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OPERATING
INSTRUCTIONS
Zamboni USA
Zamboni Company USA, Inc.
15714 Colorado Ave.
Paramount, CA USA 90723-4211
(562) 633-0751
(562) 633-9365
This manual must be kept and stored with the machine.
The manual and all related safety and service materials are available online at www.zamboni.com
Zamboni Canada
Zamboni Company Ltd.
38 Morton Ave. East, Box 1388
Brantford, ON Canada N3T 5T6
(519) 758-5000
(519) 758-0500
Zamboni Europe
Zamboni Europe AB
Murarmörkret 4
SE-811 74 Österfärnebo Sweden
+46 291 206 80
+46 291 206 83
MODEL
450
ELECTRIC
Zamboni Quebec
Robert Boileau Inc.
1425 Boulevard Pitfield
Saint-Laurent, Quebec, Canada H4S 1G3
(514) 333-8420
(877) 333-8420
DM-20080/ REV 8/6/23
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Related Manuals for Zamboni 450 ELECTRIC
Summary of Contents for Zamboni 450 ELECTRIC
- Page 1 (519) 758-0500 +46 291 206 80 +46 291 206 83 (514) 333-8420 (877) 333-8420 This manual must be kept and stored with the machine. DM-20080/ REV 8/6/23 The manual and all related safety and service materials are available online at www.zamboni.com...
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Page 2: Table Of Contents
Warning Signs and Labels Crushing or Cutting Prevention Fire or Explosion Prevention Oils Batteries Lubricants Lines, Tubes and Hoses Safe Operation Before Operating the Zamboni Ice Resurfacer Mounting and Dismounting Operation Parking Maintenance Walk-Around Inspection Cold Storage Applications 1-10 General Operating and... - Page 3 Contents Air Quality Monitoring Ice Resurfacer Components Front View Rear View Operator's Platform Power Package (Motor and Pumps) Battery Pack Battery Charger (GEN 1, GEN 2, GEN 3) Operator's Station Multi Function Display Machine Operation Switches Operating the Ice Resurfacer Driving the Machine Before Driving the Machine Machine Controls...
- Page 4 Contents Operating Pointers 7-14 Resurfacing Patterns 7-14 Sharp Turns 7-14 Excessive Loads 7-15 Water System Optional Connection Valve Maintaining the Cutting Blade Changing the Blade New Blade Blade Controls on Conditioner Side Controls Used Blade Hand Wheel Holding and Securing the Blade Procedure for Setting Blade Angle and Depth of Cut Blade Angle Adjustment Decal Conditioner Down Pressure...
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Page 5: Introduction
Introduction This manual has been prepared to acquaint you with the operation of your Zamboni ® resurfacer and to provide important safety information. Read, understand and comply with the information in this manual. All new operators must read this manual before operating the machine for the first time. -
Page 6: Safety Symbols
Safety Symbols Safety Symbols Safety Symbols The safety symbols listed outline basic safety precautions. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE OPERATING, OR PERFORMING LUBRICATION AND MAINTENANCE. Personal Safety These symbols indicate when your safety or the safety of others may be at risk. DANGER! This safety symbol warns of possible personal injury or death. -
Page 7: Ice Resurfacer Guards
Ice Resurfacer Guards Ice Resurfacer Guards The safety guards used on the Zamboni ice resurfacer are illustrated in Figures 1.1 and 1.2. Vertical Auger Coupling Guard Snow Transfer Guard Chain and Pulley Guard, Conditioner Covers Horizontal Auger Figure 1.1 Ice Resurfacer Guards... - Page 8 Ice Resurfacer Guards Snow Tank Safety Stand Figure 1.2 Ice Resurfacer Guards - Snow Tank Safety Stand viii...
