Sport Ice 240E Elektro Operation Manual Small Machines. Big Performance. Great Ice. 1
Introduction: The Sport Ice 240E Elektro is a compact ice resurfacing machine designed to be used on small ice surfaces. The machine has been designed to produce a high quality ice surface. The typical ice surface for this machine is approximately 650 square meters (7000 sq. ft). The machine has been used successfully on surfaces ranging in size from 250 sq. meters to 1000 sq. meters (2600 to 11,000 sq/ ft). Successful operation of the machine will give you, the skilled operator, the ability to produce a good sheet of ice. It is important that you learn the machine s features and capabilities and operate the machine as intended so that you will be able to produce a quality ice surface. As you practice and operate the machine, your knowledge and skill level will increase. Review this manual often to refresh and educate yourself. 2
Safe Operation: 1) Keep all guards in place. 2) Only operate the machine when no one is on the ice surface. 3) No riders. Single operator only. 4) Make sure the floor/ice surface can safely support the machine. 5) Only drive the machine if you have been trained in the correct and safe operation of the machine. 6) Make sure the headlights, tail-light and horn, are functional each time you use the machine. 7) Perform a safety walk-around on the machine every time BEFORE you operate the machine. 8) Always park the machine in a secure place, set the parking brake and remove the key switch, when done. 9) Take care when turning the machine, reduce your speed for sharp turns. 10) Always operate while sitting down in the operator s seat. 11) Always have the High-Power switches turned off when the machine is not on the ice. 3
Safety Walk-Around : The Safety Walk-Around is an important activity performed each time the operator gets on the machine. To perform the Safety Walk-Around : 1) Inspect the wheel lug nuts. Make sure that all 4 nuts on each wheel are in place and appear tight. 2) Look for loose tire studs or ice screws. 3) Make sure the floor plates are in place. Make sure that the conditioner covers are in place before resurfacing (these are normally bolted in place). 4) Make sure that the chain guards on the vertical auger housing are in place. 5) Make sure that the snow shield on the snow tank is in place. 6) Make sure that the control levers are in the OFF or NEUTRAL position. 7) Look for signs of oil leaking. Make sure the hydraulic hoses appear in good condition. 8) Look for loose nuts, bolts and other fasteners. 9) Look for debris in the path of the machine. 10) Look for people in the vicinity of the machine. Remain aware of their proximity to the machine. 11) Note if the water tank fill hose is inserted in the machine. 12) Note if the battery charger is connected to the machine s batteries. 13) Make sure that the safety nameplates are visible. 14) Inspect the cutting blade position. Use caution around the blade. 4
Left Side Machine View Snow Tank Lid Snow Tank Water tank (inside body panels) Board Brush Ice Conditioner 5
Right Side Machine View Vertical auger housing Oil tank Ice conditioner 6
Rear Machine View Blade control Water pipe Vertical auger housing Snow breaker rod Ice conditioner 7
Accelerate/Brake Pedals Accelerator pedal Parking brake (top portion of brake pedal). To apply; push down on pedal, then rocker top section. To release; push on lower section of pedal. Brake pedal 8
Vertical Auger Area (as seen from operators seat) Snow shield Vertical Auger motor Vertical auger bearing Auger drive chain guard 2 Snow Breaker Rod Control Valve Levers Water Control Rod Snow Slinger housing DANGER! Do not place hand or fingers near the exhaust chute. If a snow jam should occur, see the instructions on page 11. 9
Front Battery Battery hold down bracket Battery Rear Battery Hydraulic pump Water tank 10 Battery charger connection
Machine Operation: Before going on the ice: 1) Perform the Safety Walk-Around (see page 4 for complete directions). 2) Start the machine in the following manner: a. The directional Forward/Reverse switch must be in neutral. b. The accelerator pedal (and switch) must be open (not depressed). c. Make sure the High Power and Intermediate Power switches are turned OFF. d. Turn the key switch to the right one position. Wait two seconds for the traction control to energize. e. Turn off the key switch. Immediately turn the key switch back on, this will allow the pump control to energize. (You will hear the pump motor start). f. Raise the conditioner/vertical auger housing to its full height. g. Remove the parking brake by pushing on the center of the brake pedal. h. Select a drive direction (forward or reverse). i. Push on the accelerator pedal. The machine will begin to move. Vary the machine s ground speed as needed. j. Drive, brake and turn in a smooth manner. To stop the machine: 1) Slow and stop in a smooth manner using the brake pedal. 2) Note: machine plugging will also help slow the machine. 3) Turn off the High Power and Intermediate Power switch. 4) Lower the conditioner onto wood blocks 5) Turn off the key switch. 6) Set the parking brake by pushing on the top portion of the brake pedal (marked as Parking Brake ). 7) Remove the key switch. 11
