the SCR/Diode Blocks:

Disconnect the battery.

Disconnect the AC power.

You will be testing the SCR/Diode Blocks to see whether there is continuity or forward leakage 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 directions, the SCR/Diode Block may be open. To prove the SCR/Diode

Block functions properly, you need to go to the next test (Second SCR/Diode Block Test) to check the gating operation of the SCR/diode block.

Second SCR/Diode Block Test

Please follow these steps before testing the SCR/Diode Block:

Disconnect the battery.

Disconnect the AC power.

You can test a single SCR/Diode Block at a time. You will need a Flashlight tester or a Continuity tester with 2 AA batteries in it to do this.

Please follow these steps:

1) Disconnect the three phase input wires to each of the SCR/Diode Blocks.

2) Disconnect the nylon connector from the SCR/Diode Block (gate drive).

EnForcer™ SCR Service Manual I.B. 1561

3) Connect the negative potential of your tester to the positive buss bar.

4) Connect the positive potential of your tester to the input connection of the SCR/Diode Block under test. Then by using a jumper wire touch the SCR/Diode Block gate pin (white lead connects there) to the SCR/Diode Block input connection. The tester will light.

NOTE: If your tester lights before connecting to the SCR/Diode Block input, then the SCR/Diode Block is defective. Test one SCR/Diode Block at a time to find the faulty one(s).

5) Disconnect the jumper wire to the SCR/Diode Block gate pin. The tester should remain lit.

6) The SCR/Diode Block is defective if the tester did not remain lit.

DIODE TEST

Please follow these steps before testing the diode:

Disconnect the battery.

Disconnect the AC power.

You will be testing the diode to see if it is shorted.

1) Disconnect the three phase input wires to the SCR/Diode Blocks.

2) Use an analog meter set to its X1 scale, or use a DVM set to its diode scale.

3) Connect the meter’s negative lead to the input connection of the SCR/Diode Block.

4) Connect the meter’s positive lead to the (-) buss bar.

5) If you are using an analog meter, it should read close to 0 ohms.

6) If you are using a DVM, it should read a .7V drop on the diode scale.

7) Reverse the wires on the meter.

8) The needle should not move on the analog scale (measurement of infinity). The DVM should not get a reading.

9) The SCR/Diode Block is shorted if the meter measures 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 tests as an open circuit (infinity), replace it.

3) If there is continuity across the fuse (less than 1 ohm), it is working properly.

PRINTED CIRCUIT BOARD FUSES AND VOLTAGES

Measure the voltages on the bottom terminals of the circuit board fuses with the charger AC power connected and the battery disconnected.

Measurement

F5-F8

F6-F8

F7-F8

Expected voltage (VAC)

10 ± 10%

Please note that these voltages are dependent on the line voltage.

PRINTED CIRCUIT BOARD

The printed circuit board is not field calibrated. No pots or jumpers are contained on the control board. In order to verify proper operation, insure that all USER and SERVICE parameters are set properly, especially the charger/battery cell size and amp hour ratings. Please follow these steps before testing the PC Board:

Set correct control board battery and charger cell size and amp hour ratings in USER/SERVICE parameters.

1) Connect appropriate size battery to charger. Battery terminal voltage should be at around 2 volts/cell.

2) Charger should detect battery and start a charge cycle. If charger does not respond, check wiring and ensure that

DC battery voltage is being read at the control board..

3) Faulty control boards cannot be field modified. Replace faulty control boards and return to factory for evaluation.

EnForcer™ SCR Service Manual I.B. 1561

SNUBBER ASSEMBLY

Please follow these steps before testing the snubber assembly:

Disconnect the battery

Disconnect the AC power.

The snubber assembly consists of a series resistor and a capacitor.

Before taking measurements on the Snubber assembly

1) Verify that the mounting wire is sound-properly screwed on and not broken.

2) Verify that the Snubber assembly is not burned, broken, or smoking.

To test the Snubber assembly

1) Disconnect a mounting wire and check for no continuity.

2) Replace if your meter reads less than 200K ohms.

REPLACING COMPONENTS

CAUTION:

THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET.

ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY

CHARGER.

INTRODUCTION

Return all replaced components to your service center.

The following sections explain how to replace each component. After replacing a component, be sure to:

1) Reconnect all leads exactly as they were removed.

2) Replace any heat-shrink tubing if any old tubing was removed.

3) Retighten all connections

4) Replace covers.

Preparation

Please follow these steps before removing or replacing any component:

Disconnect 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 the back compartment of the charger, remove the bolts (as many as 6) that hold the transformer to the charger frame.

WARNING: The transformer is heavy. Use appropriate equipment to lift it.

Replacement

To insert a transformer, follow these instructions:

1) Place the new transformer into the back of the charger, taking care of the transformer’s pigtail.

2) Replace the bolts that secure the transformer to the charger frame.

3) Connect the AC input wires onto the 3 terminal input blocks. Do this by pre-bending the wires and trimming the double leads (wires #2 and #5) to the same length. The purpose for doing this is so that when you install the double leads into the terminal block, they both get properly secured when the screw is tightened down on them.

4) Be sure that all wires being connected to the terminal strip are bare. Make sure insulation is removed from the wires for good connections.

5) Avoid placing the A phase primary leads near the top panel’s mounting hole.

EnForcer™ SCR Service Manual I.B. 1561

WARNING: Be sure to install phase A, phase B, and phase C wires to their proper terminals in the front of the charger (A is on the left, C is on the right).

When installing primary leads into the terminal blocks, take special precaution in preparing the double-wire leads (wires #2 and #5) for insertion into the terminal blocks.

6) Connect the transformer’s control voltage wires to the fuses.

WARNING: Be sure to install 7A, 7B, and 7C in proper order (A is on the left, C is on the right). If they are not connected properly, a phase control problem will occur.

7) Connect the secondary leads to the SCR/Diode Blocks. Again, be careful to connect phase A to phase A, phase

B to phase B, etc.

SCR / DIODE BLOCK

Specifications for mounting SCR / Diode Blocks on Flat Aluminum Heat Sinks:

Surface

1) No scratches, gouges, or burrs allowed in the SCR / Diode block contact area.

2) No oil, dirt, paint, adhesive or other foreign substances are permitted in the contact area.

3) Apply a light coating of heat sink thermal compound to the flat side of the SCR / Diode Block.

Mounting Instructions

1) Tighten the nut with your fingers as far as possible. Then use the torque wrench. Do not exceed the torques shown in the following table.

2) Do not use any other wrench to tighten the nut.

SCR / Diode Block

Size

104 Amp

162 Amp

250 Amp

285 Amp

SCR / Diode Block Mounting Torque (in/lb)

Bolt Size

10-32 X 1.25

10-32 x 1.25

Max

19.0

Buss Bar Mounting Torque (in/lb)

Bolt Size

5mm

6mm

8mm

Max

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) Remove the DC cable leads.

2) Remove the DC control leads (red) from the PC board.

3) Unplug the SCR / Diode Blocks gate leads.

4) Remove the secondary transformer leads from the input of the SCR / Diode Block.

5) Unscrew the two buss bars from the SCR / Diode Blocks. Note on the units where the buss bar is directly attached to the jumper wire, leave the buss bar attached to the jumper wire and just move the buss bar away from the SCR / Diode Blocks.

6) Now you can remove the SCR / Diode Block from the heat sink.

Replacement

1) Remove old silicone-heatsink compound from the heatsink.

2) Apply silicone heatsink compound (i.e., thermalloy 249, Aavid 1001, etc.) to the SCR / Diode Block and fasten it to the heatsink. (Use the proper torque. See table above.)

3) Replace the heatsink into the charger case, being careful to slide it onto its holder.

4) Mount the two buss bars back to the SCR / Diode Blocks.

5) Connect the secondary transformer leads to the inputs of the SCR / Diode Blocks.

6) Reconnect the SCR / Diode Block gate leads.

7) Connect the DC control leads to the PC board.

8) Replace the DC cable leads.

EnForcer™ SCR Service Manual I.B. 1561

Since you have removed the SCR / Diode Block gate leads from the harness, take special care in reconnecting the SCR /

Diode Blocks firing lead connections making sure that:

1) Phase A is connected to phase A.

2) Phase B to phase B.

3) Phase C to phase C.

PRINTED CIRCUIT BOARD (PCB)

Removal

CAUTION: Use an anti-static wrist strap (i.e. EnerSys part number 174-2-1) when handling, removing and replacing circuit board assemblies.

Please follow these steps to remove a PC board. (Be sure your hands are clean before touching a PCB).

1) Turn the AC power OFF.

2) Unplug the battery.

3) Touch your finger to a ground to remove any static charge.

4) Unplug the connectors from the PCB.

5) Remove the 11/32” nuts from PEM studs that hold the PCB to charger door.

NOTE : Handle the PCB with care. Do NOT place it on top of the battery or other acid-contaminated surfaces.

6) Place the removed PCB into the anti-static bag (or foam) that the replacement board was in.

Replacement

Please follow these steps to install a PCB:

1) Using the 11/32” nuts that held the old PCB to the PEM studs, mount the replacement board on the door.

2) Tighten the 11/32” nuts slowly and gently. Tighten nuts only enough so that the tactile switches are just 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 USER/SERVICE parameters such as cell size, amp-hours etc. accordingly.

5) Turn AC power ON. Connect battery and insure proper charger operation.

VOLTAGE CONVERSION

These chargers are designed to operate from nominal line voltages as marked on the nameplate. The line voltage to which the charger is to be converted must be one of the voltages shown on the charger nameplate.

DANGER:

POWER MUST BE DISCONNECTED BEFORE CHANGING AC INPUT CONNECTIONS.

AC INPUT CHANGE (STANDARD)

NOTE: Chargers with optional Quick Tap™ please refer to AC INPUT CHANGE WITH QUICK TAP™.

1) Change AC fuses to the value of the desired line voltage available for this charger. AC fuse values can be found on the decal inside the charge, or in charts contained in this manual.

2) Change provided jumpers, on the main transformer primary tap location, as shown on the decal inside the door of the charger, or on the following charts. Jumpers not being used are stored in the manual envelope, inside the charger.

3) Indicate the line voltage change on the decal inside the charger.