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Page 9: Zamboni Ice Resurfacer Specifications
Some features described or shown may be optional at extra cost and prices, colors, materials, specifications and models are subject to zamboni.com change. Some options are required in combination with other options. ZAMBONI and the configuration of the Zamboni® ice resurfacing machine are registered trademarks of Frank J. Zamboni & Co., Inc. © Zamboni 2022... - Page 10 Some features described or shown may be optional at extra cost and prices, colors, materials, specifications and models are subject to zamboni.com change. Some options are required in combination with other options. ZAMBONI and the configuration of the Zamboni® ice resurfacing machine are registered trademarks of Frank J. Zamboni & Co., Inc. © Zamboni 2022...
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Page 11: Foreword
• It is mandatory that all operators review in detail this manual before performing any operation • Read - understand - and keep this manual with the Zamboni ice resurfacer • Some illustrations show details or attachments that may be different from your machine. -
Page 12: General Safety Practices
OSHA rules and regulations. Please refer to your provincial Health and Safety regulatory body for a complete list of CCOHS rules and regulations. Regulations vary from state to state; province to province as well as country to country. Operate your Zamboni ice resurfacer in accordance with local regulations. - Page 13 The warnings in this manual and on the machine are therefore not all-inclusive. If a procedure, tool or work method not specifically recommended by Zamboni is used, a competent person must be consulted to assure the safety of you and others and that the machine will not be damaged or made unsafe by the procedures you choose.
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Page 14: Warning Signs And Labels
• Keep all guards in place. Do not operate the Zamboni machine if any guard is damaged or missing. • Check all controls and warning devices for proper operation •... -
Page 15: Crushing Or Cutting Prevention
General Safety Practices • Be sure operating surface can safely support machine • Observe safety rules when handling fuel on engine powered machines and when changing or charging batteries for electric machines • Never cover, hide or remove any safety label •... -
Page 16: Batteries
• Remove the hydraulic tank filler cap slowly to relieve pressure Batteries WARNING! The battery pack in the Zamboni Model 450 is a sealed unit from the factory. Service of the battery pack should only be performed by a trained technician. -
Page 17: Lines, Tubes And Hoses
• Adjust the seat so that full pedal travel can be obtained with the operator's back against the seat back. • The Zamboni machine is equipped with a lighting system, make sure all lights are working properly. • Make sure no one is working on, underneath or close to the ice resurfacer before turning on the key or beginning to move the machine. -
Page 18: Mounting And Dismounting
• Never get on or off a moving Zamboni machine. Never jump off the machine. • Do not try to climb on or off the ice resurfacer when carrying tools or supplies Operation •... -
Page 19: Maintenance
Maintenance Walk-Around Inspection For maintenance and operator personnel safety and maximum service life of the Zamboni machine, make a thorough walk-around inspection when doing lubrication and maintenance work. Look around and under for such items as loose or missing bolts, trash or dirt build-up, oil leaks and cut or gouged tires. - Page 20 General Safety Practices • Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designated access system, provide ladders, scaffolds or work platforms to perform safe repair operations.
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Page 21: Cold Storage Applications
There is a reduction in battery capacity in very cold applications. For this reason, it is important to: • Be sure the battery is completely charged at the start of each work cycle • If possible, keep the Zamboni machine in a warm storage area when it is not in use. 1-10... -
Page 22: General Operating And Maintenance Information
The Zamboni Model 450 ice resurfacer is designed with state-of-the-art electronic machine controls and features. Owners and operators of the Model 450 should be aware of the different operation of the Model 450 versus the operation of other Zamboni products which are fuel-powered or electric-powered. -
Page 23: Starting The Machine
The electric motor in your Zamboni Model 450 is a sealed and maintenance free unit. The battery pack is also a sealed unit and should only be opened by a trained and authorized technician. -
Page 24: Charging The Machine
• Park the machine in authorized areas only. • Lower the conditioner into the floating position demonstrated in detail at https://zamboni.com/zamboni-performance-tip-resting-the-conditioner/. The conditioner weighs approximately 1000 pounds. This weight should not hang on the lift bar nor be supported by the hydraulic system during storage. Lowering the conditioner must be done cautiously as putting hydraulic down pressure (in excess of the weight of the conditioner) can stretch the down pressure leaf springs. -
Page 25: Travel On Highways
General Operating and Maintenance Information Travel on Highways The machine is not designed for highway use. Fast driving on the highway and bouncing the machine over bumps can seriously damage the machine. Travel over extended distances should be avoided, if possible. If such travel is required: •... -
Page 26: Safe Operation
Safe Operation Safe Operation Your Zamboni ice resurfacer is the result of many years of experience in the ice resurfacing field. The engineering and safety features that have gone into your Zamboni machine will be enhanced by you, the safe operator... - Page 27 Safe Operation DANGER! Turn off and remove the ignition key before adjusting, repairing, cleaning, or servicing the conveyors. The vertical and horizontal augers will continue to rotate for a short period of time after the auger control valves have been shut off.