To get ready to Resurface: 1. Make sure the batteries are properly charged. Disconnect the batteries from the charger. Connect the batteries to the machine. 2. Fill the water tank. 3. Place the towel bar in the lower position on the conditioner. To Resurface: 1. Safely drive onto the ice surface. 2. With the machine moving slowing forward, lower the conditioner completely. 3. Turn on the High Power or Intermediate Power switch, depending on snow and ice load. You will hear the pump motor speed up. 4. Turn on the augers and snow slinger by pulling up on the center control lever. 5. Turn on the ice making water valve and regulate the water as needed. 6. Adjust the ice shaving blade as needed. 7. You can view the snow transfer into the snow tank via the snow tank windows. 8. Drive as smoothly as possible and at a consistent speed. Try not to drive fast and then slow, as this will affect the snow transfer system and the water delivery. Overlap the conditioner to the previous lap by approximately 150 mm or 6 inches. 9. At the end of the resurfacing: a. Turn off the water b. Turn off the augers and snow slinger. Raise the conditioner completely before driving off the ice. Failure to raise the conditioner completely before the front wheels exit the ice surface may cause damage and component failure to the machine. 12
c. Turn off the High Power and/or Intermediate Power switches. d. Slowing drive off the ice. Watch out for pedestrians and other vehicles. e. Dump the snow from the snow tank. After resurfacing: 1. Wash out the conditioner, the vertical auger and snow slinger to remove snow and ice. 2. Refill the water tank. 3. Plug the batteries into the charger. Charge the batteries. 4. Lower the conditioner onto wood blocks. 5. Place the towel in the upper location on the conditioner. 13
IN CASE OF SNOW JAM IN AUGER, SLINGER OR CONDITIONER From time to time, depending on snow and water load, etc. a snow jam may occur in the vertical auger, snow slinger, or horizontal auger; DO NOT attempt to clear the snow with your hand or a tool or a stick. To place your hand or fingers in the discharge chute or in close proximity to the augers places you in danger! You risk severe injury or death! The correct and only way to clear a snow jam is to: 1. Turn off the augers by closing the auger/snow slinger control lever 2. Turn off the High Power or Intermediate Power switch 3. Raise the conditioner and dump tank before driving off the ice. (See page 14) 4. Use a hose and water stream and spray it into the discharge chute of the snow slinger and vertical auger or the intake chute of the vertical auger or the horizontal auger (depending on which auger is frozen) to clear away the snow and ice that is causing the snow jam. 5. After the snow and ice are removed by the water stream; rotate the augers on low speed, then intermediate or high speed, making sure that they rotate freely and properly. 14
Operator Controls The machine has the following operator controls: -Steering wheel -Horn switch -headlight/taillight switch - High Power switch -Dash display -Battery Discharge Indicator (BDI) -Fault codes -Hourmeter -Directional switch (Forward/Reverse) -Key switch -Water control rod -Control levers for machine functions -Conditioner up/down -Augers on/off -Dump tank up/down Dash Display -Battery Discharge Indicator -Fault codes -Hourmeter Directional Switch Horn switch Key Switch Steering wheel Headlight switch Intermediate Power Switch High Power switch 15
Operator Controls: The machine drives, steers, and brakes in a manner similar to an automobile. The steering wheel controls the driving direction. The accelerator pedal controls the vehicle speed. The foot pedal brake controls the brakes. Note: The traction control has been programmed for regenerative braking. This means that when the operator lifts his foot from the accelerator pedal, the traction drive motor begins to act like a brake. Intermediate and High Power Switches: These switches are located on the dash (see the photo). They are used to change the pump motor speed from low speed to either intermediate or to high speed. High speed pump operation will provide the most power for the hydraulic system. It will not change the power level to the traction system that propels the machine. Intermediate and High speed operations should only be used when resurfacing. During a resurfacing with a light to medium snow load, the intermediate speed may provide enough power for the augers. Using the intermediate setting will extend the battery charge. When using the intermediate setting, pay attention to the vertical auger speed and the snow transfer from the vertical auger. If the auger bogs or slows down appreciably, then turn on the high speed setting. This should allow the snow load to clear from vertical auger. You can then return to the intermediate setting if desired. Use the High speed setting whenever there is a heavy snow load on the ice or when using the board brush system (if so equipped). After board brush use, you can return to the intermediate power setting. 16