EnForcer™ SCR Service Manual I.B. 1561

MODEL B *

WIRE MARKER

WIRE CONNECTION CHARTS (3 PHASE SCR CHARGERS)

208 VOLT INPUT

CONNECTION

240 VOLT INPUT

CONNECTION

480 VOLT INPUT

CONNECTION

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

A1 TO A4

A2 TO A5

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A1 TO A4

A3 TO A6

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

V3 TO C1

A3 TO A4

B3 TO B4

B1 TO B4

B2 TO B5

C1 TO C4

C2 TO C5

B1 TO B4

B3 TO B6

C1 TO C4

C3 TO C6

C3 TO C4

A3 TO A4

B3 TO B4

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

WIRE MARKER

480 VOLT INPUT

CONNECTION

550 VOLT INPUT

CONNECTION

600 VOLT INPUT

CONNECTION

*INDICATES TWO JUMPERS

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

A2 TO A4*

B2 TO B4*

C2 TO C4*

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A2 TO A4*

B2 TO B4*

C2 TO C4*

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A3 TO A4*

B3 TO B4*

C3 TO C4*

EnForcer™ SCR Service Manual I.B. 1561

WIRE CONNECTION CHARTS (3 PHASE SCR CHARGERS con’t)

MODEL D

WIRE MARKER

220 VOLT INPUT

CONNECTION

380 VOLT INPUT

CONNECTION

440 VOLT INPUT

CONNECTION

MODEL E

WIRE MARKER

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A1 TO A4

A3 TO A6

B1 TO B4

B3 TO B6

C1 TO C4

C3 TO C6

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

A2 TO A4

B2 TO B4

C2 TO C4

A2 TO A4

B2 TO B4

C2 TO C4

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A3 TO A4

B3 TO B4

C3 TO C4

A3 TO A4

B3 TO B4

C3 TO C4

400 VOLT INPUT

CONNECTION

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

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 found on the decal inside the charger, or in the charts contained in this manual.

2) Change Quick Tap™ plug to the desired line voltage as marked under the sockets.

3) Indicate the line voltage change on the decal inside the charger.

WIRING CONNECTION ILLUSTRATION

EnForcer™ SCR Service Manual I.B. 1561

MAINTENANCE

The charger requires a minimum of maintenance. Connections and terminals should be kept clean and tight. 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

EnForcer™ SCR Service Manual

ES3

REPLACEMENT PARTS

SCHEMATICS

I.B. 1561

EnForcer™ SCR Service Manual I.B. 1561

REPLACEMENT PARTS

CAUTION:

THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET.

ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY

CHARGER.

X1060-09-ES3-1

PRINTED CIRCUIT BOARDS (CONTROL)

STANDARD MODELS

X1060-09-ES3-2 41-80 CELL

DESCRIPTION

DOOR

TOP PANEL

BACK PANEL

SIDE PANEL, LEFT

SIDE PANEL, RIGHT (STANDARD OUTPUT HOLES)

SIDE PANEL, RIGHT (OUTPUT HOLES FOR 4/0 CABLE)

UPRIGHT

PART NUMBER

X054-99-3-17

X052-99-3-12

X057-99-3-16

X057-99-0-5

X057-99-0-6

X057-99-0-7

X052-99-0-6

DOOR LATCH

RIVET FOR DOOR LATCH

TERMINAL BOARD, MAIN XFMR, LEFT

TERMINAL BOARD, MAIN XFMR, RIGHT

DC CABLE CLAMP (#2, 1/0, 2/0, & 3/0 CABLE)

DC CABLE CLAMP (4/0 CABLE)

FUSE REDUCER (<70A FUSE INTO 100A FUSE BLOCK)

FUSE REDUCER (<40A FUSE INTO 60A FUSE BLOCK)

X044-1-32

164-8-6

256-99-12

256-99-13

356-5-15

356-5-16

X014-17-6

X014-17-5

GROUND LUG X012-7-24

PC BOARD FUSE X014-7-28

Base kits are required for base replacement. Each kit includes the base and cross-members for heat sink and transformer mounting. Determine the appropriate kit for your charger from the following chart:

DESCRIPTION

11 INCH DISTANCE BETWEEN TRANSFORMER BRACKETS

15 INCH DISTANCE BETWEEN TRANSFORMER BRACKETS AND ALSO FOR (3) HEAT SINK

EXTRUSIONS

KIT PART NUMBER

X225-99-3-11

X225-99-3-15

6-550B

6-680B

6-850B

12-550B

12-680B

12-750B

12-850B

12-950B

12-1050B

12-1200B

12-1500B

18-550B

18-680B

18-750B

18-850B

18-950B

18-1050B

18-1200B

18-1500B

18-1700B

18-2000B

EnForcer™ SCR Service Manual

AMPERE HOURS

0-680

681-1200

1201 & UP

SHUNT REPLACEMENT

VALUE

150A

300

2 X 300

PART NUMBER

X117-99-2

X117-99-1

AMPERE HOURS

380

450-680

750-850

950-1050

1200

1500

1700

2000

DC FUSE REPLACEMENT

VALUE

100

150

200

250

300

350

400

250 X 2

PART NUMBER

X014-11-2

X014-11-3

X014-11-9

X014-11-16

X014-11-17

X014-11-13

X014-11-14

X014-11-16 (X 2)

MODEL NUMBER

MODEL NUMBERS WITH THE LETTER CODES T, W, X, & Y SHALL BE REFERRED TO THE TABLES WITH

THE LETTER CODE “B”.

TRANSFORMER PART NUMBER

ES3-X (B MODELS)

SCR MODULE PART NUMBER

I.B. 1561

X127-S06-680B

X127-S06-850B

X127-S12-550B

X127-S12-680B

X127-S12-850B

X127-S12-1050B

X127-S12-1200B

X127-S12-1500B

X127-S18-550B

X127-S18-680B

X127-S18-1050B

X127-S18-1200B

X127-S18-1500B

X127-S18-1700B

R507-18-2

R507-18-3

R507-18-4

R507-18-2

R507-18-3

R507-18-4

18-750D

18-850D

18-950D

18-1050D

18-1200D

18-1500D

18-2000D

24-550D

24-850D

24-1050D

24-1200D

24-1500D

40-550D

40-600D

EnForcer™ SCR Service Manual

MODEL NUMBERS WITH THE LETTER CODES T, W, X, & Y SHALL BE REFERRED TO THE TABLES WITH

THE LETTER CODE “B”.

MODEL NUMBER TRANSFORMER PART NUMBER

ES3-X (B MODELS)

SCR MODULE PART NUMBER

I.B. 1561

24-200B

24-680B

24-750B

24-850B

24-950B

24-1050B

30-1050BNC

30-680BNC

X127-S24-200B

X127-S24-680B

X127-S24-850B

X127-S24-1050B

X127-S40-1050B

X127-S40-680B

R507-18-2

R507-18-3

R507-18-2

36-450B

36-550B

36-850B

40-450B

40-550B

40-680B

40-850B

MODEL NUMBER

X127-S40-550B

X127-S40-850B

X127-S40-550B

X127-S40-680B

X127-S40-850B

TRANSFORMER PART NUMBER

ES3-X (D MODELS)

R507-18-2

SCR MODULE PART NUMBER

12-550D

12-680D

12-850D

12-1050D

18-550D

18-680D

X127-S12-550D

X127-S12-680D

X127-S12-850D

X127-S12-1050D

X127-S18-680D

R507-18-2

R507-18-3

R507-18-2

X127-S18-850D

X127-S18-1050D

X127-S18-1200D

X127-S18-1500D

X127-S18-2000D

X127-S24-550D

X127-S24-850D

X127-S24-1050D

X127-S24-1200D

X127-S24-1500D

X127-S40-550D

R507-18-2

R507-18-3

R507-18-4

R507-18-2

R507-18-3

R507-18-4

R507-18-2

EnForcer™ SCR

MODEL NUMBER

24-680J

24-750J

24-850J

24-950J

24-1050J

24-1200J

24-1500J

24-1600J

40-450J

40-550J

40-680J

40-850J

12-550J

12-680J

12-750J

12-850J

12-950J

12-1050J

12-1200J

18-550J

18-680J

18-750J

18-850J

18-950J

18-1500J

18-1700J

18-2000J

24-550J

MODEL NUMBER

12-850E

18-850EL13

24-550E

36-850E

40-550E

40-850E

Service Manual

TRANSFORMER PART NUMBER

ES3-X (J MODELS)

X127-S12-550J

X127-S12-680J

X127-S12-1050J

X127-S12-1200J

X127-S18-550J

X127-S18-680J

X127-S18-850J

X127-1050J

X127-S18-1500J

X127-S18-1700J

X127-S24-681J

S24-850J

X127-S24-850J

X127-S24-1050J

X127-S24-1200J

X127-S24-1500J

X127-S40-550J

X127-S40-680J

X127-S40-850J

SCR MODULE PART NUMBER

R507-18-2

R507-18-3

R507-18-2

R507-18-3

R507-18-4

R507-18-2

R507-18-3

R507-18-4

R507-18-2

I.B. 1561

TRANSFORMER PART NUMBER

ES3-X (E MODELS)

X127-S12-850E

X127-S18-850E

X127-S24-550E

X127-S36-850E

X127-S40-550E

X127-S40-850E

SCR MODULE PART NUMBER

R507-18-2

EnForcer™ SCR Service Manual I.B. 1561

REPLACEMENT AC FUSES

NOTE: Special charger models might not be listed in these tables. AC input is listed on the charger’s nameplate. AC fuse values are listed on a decal inside the charger. The AC fuse part number would be: X014-99-X, where X = AC fuse value.