- Page 28 Safe Operation DANGER! The resurfacer must be kept properly maintained and serviced at all times. Each person who operates and maintains the resurfacer should be so instructed. Please keep in mind that the condition of the machine is, at all times, the complete responsibility of the rink. •...
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Page 29: Adequate Ventilation
Ice Rink Air Quality Ice Rink Air Quality With its sealed battery package, the Zamboni Model 450 is a Zero Emission machine and will not negatively impact air quality. However for a rink to have the best air quality possible, the Zamboni machine must be operated properly in a rink that: •... -
Page 30: Ice Resurfacer Components
Ice Resurfacer Components Ice Resurfacer Components Front View Snow Tank Lid Snow Tank Board Brush Motor Compartment (Option) Access Door Guide Wheel Horizontal Auger Conditioner Figure 5.1 Ice Resurfacer Components (front view) -
Page 31: Rear View
Ice Resurfacer Components Rear View Vertical Auger Drive Wash Water Return Wash Water Tank Conditioner Chain Guard Conditioner Squeegee Ice Making Water Distribution Pipe Figure 5.2 Ice Resurfacer Components (Rear View) -
Page 32: Operator's Platform
Ice Resurfacer Components Operator's Platform Wash Water Tank Ice Making Wash Water Instrument Panel Water Control Control Blade Adjustment Wheel Snow Tank Control Auger Control Conditioner Lift Figure 5.3 Ice Resurfacer Components - Operator's Platform... -
Page 33: Power Package (Motor And Pumps)
Ice Resurfacer Components Power Package (Motor and Pumps) Hydroback (Neutral Return) Motor Phase Cable Connection Hydrostatic (Drive) Pump Auxiliary Pump PMAC Motor Motor Mount Figure 5.5 Ice Resurfacer Components - Power Package Battery Disconnect Charge Cables Figure 5.6 Ice Resurfacer Components - Power Package... - Page 34 Ice Resurfacer Components Snow Tank Safety Stand Ice Making Water Tank Battery Pack Figure 5.7 Ice Resurfacer Components - Snow Tank Safety Stand...
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Page 35: Battery Pack
Ice Resurfacer Components Battery Pack Positive Cable Battery Modules Communication Cables Ground Cable Main Fuses Bus Bars Butyl Sealing Tape Battery Retainer Figure 5.8 Ice Resurfacer Components - Battery Pack... -
Page 36: Battery Charger (Gen 1, Gen 2, Gen 3)
Ice Resurfacer Components Battery Chargers BASSI CHARGER (GEN 1) Power Switch Status Window Figure 5.9 Ice Resurfacer Components - Battery Charger (GEN 1) Figure 5.10 Ice Resurfacer Components - Battery Charge Connector... - Page 37 Ice Resurfacer Components Universa Univers BASSI CHARGER (GEN 2) MAXIMIZES B MAXIMIZES B REDUCE ENER REDUCE ENER Technology: Current ratings: Voltages: Figure 5.11 Ice Resurfacer Components - Battery Charger (GEN 2) BASSI CHARGER (GEN 3) Product Description Main Fe Product Description Main Fe...