Using the intermediate and high power settings properly will conserve battery energy and extend the operating time for the machine. To turn on the Intermediate and High Power functions, activate the appropriate rocker switches located on the left side of the dash. Directional Switch: The directional switch is used to select the machine s travel direction. Push the switch lever to the top to go forward. Move it to the bottom position to select reverse direction. Note: Always return the directional switch to neutral after the machine operation is complete. The controls are programmed to ensure a neutral start condition. This means that the directional switch must be in neutral to start up. If the machine is started with the direction switch in forward or reverse or the accelerator is depressed, the dash display will show a fault code; such as 04005, 04006, etc. The means sequence fault and the machine will not drive until the directional switch is placed in neutral (with the accelerator pedal NOT depressed). Then select the drive direction by moving the lever. Dash Display: The dash display provide the following information to the operator -Battery Discharge Indicator (BDI) -Hourmeter -Fault Codes Battery Discharge Indicator The BDI is displayed with a 10 segment bar display along the top of the dash display. Each segment represents 10% of the battery s usable energy. The BDI meter is most accurate when the machine is driving. Watch and record the battery capacity after each resurfacing. 17
Hour-meter Use the hour-meter to record operating time and refer to the maintenance schedule for items to be performed based on hours of operation. Fault Codes The dash display will inform the operator of diagnostic fault codes. Common operational fault codes that may be seen include 04005, 04006, etc. This means that the operator controls were activated out of sequence and for safety reasons, the machine will not drive. To clear a sequence fault, place the directional lever in neutral and take your foot off the accelerator pedal. Then, select a drive direction and press on the accelerator pedal. Other faults may be displayed. Refer to the electrical control section for more information 18
Control Levers (Viewed from operator s seat) Auger/snow slinger lever Lift bar lever Dump tank lever Control Levers The control levers are used in the following manner: 1. The left side lever raises and lowers the conditioner and auger housings. 2. The center lever turns on the augers and snow slinger. 3. The right hand lever raises and lowers the dump tank. 4. The 4 th lever to the right is for the optional board brush system. 5. The water control rod regulates the water flow to the ice. 6. The blade control hand-wheel adjusts the cutting depth of the blade. 19
Ice Conditioner: The ice conditioner allows the operator to produce a high quality ice surface. The ice conditioner: Cuts the ice with the shaving blade. Conveys the shaved ice via the auger system to the dump tank. Applies water to the ice surface to become the new skating surface. Blade Control Hand-wheel Ice Conditioner Details Water discharge pipe Conditioner cover plates (3 places) Blade leveling screws Squeegee 20
Blade Control: The depth of cut is adjusted by the blade control lever and hand wheel. Rotate the hand wheel in a clockwise direction to increase the amount of cut. For proper blade operation, the blade must be set -at the correct shaving angle -leveled to the conditioner runners. Set the blade so that it is at 10 when the front edge of the blade is level with the bottom of the conditioner runner on each side of the conditioner. Adjust the level via the blade leveling screws located on each side of the conditioner. Adjust the blade angle using the blade control handwheel. Note: When the blade is level and at the correct angle, the center of the blade will be approximately 1.1 mm (.045 in.) into the ice. This will produce quite a cut. Reduce the depth of cut by rotating the handwheel in the counter-clockwise direction a couple of turns before resurfacing. Blade control hand wheel 21
Installing the cutting blade: Note: Extreme care must be taken when working with the cutting blade. The blade can cut and severely injure you or another EVEN when it is dull. 1. Raise the conditioner completely 2. Loosen the blade holding nuts and bolts using the 3/8 hex key and ¾ socket. 3. When the blade holding fasteners are loose, place wood blocks under the conditioner, and lower the conditioner until the blade is slightly above the wood blocks. 4. Remove the blade holding fasteners and lower the blade onto the wood blocks. Slide the blade along the wood blocks toward the rear of the conditioner and immediately place the blade into the blade scabbard. 5. Inspect the bottom mounting surface of the blade holding bar in the conditioner. Remove any debris or build up. Wipe clean with a cloth. 6. Position the new blade on the wood blocks. Slide it into the position in the conditioner. 7. Loosely install the blade bolts and nuts in the outside hole locations on each side of the conditioner. 8. Install the remaining blade mounting hardware. 9. Tighten the bolts beginning in center and work outboard, alternating between the sides of the blade 22