Replacement part numbers for chargers with letter codes T, W, X, and Y shall be referred to the charger’s tables with code letter “B”

CHARGER

MODEL

,AC FUSES; MODEL B

240 VOLTS

6-550

6-680

6-750

6-850

6-950

6-1050

12-550

12-680

12-750

12-850

12-950

12-1050

12-1200

18-550

18-680

18-750

18-850

18-950

18-1050

18-1200

18-1500

18-1700

18-2000

24-550

24-680

24-750

24-850

24-950

24-1050

24-1200

24-1500

36-550

36-680

36-750

36-850

36-1050

40-550

40-680

40-750

40-850

40-1050

I AC

N/A

208 VOLTS

VALUE

P/N

X014-99-12

100

N/A

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-30

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-80

X014-99-90

X014-99-100

X014-99-40

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-100

X014-99-60

X014-99-70

X014-99-80

X014-99-90

X014-99-100

X014-99-60

X014-99-80

X014-99-90

X014-99-100

N/A

I AC

VALUE

100

P/N

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-90

X014-99-35

X014-99-45

X014-99-50

X014-99-60

X014-99-70

X014-99-90

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-90

X014-99-60

X014-99-70

X014-99-90

X014-99-100

I AC

480 VOLTS

VALUE

P/N

X014-99-5

X014-99-7

X014-99-8

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-30

X014-99-40

X014-99-45

X014-99-50

EnForcer™ SCR

CHARGER

MODEL

18-1000

18-1050

18-1200

18-1500

18-1600

18-1700

18-2000

24-550

24-680

24-750

24-850

24-950

24-1000

24-1050

24-1200

24-1500

36-450

36-550

36-680

36-750

6-550

6-680

6-750

6-850

6-950

6-1000

6-1050

12-550

12-680

12-750

12-850

12-950

12-1000

12-1050

12-1200

18-550

18-680

18-750

18-850

18-950

36-850

36-1000

36-1050

40-450

40-550

40-680

40-750

40-850

40-1000

40-1050

I AC

Service Manual

480 VOLTS

VALUE

P/N

X014-99-5

X014-99-7

X014-99-8

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-40

X014-99-50

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-25

X014-99-30

X014-99-40

X014-99-45

X014-99-50

REPLACEMENT AC FUSES (con’t)

,AC FUSES; MODEL J

550 VOLTS

I AC VALUE P/N

X014-99-5

X014-99-7

X014-99-8

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-40

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-20

X014-99-25

X014-99-35

X014-99-40

X014-99-45

X014-99-50

I AC

I.B. 1561

600 VOLTS

VALUE

P/N

X014-99-5

X014-99-7

X014-99-8

X014-99-10

X014-99-12

X014-99-15

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-35

X014-99-40

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-40

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

EnForcer™ SCR

CHARGER

MODEL

18-1000

18-1050

18-1200

18-1500

18-1600

18-1700

18-2000

24-550

24-680

24-750

24-850

24-950

24-1000

24-1050

24-1200

24-1500

36-450

36-550

36-680

36-750

6-550

6-680

6-750

6-850

6-950

6-1000

6-1050

12-550

12-680

12-750

12-850

12-950

12-1000

12-1050

12-1200

18-550

18-680

18-750

18-850

18-950

36-850

36-1000

36-1050

40-450

40-550

40-680

40-750

40-850

40-1000

40-1050

I AC

Service Manual

100

220 VOLTS

VALUE

P/N

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-100

X014-99-40

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-100

X014-99-45

X014-99-60

X014-99-70

X014-99-80

X014-99-100

X014-99-50

X014-99-60

X014-99-70

X014-99-80

X014-99-90

X014-99-100

REPLACEMENT AC FUSES (con’t)

,AC FUSES; MODEL D

380 VOLTS

I AC VALUE P/N

X014-99-7

X014-99-8

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-25

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-60

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-30

X014-99-40

X014-99-45

X014-99-50

X014-99-60

X014-99-70

I AC

I.B. 1561

440 VOLTS

VALUE

P/N

X014-99-5

X014-99-7

X014-99-8

X014-99-10

X14-99-10

X014-99-10

X014-99-12

X014-99-15

X014-99-20

X014-99-15

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-20

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-50

X014-99-25

X014-99-30

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-25

X014-99-35

X014-99-40

X014-99-45

X014-99-50

X014-99-60

EnForcer™ SCR

SCHEMATIC DIAGRAM, ES3

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

ES3

ASSEMBLY DRAWING

I.B. 1561

EnForcer™ SCR

Note : The illustration below identifies the location of some important components in standard chargers. The component P/N may vary from charger to charger. (For a P/N, refer to the 'Replacement Parts' tables).

ITEM #

Cabinet, Base

Cabinet, Right side

Cabinet, Left side

Cabinet, Top/Back

Upright

Cross Member, Main Transformers

Main Transformer

DESCRIPTION

Heat Sink Assembly 8

SCR diode/block

Buss bar

Cross Member, Heat Sink

PC Board Fuses

Shunt

DC Fuse

Terminal Board Primary, Main Transformer

Panel, Sub-assembly

AC Block / Input Fuses

Door

Ground Lug

DC output cables and clamp

W-1 Wire Group, Primary Voltage

W-2 Wire Group, PC Board

W-3 Cable Connecting Heat Sink & Shunt

Service Manual

I.B. 1561

EnForcer™ SCR

INTERIOR VIEWS:

Service Manual I.B. 1561

EnForcer™ SCR

SINGLE EXTRUSION HEAT SINK ASSEMBLY

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

SINGLE EXTRUSION HEAT SINK ASSEMBLY (HARDWARE STACK-UP DETAILS)

TO BUSS BAR

TO J4

BLACK TO BATT

I.B. 1561

EnForcer™ SCR

THREE EXTRUSION HEAT SINK ASSEMBLY

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

THREE EXTRUSION HEAT SINK ASSEMBLY (HARDWARE STACK-UP DETAILS)

FROM BUSS BAR

TO J4

BLACK TO BATT

I.B. 1561

EnForcer™ SCR Service Manual

SUB-ASSEMBLY PANEL ASSEMBLY

I.B. 1561

EnForcer™ SCR

MODEL B

WIRE MARKER #

MODEL D

WIRE MARKER #

Service Manual

SUB-ASSEMBLY PANEL WIRING

LOOSE WIRE

MARKER #

208 V CONNECTIONS

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

A1 TO A4

A2 TO A5

B1 TO B4

B2 TO B5

C1 TO C4

C2 TO C5

COLOR

GREEN

240 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A1 TO A4

A3 TO A6

B1 TO B4

B3 TO B6

C1 TO C4

C3 TO C6

MARKER #

220 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A1 TO A4

A3 TOA6

B1 TO B4

B3 TO B6

C1 TO C4

C3 TO C6

LOOSE WIRE

COLOR

GREEN

380 V CONNECTIONS

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

A2 TO A4

B2 TO B4

C2 TO C4

A2 TO A4

B2 TO B4

C2 TO C4

I.B. 1561

CONNECTION

G1 TO DOOR

480 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A3 TO A4

B3 TO B4

C3 TO C4

A3 TO A4

B3 TO B4

C3 TO C4

CONNECTION

G1 TO DOOR

440 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A3 TO A4

B3 TO B4

C3 TO C4

A3 TO A4

B3 TO B4

C3 TO C4

EnForcer™ SCR

MODEL J

WIRE MARKER #

MARKER #

Service Manual

SUB-ASSEMBLY PANEL WIRING (con’t)

LOOSE WIRE

COLOR

GREEN

208 V CONNECTIONS

F1 TO A1

F1 TO C5

F2 TO A5

F2 TO B1

F3 TO B5

F3 TO C1

240 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A2 to A4*

B2 TO B4*

A2 TO A4*

B2 TO B4*

C2 TO C4* C2 TO C4*

*INDICATES DOUBLE JUMPER

MODEL E

400 V CONNECTIONS

WIRE MARKER #

CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

I.B. 1561

CONNECTION

G1 TO DOOR

480 V CONNECTIONS

F1 TO A1

F1 TO C6

F2 TO A6

F2 TO B1

F3 TO B6

F3 TO C1

A3 TO A4*

B3 TO B4*

C3 TO C4*

EnForcer™ SCR

DOOR ASSEMBLY

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

PARALLEL CABLES (OPTIONAL)

I.B. 1561

EnForcer™ SCR

DISCONNECT SWITCH (OPTIONAL)

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

CABINET ASSEMBLY

I.B. 1561

EnForcer™ SCR

CABINET ASSEMBLY, EXPLODED VIEW

Service Manual I.B. 1561

EnForcer™ SCR Service Manual I.B. 1561

ES3

LARGE CABINET

REPLACEMENT PARTS

SCHEMATIC

REPLACEMENT PARTS / FUSE VALUES

CAUTION:

THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET.

ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS

BATTERY CHARGER.

PRINTED CIRCUIT (CONTROL) BOARD

Charger Model Number PCB Part Number

ES3-30-1700YNC X1060-09-ES3-1

COMMON PARTS TO ALL MODELS

Description

Door

Top Panel

Back Panel

Left Side Panel

Right Side Panel

Base

Cross Member, Heat Sink Mtg.

Cross Member, Xfmr Mtg, Front

Cross Member, Xfmr Mtg, Back

Upright Support

Door Latch

Door Latch Rivets

SHUNTS

Charger Model Number

ES3-64-1250J

X054-99-3-19

X057-99-3-23

X057-99-3-3

X057-99-3-13

X057-99-3-22

013-99-3-3

X051-99-3-13

X051-99-3-14

X051-99-3-15

X052-99-0-6

X044-1-32

164-8-6

Part Number

PCB Part Number

X1060-09-ES3-2

EnForcer™ SCR Service Manual I.B. 1561

Ampere Hours

0-680

681-1200

1201 & UP

PARTS / FUSE VALUES FOR ES3-30-1700YNC

Description

Value

150

300

300 X 2

Part Number

X117-99-2

X117-99-1

Part Number

Transformer

AC Fuses (70A)

DC Fuse (400A)

Shunt (300A)

PARTS / FUSE VALUES FOR ES3-64-1250J

Description

X127-S30-1700Y

X014-99-70

X014-30-7

X117-99-1

Part Number

Transformer

AC Fuse, 480V Connection, 100A

AC Fuse, 550/600V Connection, 90A

DC Fuse (250A)

X127-S64-1250J

X014-99-100

X014-99-90

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 inside the charger. The AC Fuse part number would be:

X014-99-X , where X would equal the AC Fuse Value.

EnForcer™ SCR

SCHEMATIC DIAGRAM

Service Manual I.B. 1561

EnForcer™ SCR Service Manual

ES3

LARGE CABINET

ASSEMBLY DRAWINGS

I.B. 1561

EnForcer™ SCR

CHARGER INTERIOR VIEW

Service Manual I.B. 1561

EnForcer™ SCR

TRANSFORMER CONNECTIONS

Service Manual I.B. 1561

EnForcer™ SCR

HEAT SINK ASSEMBLY

Service Manual I.B. 1561

EnForcer™ SCR

HEAT SINK ASSEMBLY (CON’T)

Service Manual I.B. 1561

EnForcer™ SCR

SUB-ASSEMBLY PANELS

Service Manual I.B. 1561

EnForcer™ SCR

CABINET ASSEMBLY

Service Manual I.B. 1561

EnForcer™ SCR

CABINET ASSEMBLY (CON’T)

Service Manual I.B. 1561

Ersatzteilliste

Spare Parts list

GP 25

Gültig für: / Valid for:

4699 825 013 / 4699 825 014 / 4699 825 016

4699 825 017 - 4699 825 022

4699 825 024 - 4699 825 033

4699 825 037 - 4699 825 039

4699 825 042 / 4699 825 048 / 4699 825 049

Ausgabe/Edition: 01.06.2010

Aufgrund möglicher technischer Veränderungen des hier beschriebenen 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. Technical modifications are to be considered as modifications in production, processing and appearance of the product.