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Page 38: Operator's Station
Operator's Station Operator's Station Instrument Panel Battery Discharge Indicator Control Switches Figure 6.1 Operator Area... -
Page 39: Multi Function Display
Operator's Station Multi-Function Battery Display Emergency Stop Horn Lights Wash Water Pump (Option) Board Brush (Option) Tire Wash (option) Snow Tank Light (option) Hydraulic Snow Breaker / Manual Override (Option) Motor Speed Switch Figure 6.2 Instrument Panel Ignition / Enable Switch Multi Function Display This display gives the operator an accurate battery charge level at a glance. -
Page 40: Machine Operation Switches
Operator's Station Machine Operation Switches The switches located on the dash operate the following machine functions: • Horn • Lights • Board brush (if equipped) • Wash water pump (if equipped) (illuminated) • Tire wash system (illuminated) (if equipped) • Advanced water system (illuminated) (if equipped) •... -
Page 41: Operating The Ice Resurfacer
Do not operate the machine if the guards are not in place or broken. Machine Controls The Zamboni ice resurfacer has familiar automobile-style driving controls. The ice resurfacer is steered with the steering wheel. It has two foot pedals, one that controls the direction and acceleration and the other one is a brake pedal. -
Page 42: Hydrostatic Transmission
Operating the Ice Resurfacer Hydrostatic Transmission The hydrostatic transmission is an infinitely variable hydraulic pump and motor combination. The machine's speed and direction of travel are selected with the acceleration foot pedal (Figure 7.1). The transmission must be in neutral for starting the machine (foot off of the accelerator pedal). -
Page 43: Throttle Switch And Hydrostatic Transmission Control
Operating the Ice Resurfacer Throttle Switch and Hydrostatic Transmission Control Speed Selector Switch Brake Pedal Accelerator Foot Pedal Figure 7.1 Motion Controls Figure 7.2 Direction Decal... -
Page 44: Resurfacing Procedures
Operating the Ice Resurfacer Resurfacing Procedures In order to achieve the desired level of ice quality several processes must happen simultaneously: • The ice is shaved by the blade • The shavings are collected into the snow tank • The ice is washed using the wash water system •... -
Page 45: Learning To Resurface
Operating the Ice Resurfacer Learning to Resurface Before Going to the Ice • Check the water level in the water tanks • The blade must be level (see Figure 9.5) and at the correct angle (see Figure 9.6) • The conditioner must be raised completely •... -
Page 46: Shaving Or Cutting
Operating the Ice Resurfacer Shaving or Cutting • Proceed from the storage area onto the ice (see Figure 7.4) • When starting the resurfacing pattern, it is recommended to start down the center of the ice surface so the functions can be started and blade adjustments can be made at some distance from the walls or boards. -
Page 47: (Optional) Reversible Auger Operating Instructions
Operating the Ice Resurfacer (Optional) Reversible Auger Operating Instructions The vertical auger is equipped to rotate in both directions. The normal rotation for resurfacing is FORWARD, as shown by the information decal located near the valve operating handle. Note: Since the vertical and horizontal augers are hydraulically connected in series, both augers will rotate in the reverse direction if the optional reverse auger funtion is enabled. -
Page 48: Typical Resurfacing Operation
Operating the Ice Resurfacer Typical Resurfacing Operation Storage Room: Check water levels Check blade Raise conditioner Adjust blade Open ice making water valve Open wash water valve Start forward slowly Lower conditioner completely Start conveyor Start Water Pump Back out of storage area and onto ice Figure 7.4 Going onto the Ice... -
Page 49: Using The Snow Breaker
Operating the Ice Resurfacer Using the Snow Breaker The operator should use the snow breaker several times a minute (or more as required). The snow breaker helps remove snow or ice that will build up in the corners of vertical auger opening. -
Page 50: Ice Making Water
Operating the Ice Resurfacer Ice Making Water Using hot water for the ice making water will generally produce the best ice surface. Do not use water hotter than 160 F (70 C) as this could damage the plastic ice making water tank. To use the ice making water during a resurfacing: •... -
Page 51: Removing Excess Water From The Ice