Shaving Blade Set-up Notes and Commentary: depth. The key to correct shaving is to have the shaving blade set at the proper angle and Blade Control: The depth of cut is adjusted by the blade control lever and hand wheel. Rotate the hand wheel in a clockwise direction to increase the amount of cut. Blade control handwheel Blade leveling screws 23
For proper blade operation, the blade must be set -at the correct shaving angle -leveled to the conditioner runners. Set the blade so that it is at 10 when the front edge of the blade is level with the bottom of the conditioner runner on each side of the conditioner. 10 Shaving blade Conditioner Runner Angle finder shows conditioner level and 0 24
Blade leveling screw Blade down pressure screw DO NOT ADJUST when setting the blade angle Angle finder shows that the blade bar is now 10 to the ground level which is also 10 to the conditioner runner. Blade bar Blade bar 10 Shaving blade Conditioner Runner 25
Adjust the level via the blade leveling screws located on each side of the conditioner. Adjust the blade angle using the blade control hand-wheel. Note: When the blade is level and at the correct angle, the center of the blade will be approximately 1.1 mm (.045 in.) into the ice. This will produce quite a cut. Reduce the depth of cut by rotating the handwheel in the counter-clockwise direction a couple of turns before resurfacing. 26
Battery Charging and Care The batteries require proper charging, care and maintenance for ideal machine operation. Learning this information and following the correct practices will help the machine s batteries perform to their fullest capacity. Battery Charging: 1. Make sure to start the beginning of each day with a full battery charge. This normally means that the batteries must be placed on the charger the previous evening and allowed to charge through the night. 2. During the day, after each resurfacing, plug the batteries into the charger. Turn on the charger if it does not start automatically, and charge the batteries between each resurfacing. This will ensure that you have enough battery power for correct machine operation throughout the day. 3. At the end of each day, plug the batteries into the charger and allow the charger to operate until it automatically shuts down. 4. DO NOT allow smoking or open flames near the batteries when charging. Battery Inspection: 1) Once per week, after the batteries have been fully charged (within one hour of full charge); 2) Verify the water level in each cell the correct level is to have electrolyte over the top of the battery plates but below the bottom of the filler cap neck. a. Use a hydrometer to measure the Specific Gravity (S.G.). Note the per cell value on the battery inspection chart. Note the appearance of the electrolyte it should be clear and colorless. b. Measure the batteries Open Circuit Voltage (OCV) with a voltmeter or multi-meter. Record the measure value on the battery chart. c. Add water to cells that need it but ONLY ADD WATER within one hour of the battery completing its full charge. Adding water to a cold battery 27
and then charging will lead to boil over and will reduce the battery life as well as damage the machine due to the acid boiling over. i. Municipal water should normally be acceptable to use in the batteries. If you have any doubts about the municipal water quality, use distilled water. 3) Battery Problems a. The batteries may need a boost charge when the machine first arrives. This due to the lengthy transport time. To make boost charge; i. Using a 12V automobile charger, make two 12 V sections by removing one battery jumper cable from one end of two batteries (the batteries are in series). Charge the batteries on the 12V 30 A setting on the auto battery charger. Allow the battery charger to run for several hours. Repeat the charging with the other two batteries connected in series as a 12 VDC system. b. If at anytime the batteries show a difference in their S.G. of more than.05, use the boost charge technique to bring the batteries into an equal charge level. c. If the battery life appears to be reduced; i. Verify the battery cable connections are tight ii. Verify that the OCV and S.G. are consistent across the batteries iii. Verify correct water level iv. Perform a boost charge. 4) Summer storage a. Verify the batteries are fully charged before taking the machine out of service. b. Verify that the electrolyte level is correct. c. Disconnect the batteries from the machine during the storage period. d. Each month; i. Charge the batteries fully. 28
ii. After a full charge, operate the machine by turning on the augers at high speed for 15 to 30 minutes. iii. Then fully charge the batteries again. Verify water level. Fill as required. Disconnect the batteries from the machine iv. Repeat each month that the machine is out of service. 29
NOTES 30