ZF Gotha GmbH • Passauer Str. 1 • D-99867 Gotha

GP 25

1. Inhaltsverzeichnis:

1. Inhaltsverzeichnis ........................... 2

2. Vorwort .......................................... 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

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

2 von / of 16

GP 25

2. Vorwort

Die Ersatzteilliste ist nur gültig für die auf der Titelseite angegebenen

Getriebetypen. Die Typenbezeichnung Ihres Getriebes können Sie dem

Typenschild entnehmen. Verwenden Sie nur Original ZF Ersatzteile oder von

ZF freigegebene Ersatzteile. Für Schäden, die durch die Verwendung von nicht Original ZF Ersatzteilen und Zubehör entstehen, übernehmen wir keine

Haftung oder Gewährleistung.

Bei Bestellungen von Ersatzteilen bitte angeben:

Getriebetyp und Bauart

Getriebeausführung, Seriennummer und

Identnummer

Pos. Nr., Benennung, Identnummer und Menge der benötigten Teile gewünschte Versandart

Für die Lieferung der Ersatzteile gelten unsere allgemeinen

Lieferbedingungen sowie die Kundendienstregelungen 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: [email protected]

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 parts approved by ZF. We will not accept any liability or guarantee for damage resulting from the use of spare parts or accessories that did not originate from ZF.

When ordering spare parts, please state:

Transmission type

Transmission serial no and transmission ident no

Item No., part name, part no. and quantity of parts required

Shipment desired

The supply of spare parts is subject to our General Terms of Delivery and the

Service agreement of ZF Gotha GmbH.

Orders to:

ZF Gotha GmbH

Passauer Str. 1

99867 Gotha

Germany

Phone: + 49 (0)3621 311 4400

Fax: + 49 (0)3621 311 4419

E-Mail : [email protected]

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

3 von / of 16

GP 25

3. Identifizierung des Antriebssystems / MDU identification

Typenschild / Type plate

Pos. Nr. / Item no Bezeichnung

Getriebetyp

Seriennummer

Identnummer

Übersetzung

Kundenidentnummer

(optional)

Ersatzteilliste / Spare Parts list

Description

Transmission type

Serial number

Parts list number/ Transmission Id. No

Ratio

Customer code number

(optinal)

4699.770.019

Version B / 01.06.2010

Typenschild/ Type plate

4 von / of 16

GP 25

4. Ersatzteile / Parts

4.1. Gehäuseteile / Housing parts

101.010

101.070

101.020 101.030

101.050

101.060

101.050

101.060

101.040

101.090

Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen!

Illustrations may differ from actual design!

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

5 von / of 16

GP 25

Gehäuseteile / Housing Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No. Bezeichnung Name

101.010 Gehäuse

101.020

Gehäusedeckel

101.030

Zylinderschraube

101.040 Zylinderstift

101.050 Dichtring

Housing

Housing cover

Cylindrical screw

Cylindrical pin

Sealing ring

Bestellnummer

/ Order

Number

4699 301 145 1 1 1

4699 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

4699 309 083

4699 309 085

0636 101 411

0631 302 212

0634 801 038

Verschlussschraube mit

101.060 Magnet

Screw plug with magnet 0501 319 149 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

101.070 Entlüfter Breather 0637 885 613 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

101.090

Verschlussschraube Screw plug 0636 302 013 0 2 0 2 2 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 2 0 0 0

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

6 von / of 16

GP 25

4.2. Bremsenteile / Brake system parts

109.110

109.070

4x 3x

109.010

109.090 109.100

109.020

Ersatzteilliste / Spare Parts list

109.000

Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen!

Illustrations may differ from actual design!

4699.770.019

Version B / 01.06.2010

7 von / of 16

GP 25

Bremsenteile / Brake System Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No.

109.000

Bezeichnung Name

Kit

Verschleißteile Bremse

Kit

Brake wearing parts

Axiallager

Zylinderstift

Außenlamelle

Innenlamelle

Druckscheibe

Druckscheibe (Set)

Druckfeder

Dichtring

Druckstift

(Set)

Axial bearing

Cylindrical pin

Outer clutch disc

Inner clutch disc

Pressure disc

Pressure disc (set)

Pressure spring

Sealing ring

Pressure pin (set)

Bestellnummer

/ Order

Number

4699 195 039 1

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

8 von / of 16

GP 25

Bremsenteile / Brake System Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No. Bezeichnung Name

Bestellnummer

/ Order

Number

109.010 Axiallager

109.020 Zylinderstift

109.070 Druckfeder

109.090 Dichtring

109.100

Druckstift

(Set)

Axial bearing

Cylindrical pin

Pressure spring

Sealing ring

Pressure pin (set)

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

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

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

0634 502 084 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

4699 209 004 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

109.110 Bremshebel Brake lever 0501 319 755 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

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

9 von / of 16

GP 25

4.3. Eintriebsteile / Input parts

102.070 102.060 102.050

102.040 102.030

102.000

Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen!

Illustrations may differ from actual design!

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

102.010

10 von / of 16

GP 25

Eintriebsteile / Input Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr. /

Pos. No. Bezeichnung Name

102.000

Kit

Stirnrad

Kit

Spur gear

Stirnrad Spur gear

Antriebsritzel Input pinion

Ball bearing Kugellager

Sicherungsring Circlip

102.010 Antriebsritzel Input pinion

Ball bearing 102.030 Kugellager

102.040

Sicherungsring

102.050

Innenlamellenträger

102.060 Halteblech

Circlip

Inner disc carrier

Fixing plate

Bestellnummer /

Order Number

4699 195 036 1 1 1 1 1

4699 195 037 1 1 1

4699 195 038 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4699 195 041 1 1

0630 501 028

4699 303 085

4699 303 103

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

4699 302 217 1 1

0635 331 100 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

102.070 Torxschraube Torx screw 0501 323 470 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

11 von / of 16

GP 25

4.4. Abtriebsteile / Output parts

103.200 103.190 103.090 103.130 103.180

103.080 103.010 103.100 103.120 103.150 103.160 103.070 103.020 103.140

Ersatzteilliste / Spare Parts list

Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen!

Illustrations may differ from actual design!

4699.770.019

Version B / 01.06.2010

103.110

12x

103.500

103.600

12 von / of 16

GP 25

Abtriebsteile / Output Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No. Bezeichnung Name

103.500 Kit Hohlrad

Ring Gear

Kit

Hohlrad

Zahnscheibe

Internal gear

Lock washer

Ring Ring

Torxschraube Torx screw

Bestellnummer

/ Order

Number

4699 195 042 1

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 Planetenradsatz

Planet gear set

Planetenrad Planet gear

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

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

103.010 Radwelle

103.020

Planetenträger

Cyl. roller bearing

Wheel shaft

Planet carrier

4699 303 126

4699 303 127

103.070

Ausgleichscheibe

103.080 Radbolzen

Shim

Wheel bolt

4697 202 004

4699 300 110

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 1 103.090 Nutmutter

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

13 von / of 16

GP 25

Abtriebsteile / Output Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No. Bezeichnung Name

103.100 Dichtring

Sealing ring

Bestellnummer

/ Order

Number

0501 323 422 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

103.110 Torxschraube Torx-Screw 0501 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

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 1 103.120 Nilosring

103.130

Wellendichtring

103.140 Nadelhülse

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

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

103.160

Kegelrollenlager

103.180 O-Ring

Taper roller bearing 0750 117 615 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

Taper roller bearing 0635 370 019 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

0634 306 253 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 O-ring

Cylindrical pin 0631 315 604 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 103.190 Zylinderstift

103.200 Schutzkappe

Protection cap 0501 325 098 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

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

14 von / of 16

GP 25

4.5. Anbauteile / Attaching Parts

170.020 170.010

Die Abbildungen können von der tatsächlichen Getriebeausführung abweichen!

Illustrations may differ from actual design!

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

15 von / of 16

GP 25

Anbauteile / Attaching Parts Benötigte Teilestückzahl / Required Number Of Pieces

Pos.Nr.

/ Pos.

No. Bezeichnung Name

170.010 Motor Motor

Bestellnummer

/ Order

Number

0501 213 927 1

0501 319 869

0501 007 341

0501 217 044

0501 214 992

0501 215 738

0501 215 832

0501 215 724

Motoreinheit Motor unit 0501 327 583

Assembly

170.020 Montageteile parts 4699 270 005 1

1 1

1 1 1 1

1 1

1 1 1 1 1 1 1 1 1 1 1 1 1

4699 270 018 1

Ersatzteilliste / Spare Parts list 4699.770.019

Version B / 01.06.2010

16 von / of 16

Models 11860-Series

11870-Series

SELF-PRIMING PUMPS

ELECTRO-MAGNETIC CLUTCH UNIT

FEATURES

Body:

Impeller:

Shaft:

Seal:

Ports:

Bearings:

Weight:

Bronze

Nitrile

Stainless Steel

Carbon-Ceramic, Face Type

11860-Series, 1" NPT Internal

11870-Series, 1-1/4" NPT Internal

Shielded Ball Bearings

11860-Series, 15 lb (6.8 kg) Approx.

11870-Series, 19-1/2 lb (8.9 kg) Approx.

Model

11860-0005

11860-0045

11860-0006

11860-0046

11870-0005

11870-0045

11870-0006

11870-0046

11870-0007

Clutch

Volt/Belt

12 / 2-A

12 / 1-B

24 / 2-A

24 / 1-B

12 / 2-A

12 / 1-B

24 / 2-A

24 / 1-B

32 / 2-A

Cam

Brass

Impeller Insert

Nitrile

Brass

APPLICATION

MARINE: Pumping bilges, Washdowns, Circulating water in bait tanks, Utility dock-side pump.

INDUSTRIAL: Circulating and transferring, Velocitymixing, Pumping machine tool coolants, Return spill,

Sump drainage, Chemicals, Pharmaceuticals, Soap,

Liquors, Ink, Dyes, Alcohol, Various acids, Tanning

Liquors, Glycerine, Brine, etc.

FARMING: Pumping water stock, Pumping water from shallow wells and cisterns.

PLUMBING AND HOME EMERGENCY USE: Pumping out flooded basements, Cesspools, Sumps, Water heaters and water closets, Drains and sinks, Draining fishponds and pools.

PUBLIC UTILITIES AND MUNICIPALITIES: Under the hood mounting on service trucks for draining meter 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 Vacuum Switch

Model 4732-0000 for automatic shutoff.

WARNING

Injury hazard. Exposed pulleys and belts can cause injury. Install shield around pulleys and belts. Stay clear while machinery is operating.

WIRING

Connect wires as shown for manual on-off operation. Install appropriate size fuse (see Electrical Specification Chart) in positive lead as close to power source as possible. For complete wiring instruction, see diagram on last page.