Operating the Ice Resurfacer • After a complete lap of the ice surface next to the boards, retract the board brush by turning off the board brush switch. This will also stop the brush motor. • Proceed with the other resurfacing operations over the remainder of the ice surface Removing Excess Water from the Ice If there is an excess amount of water on your ice either from rainfall or excessive melting, it can be removed quickly by using the following procedure. -
Page 52: Removing Slush (Ice And Water Mixed) From The Ice
Note: Whenever excess water or slush is being removed from the ice surface and conveyed into the snow tank, the Zamboni ice resurfacer ice making water tank must be empty. Water in both the ice making water tank and the snow tank may load the machine excessively. -
Page 53: Leaving The Ice Surface
Operating the Ice Resurfacer Leaving the Ice Surface When leaving the ice surface after finishing a resurfacing (or any other time): (See Figure 7.5) • Close the wash water system valve. Turn off water pump (if used) • Turn off the auto snow breaker (if equipped) •... -
Page 54: Operating Pointers
Operating the Ice Resurfacer Operating Pointers Resurfacing Patterns The following diagram shows a good resurfacing pattern: Figure 7.6 Standard Resurfacing Pattern Sharp Turns The ice resurfacer has a power steering system which contains a hydraulic relief valve. This valve only operates when the wheels are jammed up against an object or when the operator turns the steering wheel completely to the left or the right and holds it there against the stop. -
Page 55: Excessive Loads
Operating the Ice Resurfacer Excessive Loads Taking too deep a cut with the shaving blade while driving the machine at it's full ground speed may place an excessive load on the motor. With an excessive machine load, the motor will try to draw too much power from the Sevcon Gen4 controller. This will cause the operation of the machine to suffer as well as drain the battery pack prematurely. -
Page 56: Water System
Water System Water System A. Pipe A (Figure 8.2) supplies water from the wash water tank to the conditioner. B. Hose B (Figure 8.1) carries water picked up in the conditioner, via pipe B, from the water pump back to the wash water tank. The water flows through the filtering screen at which point the water can be recirculated. - Page 57 Water System Wash Water Transfer Valve (D) Optional Wash Water Pipe (A) Ice Making Water Pipe (C) Pipe (B) Wash Water Distribution Pipe Blade Adjustment Screw & Greasable Clevis Wash Water Pickup (Suction) Wash Water Outlet (Both Ends Of Conditioner) Figure 8.2 Conditioner Underside...
- Page 58 Water System Ice Making Water Ice Making Tank Cover Water Fill Overflow Ice Making Discharge Water Tank Figure 8.3 Ice Making Water System Wash Water Return Wash Water Wash Water Tank Cover Filter Figure 8.4 Wash Water System...
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Page 59: Maintaining The Cutting Blade
Maintaining the Cutting Blade Maintaining the Cutting Blade It is essential that the blade be sharp if the resurfacer is to operate properly. Conditions vary from one rink to another, but experience has shown that normally the cutting blade is dull and needs re-sharpening after 5 to 7 days of operations. -
Page 60: Blade Controls On Conditioner
Maintaining the Cutting Blade Used Blade Use REAR mounting holes when blade is 4" wide or less. Note: Hardened material is exhausted when blade is approximately 3" wide. Discard blade. Blade Controls on Conditioner Blade Height Adjusting Screws level each side of the blade in relation to the runners. Side Controls Down Blade Height... -
Page 61: Hand Wheel
Maintaining the Cutting Blade Hand Wheel The center hand wheel control varies the angle of the blade. If the blade is level with each runner, the hand wheel will make uniform changes in depth of cut. Center Hand Wheel Down Side View Conditioner Runner Blade... -
Page 62: Holding And Securing The Blade
Maintaining the Cutting Blade Holding and Securing the Blade Blade Holding Bar (5K-78890) Blade (5K-33630) Bolt Tightening Sequence Blade Holding Bar Blade 0.08" Machined Surface on Blade Holding Bar Blade Figure 9.4 Blade Holding Bar The ends of blade holding bar are machined upward approximately 0.08" so that one cut of the ice is feathered into the adjoining cut. -
Page 63: Procedure For Setting Blade Angle And Depth Of Cut