Connect wires as shown for manual on-off operation.

ELECTRICAL SPECIFICATIONS

Voltage

Amp Draw

1.5

Fuse Size

OPERATION

Pump will self-prime at low or high speeds. Make sure that all connections are airtight. 12 Volt models are equipped with mechanical clutch engagement screws in case of electrical failure. To mechanically engage clutch, loosen locking nuts, tighten allen head screws and retighten locking nuts. Reverse procedure to disengage clutch. If the mechanical engagement feature is not desired, the screws may be removed. DO NOT RUN

PUMP DRY FOR MORE THAN 30 SECONDS. LACK

OF WATER FLOW MAY DAMAGE IMPELLER. To drain pump, loosen end cover screws. See Head Capacity

Table for head pressures and flow. To avoid costly shutdowns, keep a Jabsco Service. Kit on hand.

SERVICE INSTRUCTIONS

IMPELLER REPLACEMENT: Remove end cover gasket. Pull impeller out by grasping hub with pliers. With rotary motion in the direction the pump will be turning, push the impeller into the impeller bore. A light coating of grease in the impeller bore will protect the impeller during initial dry start up. Install gasket and end cover.

SHAFT SEAL REPLACEMENT, 11870-SERIES: Remove end cover, gasket and impeller, as outlined above. Loosen cam screw several turns.

Give cam screw a couple of sharp raps with the handle of the screwdriver to loosen the cam from the impeller bore. Remove the cam screw and cam (clean sealant from cam and impeller bore). Remove wearplate with hooked wire. Remove marcel washer, seal assembly and seal s eat assembly from seal bore with hooked wire, taking care not to scratch shaft or seal seat bore. Clean shaft surfaces behind splines and inspect for scratches or wear. Replace if necessary. Before installing new seal parts, clean any oil or grease from carbon and ceramic seal faces. Dip seal seat and gasket assembly in water and press into seal bore with boot first. Dip carbon seal assembly in water and install over shaft, carbon towards ceramic seal seat, until it bottoms firmly against ceramic seat. Slide marcel spring washer over shaft and against the rubber boot

(washer) on carbon seal assembly. Replace wearplate, aligning notch with dowel pin in body. Apply sealant to top surface of cam and cam screw threads and install cam in impeller bore. Snug up but do not tighten cam screw. Replace impeller, gasket and end cover as outlined above. Tighten end cover screws. Tighten cam screw.

SHAFT SEAL REPLACEMENT, 11860-SERIES: Refer to major repair instructions.

FIELD COIL REPLACEMENT: Remove drive belts from pulley. Remove center bolt and washer from pulley (it may be necessary to remove end cover to hold impeller from turning, while removing center pulley bolt).

Tap pulley with soft mallet to remove from shaft taper. Remove 3 bolts and washers holding field coil to adaptor (11870) or body (11860).

Remove and replace field coil, tightening the 3 bolts securely. With drive key in place in shaft, replace pulley assembly. Secure to shaft, replace pulley assembly. Secure to shaft with center bolt and washer (again, it may be necessary to hold the impeller from turning to tighten center bolt). Replace drive belts. Do not over tighten belts. A deflection of 1/2" midway between pulleys is generally considered normal.

MAJOR REPAIR: Remove pump from installation for major repair.

Disassembly: Remove end cover, gasket,impeller, cam and wearplate as outlined in shaft seal replacement, 11870-Series. Remove clutch as outlined in field coil replacement. Model 11870-Series: Use a punch to drive roll pins (key 17) in toward shaft approximately 3/8" (10mm).

Remove clutch adaptor from body. Punch roll pin out of adaptor. Model

11860-Series does not have adaptor, clutch is secured directly to body.

Remove bearing to body retaining ring. Support bearing end of body on arbor press platten. Press on impeller end of shaft to remove shaft and bearing assembly from body. Use screwdriver to pry inner bearing seal from body. Take care not to scratch or damage body bore.

11860-SERIES: Remove seal seat assembly from shaft. Support impeller end of body on arbor press platten and, using suitable tube, press seal out of seal bore towards impeller end.

11870-SERIES: Remove slinger from drain area. Carbon portion of the seal assembly will be freed from shaft when shaft is remove from body. Press seal seat assembly from bearing bore end towards impeller bore.Remove bearing to shaft retaining ring. Support bearing and press on clutch drive end of shaft 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. Lubricate bearing seal with grease and press into bearing seal bore, flush with bearing bore shoulder, with lip facing away from bearing bore. For 11870-Series only: Insert slinger in drain slot, to be picked up by shaft during shaft/bearing assembly. Insert splined end of shaft through bearing seal (and slinger on Model 11870-Series).

Press on outer bearing race to assemble shaft/bearing assembly into body, bottoming bearing firmly against bearing bore shoulder.Install

body to bearing retaining ring in groove in body with flat side against bearing. For 11870-Series only: Install clutch adaptor in bearing bore.

If re-using adaptor previously disassembled from pump, line up dowel pin holes during assembly of adaptor to body. If installing new adaptor

(which does not have pre-drilled dowel pin holes), insert into bearing bore until it bottoms and use dowel pin holes in body to pilot drill dowel pin holes through adaptor in two places, 180° apart. Clean any brass chips from bearing area. Press roll pins into body to secure adaptor.

Attach field coil to adaptor (11870-Series) or body (11860-Series) with three round head bolts. Turn body over and support on field coil.

11860-SERIES: Dip seal seat assembly, consisting of ceramic seal seat and rubber washer, in water and push over shaft, with shiny side of ceramic facing impeller bore, until bottoms firmly against shaft shoulder. Press on outside edge of seal case with carbon seal face towards ceramic seat to install seal assembly in seal bore. Press flush with bottom of impeller bore.

11870-SERIES: Assemble rubber boot over ceramic seal seat so that shiny surface of seal seat is outwards. Dip assembly in water and insert into seal bore. Press firmly but carefully on seal seat until it bottoms against shoulder of seal bore. Check to see that the seal seat assembly remains in position and does not “pop” back out. A slight twisting motion while pressing will seat it firmly in position.In this pump, either a wave washer seal or coil spring carbon seal may be used. The wave washer is used only if the carbon portion of the seal does not have a coil spring attached.

Inspect shaft and seal seat bore to be sure sealing surfaces are free of nicks or scratches. Clean shaft surface behind splines to ensure proper O-ring seal on shaft. Apply light film of grease on shaft surface behind spline area. Slide carbon ring assembly, with carbon facing ceramic, over the shaft and firmly up against the ceramic seat. If carbon portion of seal does not have an integral coil type tensioning spring, slide wave washer over the shaft and against the rubber boot on metal case containing O-ring and carbon. Install wearplate in bottom of impeller bore, locating slot in outside edge of wearplate over dowel pin in body. Apply a small amount of sealant to surface of cam and cam screw threads and install cam in impeller bore. Edge of cam should be flush with flange face of body. With a rotary motion in the direction the pump will be turning, push the impeller into the impeller bore until it is firmly bottomed. Turn body over to install clutch pulley assembly. Press key into shaft. Position clutch/pulley assembly on shaft aligning key with slot in pulley hub. Secure with bolt and washer.

To tighten bolt securely, it may be necessary to hold the impeller to prevent the shaft from turning. Turn pump assembly over. Dip gasket in water, position on pump flange face, install end cover and secure with end cover screws.

EXPLODED VIEW

PARTS LIST

Key

Description

Screw End Cover

End Cover

Gasket

Impeller Nitrile, Brass**

Wearplate

Body

(3 Per Kit)

(3 Per Kit))

Screw Cam

Cam, Brass

Pipe Plug

Slinger

Seal (Bearing)*

Ball Bearing (Pump)

Retaining Ring (Brg to Body)

Retaining Ring (Brg to Shaft)

(3 Per Kit)

Shaft

Seal (Shaft)

Roll Pin (Adaptor)

Adaptor

Key (Clutch Drive)

Clutch Assy. Complete

Replacement Field Coil

12 V – 2-A Grooves

12 V – 1-B Groove

24 V – 2-A Grooves

24 V – 1-B Groove

32 V – 2-A Grooves

12 V

24 V

32 V

Service Kit Nitrile Impeller

Qty.

Req.

* Use on pre 2002 models. Date code 01H or earlier.

**Special application model 11860-7001, use Impeller 17937-0001, Service Kit 90118-0001

11860-Series

Part No.

11867-0000

96080-0080

–

91401-0100

92300-0030

18753-0493

92300-0061

18753-0494

–

98022-0500

98022-2155

98022-0510

90118-0003

91003-0010

–

11831-0000

890-0000

920-0003

7868-0000

11864-0000

91004-0090

934-0000

92650-0070

3180-0000

913-0000

92600-0540

18724-0000

18713-0000

11870-Series

Part No.

11877-0000

6407-0010

93100-0160

11876-0000

91401-0100

92300-0030

18753-0493

92300-0061

18753-0494

92300-0050

98022-0500

98022-2155

98022-0510

90062-0003

–

91005-0040

12062-0000

816-0000

836-0003

2574-0000

18753-0585

91005-0040

834-0001

92650-0070

3181-0000

817-0000

92600-0040

18712-0000

18711-0000

DIMENSIONAL DRAWING

TABULATION OF DIMENSIONS (Inches and Millimeters)

Model A B C D-1 D-2 E F G H I J K L M N O P Q

11860

Series

11870

Series

R S T

6-3/16 5-3/8 4-29/32 3-9/16 3-7/8 5/8 1-5/16 3/4 1-1/2 1-9/16 3-1/8

157 137 125 90 98 16 33 19 38 40 79

8-3/16 6-1/16 7-1/16 5-1/4 5-9/16 5/8

208 154 179 133 141 16

——

1-7/32 2-5/16 2-1/4

31 59 57

4-1/2

114

2-3/4

102

5-1/2

140

13/32

1/4

5/16

1-7/8

2-9/16 3-13/16 5-7/8

2-1/2

4-3/4

149

2-3/8

NPT

178

2-15/16 1-1/4"

75 NPT

178

——

3/16 1-1/2

21 38

CAPACITY TABLES psi kg per sq cm

Total Head feet of meters of water water

500 RPM 1160 RPM 1750 RPM 2450 RPM 3000 RPM

GPM LPM HP GPM LPM HP GPM LPM HP GPM LPM HP GPM LPM HP

11860

Series

11870

Series

4.3

8.7

17.3

26.0

34.6

4.3

8.7

17.3

26.0

34.6

2.4

0.3

0.6

1.2

1.8

2.4

0.3

0.6

1.2

1.8

3.0

6.1

12.2

18.3

24.4

3.0

6.1

12.2

18.3

24.4

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

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

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

— — — 8.8

33.3

3/4 15.0

56.8

1 23.5

89.0

1-1/2 29.8

112.8

— — — — — — — — — 17.0

64.4

1-1/2 23.8

90.1

18.0

68.1

1/2 41.0 155.2

1 62.0 234.7 1-1/2 — — — — — —

17.0

64.4

1/2 40.0 151.4

1 60.0 227.1 1-1/2 —

14.0

53.0

1/2 37.0 140.1 1-1/2 55.0 208.2

2 —

—

— 30.0

113.6 1-1/2 50.0 189.3

— — — — 40.0 151.4

—

WIRING DIAGRAMS

Remote Control Engine Driven Pump

(While engine is running)

Remote Control and Automatic Engine Driven Bilge Pump

(While engine is running)

REMOTE CONTROL: Install a pushbutton switch at one or more locations (multiple switches should be wIred parallel). Depress pushbutton for 2 seconds. If there is water in bilge, pump will operate until dry, at which time vacuum switch will stop pump. If no water is in bilge, pump will stop when pushbutton is released.

AUTOMATIC BILGE PUMP: Install No. 30295-Series Automatic Bilge

Pump Switch where it will energize clutch at maximum high water level in bilge. When water raises switch float, pump will start. Vacuum switch will maintain closed circuit until bilge is pumped dry. Pump will automatically stop, preventing impeller damage.

THE PRODUCTS DESCRIBED HEREIN ARE

SUBJECT TO THE JABSCO ONE YEAR LIMITED

WARRANTY, WHICH IS AVAILABLE FOR YOUR

INSPECTION UPON REQUEST.

U.S.A.

Jabsco

Cape Ann Industrial Park

1 Kondelin Road

Gloucester, MA 01930

Tel: 978.281.0440

Fax: 978.281.6177

UNITED KINGDOM

Jabsco

Bingley Road, Hoddesdon

Hertfordshire EN11 OBU

Tel: +44 (0) 1992 450145

Fax: +44 (0) 1992 467132

Printed in U.S.A.

CANADA

Fluid Products Canada

55 Royal Road

Guelph, Ontario N1H 1T1

Tel: (519) 821.1900

Fax: (519) 821.2569

JAPAN

NHK Jabsco Company Ltd.

3-21-10, Shin-Yokohama

Kohoku-Ku, Yokohama, 222

Tel: 045.475.8906

Fax: 045.475.8908

GERMANY

Jabsco GmbH

Oststrasse 28

22840 Norderstedt

Tel: +49-40-53 43 73 -0

Fax: +49-40-53 53 73 -11

Form: 43000-0032 Rev. 12/2004

5 4 3 2 1

Contactor Coils

CAN LF

X30

CAN RF

X31

4 3

CAN LR

X32

CAN RR

X33

CAN Hydro

X34

CAN ELV1

X35

CAN ELV2

X36

Display

X37

4 3

1 2

4 3

CAN AUX

X39

Traction LF Traction RF Traction LR Traction RR Hydro Pump Elevator 1 Elevator 2

DC/DC 24V Switched

3 2

X12

1 4

DC/DC 24V Continu

X11

3 2 1

0K10

0K9

Pump TireWash/BinWash

X17

24Vco 1,5A AUX

X16

24V 1,5A Camera

X15

24V 1,5A Laser

24V Heater Seat

X10

F13

F14

F21

F18

Battery 80V

F12

K30

KeySwitch Relais

F11

F19

IcemakingWater Panel

Taillight Rightside

Horn

Lights

CAN Calibrator

Ice

Making

Water

Full

Ice

Making

Water

Half

Ice

Making

Water

Empty

WashWater Full

WashWater Empty

Panel 1

BiCat

6 5

Panel 1

12 11

9 8

Panel 2

18 17

7 6

3 2

13 12

4 3

AUX

X18

Display

BoardBrush Down

Valve Block

1 2

Bypass

Valve

Bin Up

3 4

Conditioner Up

SnowBreaker Up

5 6

7 8

BoardBrush Up

Bin Down

Conditioner Down

SnowBreaker Down

7 6

Hydraulic Valves

12 11 10 9

5 4 3 2

16 15

Left Under Seat

14 13 12 11

6 5

4 3 2

10 9

TireWash Pump

Connecting Box

Right Side

Head Light

5 4

Divers

8 7

3 2

IcemakingWater Panel

Washwater Panel

4 6 5 4 6 5 4

Taillight Rightside

4 3

1 3 2 1 3 2 1 2 1 2

6 5

X3B

4 6 5

X3A

Sensors Icemakingwater

Resistor Sensors Washwater

2 4

X14

1 3 2 1 3 2 1

X19 2X3B 2X3A

Washwater Valve

IcemakingWater Valve

Horn

Connecting Box under Seat

IceMakingWater

Clutch

Conditioner

Snow Dump

Elevator

Board Brush

Tire Wash

Elevator

Panel 2

WashWater SnowBreaker

Speed

Water

PowerOn

Accelerator

HandBrake Sensor

WashWater Clutch

Footbrake Switch Hand Pump Switch

Reverse Light

Taillight Leftside

IcemakingWater Level 1

IcemakingWater Level 1/2

IcemakingWater Level 0

WashWater Panel

Washwater Level 1

Washwater Level 0

DMC GmbH Herten Germany www.dmcde.de

Title

Size

Date:

Olympia Block Schematic Olympia

Document Number

41900_150b

Tuesday, October 19, 2010 Sheet

1 of 1

Rev

1.00

+80V

+80V Switched

+80V Relais

Logic Gnd

Forward drive

Reverse Drive

Light

Horn

+24V

Washwater Full

IceMaking water Empty

Washwater Empty

Icemakingwater Full

Icemakingwater Half

X1-1

X1-2

X1-3

X1-4

X1-5

X1-6

X1-7

X1-8

X1-9

X1-10

X1-11

X1-12

X1-13

X1-14

Display Can L

Can H

+10V

Gnd

X37

X30-1

X30-2

X30-3

X30-4

Logic Gnd

Elevator On

Elevator Off

Elevator Forward

Elevator Reverse

Washwater Off

Washwater On

Snow Breaker override Up

Snow Breaker override Down

Speed related water

Bin Wash

Tyre Wash

Conditioner Up

Conditioner Down

Board Brush OUT

Board Brush IN

Snow Bin Up

Snow Bin Down

Aux_1

+24V

Elevator On

Washwater On

X2-18

X2-19

X2-20

X2-21

X2-22

X2-9

X2-10

X2-11

X2-12

X2-13

X2-14

X2-15

X2-16

X2-17

X2-1

X2-2

X2-3

X2-4

X2-5

X2-6

X2-7

X2-8

Logic Gnd

IN_33

IN_24

IN_23

IN_34

+24V F13

LED Board Brush OUT

Out_01 100mA

X4-1

X4-2

X4-3

X4-4

X4-5

X4-6

X4-7

X4-8

BiCat +

BiCat Data

1 Red/White

2 Red

3 White/Black

4 Black

5 White

6 Yellow

80Vdc + perm

Key On

Main Relay Hold

0 vdc Shifter

Shifter Forward

Shifter Reverse

7 Black

8 Brown

9 Grey

0 vdc Top dash

Lights

Horn

10 Pink

11 Blue/White

12 Yellow/Black

13 Red/Blue

14 Green

15 Yellow

16 Red

17 Orange

24 vdc * sw Top Dash Lights

Wash Water Full Light

Ice Water Empty Light

Wash Water Empty Light

Ice Water Full Light

Ice Water Half Light

19 Green 20ga

20 Blue 20ga

21 Violet 20ga

22 White 20ga

23 Black

24 Green/Black

25 Green/white

26 White/Blue

27 Yellow/Blue

28 Blue/White

29 Blue

30 Yellow/Red

31 Yellow/Black

32 Green/Red

34 Orange

35 Purple

36 Purple/White

37 Brown/White

38 Brown

39 Grey

40 Black/White

42 Pink

44 Red/Blue

CAN Low signal

CAN High signal

+12Vdc Meter

0 Vdc DMC meter

0Vdc Bottom Dash

Elevator On

Elevator Off

Elevator Forward

Elevator Reverse

Wash Water Off

Wash Water On

Snow Breaker Up

Snow Breaker Down

Speed Water On

Tire Wash

Conditioner Up

Conditioner Down

Board Brush Out

Board Brush IN

Snow Bin Up

Snow Bin Down

24Vdc + Bottom Dash Lights

Wash Water ON Light

Orange

BiCat +

BiCat Data

Brown

Red

Black

Yellow

Green

Blue

Violet

White

3 b1.1

b1.2

0 1 2

Power ON

Power OFF

B2.1

B2.2

B14

H13

H31

BiCat II

Direction switch Panel

Forward drive

Reverse drive

Light

Horn

Light_ON

Washwater Full

ICE MAKING WATER EMPTY

WASHWATER EMPTY

Icemakingwater Full

Icemakingwater Half

Small Dashboard

DMC Display

H18

B6 b6.1

B6.2

B6.3

b17

B18

B20.1

B20.2

B21

B22

B23

B24

B25

B26

B27

B28

B29

B spare

Keyswitch Panel

Elevator On

Elevator Off

Elevator Forward

Elevator Reverse

Wash Water Off

Washwater On

Snow Breaker override Up

Snow Breaker override Down

Speed related Water

Bin Wash

Tire Wash

Conditioner Up

Conditioner Down

Board Brush Start OUT

Board Brush Stop IN

Snow Dump Up

Snow Dump Down

Spare

Elevator On

Washwater On

Speed Related Water ON

Board Brush ON

Power ON

Large Dashboard

Board Brush OUT Light

3 2

29-08-2010 Weidmuller Connector removed

Added X4

17 --08-2009

DMC GmbH Herten Germany

80V switched from X1-2 to Weidmuller pin16 BiCAT+ www.dmcde.de

Title

Olympia Canada

Size

Document Number

41900_151c

Date: Friday, September 03, 2010 Sheet

1 of 1

Rev

1.00

+12V accelerator supply

0 - 5V Accelerator output

Gnd Accelerator

Accelerator switch

Logic Gnd

Seat switch

Handbrake

+24V

Footbrake

Power Gnd

Taillight

Brakelight

Power +24V

Reverse light

Washwater clutch

Spare

X5-9

X5-10

X5-11

X5-12

X5-13

X5-14

X5-15

X5-16

X5-1

X5-2

X5-3

X5-4

X5-5

X5-6

X5-7

X5-8

Logic Gnd

Hydraulic pressure Conditioner

Power +24V

Edger Up

Edger Down

Snow Breaker Up

Snow Breaker Down

Conditioner Up

Conditioner Down

Board Brush IN

Board Brush OUT

Snow Bin Up

Snow Bin Down

Bypass Valve

X8-8

X8-9

X8-10

X8-11

X8-12

X8-13

X8-14

X8-1

X8-2

X8-3

X8-4

X8-5

X8-6

X8-7

Red

Brown

Green

Blue

Green

Grey

Orange

Yellow

White

Power Gnd

+24V CO

X17

X17-1

X17-2

45 Red 18ga

46 Green 18ga

47 Black 18ga

48 Blue 18ga

49 Black

50 Grey

51 Purple

52 Pink

53 Yellow/Red

54 Black

55 Brown/White

56 Red/Yellow

57 Pink

58 Yellow/Black

Foot Pedal +12V

Foot Pedal signal 0-5V

Foot Pedal -0V

Foot Pedal switch

Brake / seat / Park

Seat switch Signal

Park Brake Signal

24Vdc +sw Park Brake

Footbrake Switch

0vdc - Tail Lights

Tail Light

Brake Light

24vdc + sw Reverse Light

Reverse Light

Weather Pack Connector

WPT-5 (12034342)