Maintaining the Cutting Blade Procedure for Setting Blade Angle and Depth of Cut Step 1: Set blade at approximately 10 angle as shown on the blade angle adjusting plate (Figure 9.6) by rotating center hand wheel control. Step 2: Align leading edge of blade EVEN with BOTH conditioner runners. It is quite helpful to use a flat washer, a large coin or the blade adjusting tool (Part No. -
Page 64: Blade Angle Adjustment Decal
Maintaining the Cutting Blade Blade Angle Adjustment Decal A blade angle decal is located on the inside of the conditioner left side plate (see Figure 9.6). When the blade holding bar is lined up, parallel to the series of lines, the blade angle is approximately 10°. -
Page 65: Conditioner Down Pressure
Maintaining the Cutting Blade Conditioner Down Pressure The purpose of the conditioner down pressure system is to create downward pressure on the shaving blade thus increasing the shaving capability of the machine. Down Pressure Spring Adjustment Procedure • Lift Conditioner slightly off of the ground, just so it clears the floor •... -
Page 66: Using The Edger
Coupe-bordure Zamboni ® Au besoin, marchez autour des bandes pour réduire l'accumulation Après avoir coupé la bordure, utilisez la machine Zamboni® près des bandes et complétez le schème de surfaçage Figure 9.8 Zamboni Edger... -
Page 67: Edger Attachment
Maintaining the Cutting Blade Edger Attachment Mount the edger on the driver's side of the conditioner and bolt tightly at the three locations shown below. The depth of cut on the edger blade may be adjusted by turning the two blade adjustment set screws. -
Page 68: Emergency Operation
Emergency Operation Emergency Operation Emergency Hand Pump The emergency hand pump is located in the driver area of the machine. The pump handle must be stored where the operator can find it in an emergency. Purpose: The emergency hand pump is used to raise the conditioner or the snow tank in the event the engine will not operate. -
Page 69: Emergency Hydrostatic Bypass Valve
Emergency Operation Emergency Hydrostatic Bypass Valve Should it be necessary to move the machine when the engine is not operable, the emergency bypass valve, located on the hydrostatic pump, must be opened (see Figure 10.3). This valve is located on the hydrostatic pump and painted red for ease of identification, in the engine compartment. -
Page 70: Auger Hydraulic Stop
Emergency Operation Auger Hydraulic Stop The Model 450 Ice Resurfacing Machine is equipped with an auger hydraulic stop valve. The valve is controlled by a normally open electrical switch located near the front of the snow tank. It functions as follows: 1) When the snow tank is down, the valve is open allowing flow to the hydraulic motors that rotate the augers. -
Page 71: Emergency Stop Button
Emergency Operation Emergency Stop Button The Zamboni Model 450 ice resurfacing machine is equipped with an emergency stop button. By pressing this button all power to the motor controller will be immediately cut off and the machine will stop very suddenly. To reset the emergency stop button twist it in a clockwise direction. -
Page 72: Status Codes
Model 450 is depleted batteries or excessive drain on the batteries. In all cases, if you are unsure of the cause and remedy for a warning or fault code, please contact the Zamboni Company or your Zamboni Authorized Distributor for more information. - Page 73 Status Codes When applicable, status codes are shown in the lower portion of the display. Some common operational status codes are shown in Table 11-1. Operators should pay close attention to any of these codes as they are used to indicate important service and component information. Status Fault Description...
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Page 74: Storage Information
Storage Information Storage Information Storage Room Information Storage Area Due to the great amount of water associated with this machine, it should be stored between resurfacing in a room heated above freezing. The room should be as close to the edge of the rink as possible and the surfaces between the storage area and the rink should be paved so dirt will not be tracked onto the ice. - Page 75 Zamboni Quebec Robert Boileau Inc. 1425 Boulevard Pitfield ZAMBONI and the configuration of the Zamboni ice resurfacer ® Saint-Laurent, Quebec, Canada H4S 1G3 are registered trademarks of Frank J. Zamboni & Co., Inc. (514) 333-8420 (877) 333-8420 Part Number DM-20080...
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