557.18149

WPS-5 (12065158)

557.18150

Red

Green

Black

Yellow

Blue B3

COMSYS

POT

FS1

Blue

Black

Brown

Seat switch

Parkbrake

Siemens 3RG 4022-0GA00

B15 Footbrake

Hand Pumpswitch

MY4-24V

D36

1N4007

MOLEX MINIFIT 20 pole 3901/2201

H36.1L

H36.2L

K41.4

Hydraulic Valves

Y27

Board Brush OUT

Board Brush IN

Y26

1N4007 3

Y28

Snow Bin Up

1N4007

Y29

Y24

Snow Bin Down

Conditioner Up

1N4007

Conditioner Down

Y25

Y20.1

Y20.2

Snow Breaker Up

Snow Breaker Down

Bypass Valve

60 Blue/White Hand Pump Switch

Taillight Left

Brake light Left

Reverse light

Washwater clutch

3 2

29-08-2010 Weidmuller Connector removed

Backup Alarm removed to page 41800_153

Washwater Clutch Placed

19-08-2009 Added Backup Alarm

DMC GmbH Herten Germany www.dmcde.de

Title

Size

Date:

Olympia Canada

Document Number

41900_152c

Friday, September 03, 2010 Sheet

1 of 1

Rev

1.00

Logic Gnd

BoardBrushArm switch

+24V

Power +24V

Icemaking waterclutch

Icemaking watervalve

Washwatervalve

Horn

Power +24V

HeadLight

0F21

X6-1

X6-2

X6-3

X6-4

X6-5

X6-6

X6-7

X6-8

X6-9

X6-10

Power Gnd

Tyre Wash

Power Gnd

BinWash

X13

X13-1

X13-2

X13-3

X13-4

Power Gnd

IN_38

IN_37

IN_36

IN_35

Power +24V

IN_39

AD8

AD9

Backup Alarm

Logic Gnd

WashWater Full

Logic Gnd

Washwater Empty

2X3A

2X3A1

Logic Gnd

IceMakingWater Full

IceMakingWater 1/2

Logic Gnd

IceMakingWater Empty

2X3B

2X3B1

2X3B2

2X3B3

2X3B4

2X3B5

2X3B6

2X3A2

2X3A3

2X3A4

2X3A5

2X3A6

X18

X18-1

X18-2

X18-3

X18-4

X18-5

X18-6

X18-7

X18-8

X18-9

X18-10

M10

Pump Bin Wash

59 Yellow/Black Back Up Alarm

B13A

B11A

B13B

B12B

B11B

WashWater Full

Washwater empty

IceMakingWater Full

IceMakingWater 1/2

IceMakingWater Empty

Backup Alarm

K40.2

Ice makingwater clutch

K40.1

Icemaking watervalve

1N5404

H38a

H38b

K41.5

Washwatervalve

220nF 250V

H14.1

Horn

Headlight L

Headlight R

2 1

Removed connector

6-6-2010 Links between connector X18 and 2X3A and 2X3B only for PCB9V0. New PCB's (9V1 and up) links at the PCB

DMC GmbH Herten Germany www.dmcde.de

Title

Olympia Canada

Size

Date:

Document Number

41900_153c

Friday, September 03, 2010 Sheet

1 of 1

Rev

1.00

+24V/8R2

+24V continu

WashWatertank 1

Pwr Gnd

X3A

X3A-1

X3A-2 k35a1

X3A-3

X3A-4

X3A-5

X3A-6

4 3

Panel 3A Small washwater panel

B10a

WashWatertank full L1

Valve

GND

Panel 3B Icemaking Water Fill Station

62 Orange/Black 24 vdc +Ice Water Fill Valve

63 Green

64 Yellow

65 Black/White

66 Black

Ice Water Level Full

Ice Water Level 1/2

Ice Water Level signal

0 Vdc - Ice Water Fill Valve

B10b2

Icemaking watertank full

B10b1

Icemaking watertank 1/2 Full

D10B2

1N4007

D10B1

1N4007

Valve

GND

+24V/8R2

+24V continu

X3B

X3B-1

X3B-2

IceMakingWatertank 1

IceMakingWater 1/2

Pwr Gnd

X3B-3

X3B-4

X3B-5

X3B-6

30 k35B1

Power Gnd

TailLight R

BrakeLight R

Optional

Power Gnd

+24V

Power Gnd

+24V

X14

X14-1

X14-2

X14-3

X14-4

X15

X15-1

Option Laser 1,5A max

X15-2

X16

X16-1

X16-2

Option Camera 1,5A max

67 Black

68 Pink

20Vdc - perm spare

24Vdc + sw spare

69 Black

70 Pink

20Vdc - perm spare

24Vdc + sw spare

H36.1R

H36.2R

Taillight Right

Brakelight Right

5 4 3

DMC GmbH Herten Germany www.dmcde.de

Title

Size

Date:

Olympia Canada

Document Number

41900_154b

Friday, September 03, 2010 Sheet

1 of 1

Rev

1.00

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

Fwd

Traction Front Left

X20

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

Can L

Can H

+10V

Gnd

X30

X30-1

X30-2

X30-3

X30-4

Traction Front Right

X21

X20-1 Fwd

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

X20-8

X20-9

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

Can L

Can H

+10V

Gnd

X31

X30-1

X30-2

X30-3

X30-4

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

X19

X19-1

X19-2

Line Left Front

Line Right Front

Line Left R

Line Right R

Line M5

Line M6a

Line M6b

Backup Alarm

Bypass Valve

Main Line

X27

X27-12

X27-13

X27-14

X27-15

X27-16

X27-17

X27-18

X27-19

X27-20

X27-1

X27-2

X27-3

X27-4

X27-5

X27-6

X27-7

X27-8

X27-9

X27-10

X27-11

K6a

K6b

8R2 25W

Line LF

Line RF

Line LR

Line RR

Line Hydraulic motor

Line Horizontal Conditioner

Line Vertical Conditioner

Backup Alarm

Line Main

5 4

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

Fwd

Traction Rear Left

X22

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

Can L

Can H

+10V

Gnd

X32

X30-1

X30-2

X30-3

X30-4

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

Fwd

Traction Rear Right

X23

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

Can L

Can H

+10V

Gnd

X33

X30-1

X30-2

X30-3

X30-4

Speed-2

Speed-3

Speed-4

Speed-5

Speed-6

Inhibit

Accel 1

Accel 2

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

Speed-1

Hydraulic Pump

X24

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

Can L

Can H

+10V

Gnd

X34

X30-1

X30-2

X30-3

X30-4

Fwd

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

Elevator 1

X25

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

Can L

Can H

+10V

Gnd

X35

X30-1

X30-2

X30-3

X30-4

Fwd

Rev

Fs1

Seat

Spd1

Spd2

Handbrake

Elevator 2

X26

Footbrake

Accelerator

B+

Contactor supply

Line contactor

Aux1 contactor

Aux2 contactor

+10V

+5V

X20-8

X20-9

X20-10

X20-11

X20-12

X20-13

X20-14

X20-15

X20-16

X20-1

X20-2

X20-3

X20-4

X20-5

X20-6

X20-7

Can L

Can H

+10V

Gnd

X36

X30-1

X30-2

X30-3

X30-4

X38

Can L

Can H

+10V

Gnd

Can L

Can H

+10V

Gnd

Calibrator

X30-1

X30-2

X30-3

X30-4

X30-1

X30-2

X30-3

X30-4

In 80V -

In 80V +

X10

X10-1

X10-2

In -

In +

Out -

Out +

X11

X11-1

X11-2

X11-3

X11-4

In -

In +

Out -

Out +

X12

X12-1

X12-2

X12-3

X12-4

2x 300W or 1x 450W 24V

Battery 80V

X-1

X-2

X-3

X-4

X-5

X-1

X-2

X-3

X-4

X-5

X-1

X-2

X-3

X-4

X-5

In -

In +

Key

Out -

Out +

DC/DC

80/24

300W

In -

In +

Key

Out -

Out +

DC/DC

80/24

300W

X-1

X-2

Molex Minifit 2p

Link in Battery connector

In -

In +

Key

Out -

Out +

DC/DC

80/24

300W

10-10-2010 DCDC connection updated

19-08-2009 Added backup Alarm

Title

Size

Date:

41900_156b Panel Connections Olympia

Document Number

41900_156b

Tuesday, October 19, 2010

Sheet

1 of

Rev

1.00

5 4

Logic Gnd

MOLEX MICROFIT 14 pole

X8-1

Hydraulic pressure Conditioner

Power +24V

Edger Up

Edger Down

Snow Breaker Up

Snow Breaker Down

Conditioner Up

Conditioner Down

Board Brush IN

Board Brush OUT

Snow Bin Up

Snow Bin Down

Bypass Valve

X8-2

X8-3

X8-4

X8-5

X8-6

X8-7

X8-8

X8-9

X8-10

X8-11

X8-12

X8-13

X8-14

Red

Brown

Green

Blue

Green

Grey

Orange

Yellow

White

Power Gnd

+24V CO

X17

X17-1

X17-2

5 4

3 2 1

Omron MY4-24V

D36

1N4007

MOLEX MINIFIT 20 pole 3901/2201

20 Hand Pump switch

DMC GmbH Herten Germany www.dmcde.de

Title

Olympia Canada Panel Wiring Valves

Size

Document Number

41900_157a

Date: Thursday, September 02, 2010 Sheet

1 of 1

Rev

1.00

RED tubing

BLACK tubing

Battery connections (2/0)

AWG 2/0 - 280 cm

RED tubing

Main Fuse - 200A

RED tubing

Main DC plug - female

BiCAT II connector (at battery)

A B C

RED tubing BLACK tubing

AWG#16 - black

AWG#16 - red

AWG 2/0 - 280 cm

AWG 2/0 - 200 cm

RED tubing AWG 2/0 - 60 cm Black tubing

(only for North American machines)

BLACK tubing

15 A fuse to Accumeter (on small panel)

Pin 6

RED tubing

Main Panel

E-Stop connections (2/0)

in main panel

AWG 2/0 - 270 cm

E-Stop

use 5/16" hole lugs use 3/8" hole lug use 5/16" hole lug

Main DC plug (male)

AWG 2/0 - 420 cm

Large connector inside seat

(Connects to Main Harness)

2.20 (d1/4)

0.38 (d1/4)

2 WIRES TO MAIN DC CONNECTOR : 71-RD / WH ; 72-WH / RD

(refer to E-Stop connections diagram)

0.70 (d1/4)

1 WIRE TO BATTERY - BiCAT DATA UNIT : 17-OR

0.20 (d1/2)

0.1 (d1/4)

4 WIRES TO DMC DISPLAY : 19-GN ; 20-BU ; 21-PU ; 22-WH

(refer to Small dashboard diagram)

0.25 (d1/2)

11 WIRES TO SMAL DASHBOARD : 7-BK ; 8-BR ; 9-GY ; 10-PK

11-BU / WH ; 12-YL / BK ; 13-RD / BU ; 14-GN ; 15-YL ; 16-RD ; 17-OR

45º connector

1.67 (d29) exposed wire - 30cm

0.42 (d3/4)

MAIN HARNESS

0.52 (d3/8)

0.30 (d1/2) 18 WIRES TO LARGE DASHBOARD : 23-BK ; 24-GN / BK ; 25-GN / WH

26-WH / BU ; 27-YL / BU ; 28-BU / WH ; 29-BU ; 30-YL / RD ; 31-YL / BK; 32-GN / RD

34-OR ; 35-PU ; 36-PU / WH ; 37-BR / WH ; 38-BR ; 39-GY ; 40-BK / WH ; 42-PK

0.13 (d1/4)

3 WIRES TO KEYSWITCH : 1-RD / WH ; 2-RD ; 3-WH / BK

0.30 (d1/2)

Notes: 1. Circuit 17-OR is NOT part of the original bundle.

2. The following circuits will be branched in the 30cm

region of exposed wire : 49-BK; 52-PK; 57-PK

3. Conduit dimensions are in meters (diameter indication in brackets)

0.05 (d1/4)

3 WIRES TO DIRECTION SWITCH : 4-BK ; 5-WH ; 6-YL

0.07 (d1/2)

0.44 (d1/2)

0.48 (d1/2)

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-pole connector) : 49-BK ; 52-PK ; 53-YL / RD

Conduit runs from Front bumper JB

Use male pins on harness side where applicable

75cm (d9)

98 - RD/YL

Icemaking watertank empty

97 - BK

8cm (d9)

96 - YL

Icemaking watertank half

94 - BK

42cm (d9)

94 - BK

95 - GRN

Icemaking watertank full

94 - BK

86 - PINK

87 - BRN

86 - PINK

22cm (d12)

Front

Bumper

Horn

85 - GRAY

81- PINK

86 - PINK

R Light

87 - BRN

56 cm (d12)

88 BK 89 ORNG

86 - PINK

L Light

87 - BRN

LARGE DASHBOARD

Wrap in 1/4" tubing

4 4

3 3

3 1

4 4

3 3

4 4

3 3

4 2

3 1

X1 4

X2 3

4 4

3 3

BLACK

(50cm)

PK / BK

(50cm)

Main

Panel

BROWN

WHITE

YELLOW

GREEN

SHIELD

BROWN

WHITE

YELLOW

GREEN

SHIELD

M2

BROWN

WHITE

YELLOW

GREEN

SHIELD

M2 Motion control

M2 Motor leads

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

M0

M0 Motor RTD

Red & Black

M0 Motor leads

M0 Motion control

BROWN

WHITE

YELLOW

GREEN

SHIELD

M0 & M2 motor leads

Main

Panel

BROWN

WHITE

YELLOW

GREEN

SHIELD

BROWN

WHITE

YELLOW

GREEN

SHIELD

BROWN

WHITE

YELLOW

GREEN

SHIELD

M1, M3 & Pump motor leads

AWG 8 - RED - 195 cm

AWG 8 - BLUE - 195 cm

AWG 8 - WHITE - 195 cm

AWG 16 - BLACK - 195 cm

AWG 16 - RED - 195 cm

4 COND SHLD CABLE - 195 cm

AWG 8 - RED - 210 cm

AWG 8 - BLUE - 210 cm

AWG 8 - WHITE - 210 cm

AWG 16 - BLACK - 210 cm

AWG 16 - RED - 210 cm

4 COND SHLD CABLE - 210 cm

Pump Motor Leads

Pump Motor RTD

Red & Black

M3 Motor Leads

M3 Motor RTD

Red & Black

BROWN

WHITE

YELLOW

GREEN

SHIELD

BROWN

WHITE

YELLOW

GREEN

SHIELD

PBM1

Front bumber harness branches off and continues through PBM1

M1 leads, RTD and motion control wires go

through PBM1 box without interruption

4 CONDUCTOR SHIELDED CABLE - 570 cm

AWG 16 - BLACK - 570 cm

AWG 16 - RED - 570 cm

AWG 8 - RED - 570 cm

AWG 8 - BLUE - 570 cm

AWG 8 - WHITE - 570 cm

BROWN

WHITE

YELLOW

GREEN

SHIELD M1 Motor RTD

Red & Black

M1 Motor Leads

BLUE

RED

WHITE

BROWN

WHITE

3 YELLOW

GREEN

SHIELD

WHITE

BLUE

RED

2 x AWG#8 - 49cm - WH

2 x AWG#8 - 46cm - BL

2 x AWG#8 - 43cm - RD

BROWN

WHITE

YELLOW

GREEN

SHIELD

Horz Vert

Keyswitch

3 WH / BK 2

3 WH / BK 4

1 2 RD

3 1 RD / WH

Direction switch

4 BK 6 YL

5 WH 4 BK

Large connector under seat

(Part of Main Harness - gasketed side w.female pins)

BR / WH

RD / YL

Q P

YL / BK

OR / BK

BU / WH

BK / WH

COMSYS

(Part of Main Harness - male pins)

Parkbrake

(Part of Main Harness - male pins)

46 GN

45 RD

Jumper

47 BK 48 BU

47 BK

A B C

Footbrake

(Part of Main Harness - male pins)

A B C

SMALL DASHBOARD

19 GN

20 BU

21 PU

22 WH

8 use female pins on harness side

9 GY 3 4 7 BK

10 PK X1 X2 12 YL / BK 10 PK X1 X2 13 RD / BU

X2 3

X1 4

10 PK

X1 X2 15 YL

10 PK X1 X2 14 GN

10 PK X1 X2 11 BU / WH

3 5 8

2 4 6 9 use female insulated spade lugs (16AWG)

DMC Display

Hello! I've reviewed the Olympia Millennium-E owner's manual. This manual provides detailed instructions on the safe operation and maintenance of the Olympia Millennium-E ice resurfacer. It includes safety precautions, technical specifications, start-up procedures, cleaning instructions, and troubleshooting guides. Ask away!

Show related prompts

Assistant typing

Assistant is out of keyboard. Please, try again later.

Key features

Easy-to-use control panel
Powerful engine
Durable construction
Two-year warranty
Variety of safety and performance-enhancing options

Frequently asked questions

The Olympia Millennium-E is backed by a two-year warranty.

The dimensions of the Olympia Millennium-E are not specified in the manual.

The weight of the Olympia Millennium-E is not specified in the manual.

The noise emission of the Olympia Millennium-E is not specified in the manual.

The filling capacities of the Olympia Millennium-E are not specified in the manual.

Owner’s Manual

Welcome to the OLYMPIA Advantage

Table of Contents

Dear User!

Note:

1 SAFETY

1.1 Pictograms Used

1.2 Generally Applicable Safety Instructions

1.3 Proper Use

1.4 Improper Use

1.5 Organizational Measures

1.6 Personnel Qualifications

1.7 Obligations of the User

1.8 Operator’s Workplace

1.9 Safety Devices and Guards

EMERGENCY STOP

Horn Button

Warning Signals

1.10 Maintenance and Repair Regulations

1.11 Waste Disposal

1.12 Remaining Hazards

2 TECHNICAL DATA

2.1 Dimensions

2.2 Weights

2.3 Noise Emission

2.4 Filling Capacities

2.5 Electrical System

2.6 Brake Systems

2.7 Hydraulic System

2.8 Water System

2.9 Tires

2.10 Conditioner

2.10.1 Blades

2.10.2 Conveyor System

2.11 Materials Used

3 ON-SITE CONDITIONS

3.1 Ground Conditions

3.2 Room Ventilation

3.3 Water Connections

3.4 Water Quality

3.5 Charger

3.6 Garage Temperature

3.7 Snow Dump Pit Threshold

4 DESIGN AND FUNCTION

4.1 Ice Resurfacer Design and Chassis

Self-supporting chassis

The front axle

Body Panels

4.2 Snow Conveyor (Auger)

4.3 Hydraulic Components

5 CONTROLS

5.2 Top Control Panel

5.3 Bottom Control Panel

5.4 Ice Making Water Control Panel Optional

5.5 Wash Water Control Panel

5.6 Foot Pedals and Parking Brake

5.7 Controls for the Water

5.7.1 Ice Making Water

5.8 Controls for the Hydraulic System

6 START UP OF THE OLYMPIA MILLENNIUM - E

6.1 Charge the Batteries

6.2 Installation of the Squeegee

6.3 Blade Installation

The Order is Important

6.3.1 Blade Level Adjustment

6.4 Horizontal and Vertical Augers

6.4.1 Horizontal Auger Adjustment

6.4.2 Auger Drive Chain Adjustment

6.4.3 Down Pressure Check

6.4.4 Down Pressure Adjustment

6.4.5 Top Link Adjustment

6.5 Spreader Cloth Installation

6.6 Water Filling Procedure

6.6.1 Ice Making Water Filling Procedure

6.6.2 Wash Water Filling Procedure

6.7 Safety Circle Check

7 WORKING WITH THE OLYMPIA MILLENNIUM-E

7.1 Driving

7.1.1 Starting

7.1.2 To move the ice resurfacer