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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
650
Zamboni Quebec
Robert Boileau Inc.
1425 Boulevard Pitfield
Saint-Laurent, Quebec, Canada H4S 1G3
(514) 333-8420
(877) 333-8420
DM-20026/ REV 03/23/2023
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Table of Contents
Related Manuals for Zamboni 650
Summary of Contents for Zamboni 650
- 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-20026/ REV 03/23/2023 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 Electric Machine Operations... - Page 3 Contents Horn Switch Wash Water Pump Switch Key Switch Battery Gauge BDI Gauge Hours Counter Diagnostic / Status Messages Operating the Ice Resurfacer Driving the Machine Before Driving the Machine Machine Controls Learning to Drive the Ice Resurfacer Starting the Machine Stopping the Machine Machine Not in Use Travel on Highways...
- Page 4 Contents Traction Motor Stalling 6-15 Water System Optional Connection Valve Maintaining the Cutting Blade Changing the Blade New Blade Used Blade Blade Controls on Conditioner Side Controls Hand Wheel Holding and Securing the Blade Procedure for Setting Blade Angle and Depth of Cut Blade Angle Adjustment Decal Using the Edger Edger Attachment...
- Page 5 Contents Common Operational Status Codes 11-2 Storage Information 12-1 Storage Room Information 12-1 Storage Area 12-1 Floor Drain 12-1 Daily Storage (Indoor) 12-1 Summer Storage Tips 12-1 Battery Summer Maintenance 12-2...
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Page 6: 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 7: 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 8: Zamboni Machine Room Poster
This poster highlights important safety information. Make sure it is displayed and visible to all Zamboni machine operators. The Zamboni machine room is the preferred poster location. If you do not have this poster, contact the Zamboni Company or your Zamboni Authorized Distributor for a digital file you can have printed locally for your use. -
Page 9: 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. DANGER! Keep all guards in place! Do not operate the Zamboni ice resurfacer if any guard is damaged or missing! - Page 10 Ice Resurfacer Guards Vertical Auger Drive Coupling Cover Conditioner Cover Conditioner Cover Figure 1.2 Ice Resurfacer Guards...
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Page 11: 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 12 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 13: 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 14: 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 15 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 16: Warning Signs And Labels
For safe operation, read and follow the manual furnished with this machine and observe the following warnings • 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 17: Crushing Or Cutting Prevention
General Safety Practices • 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 • Never stand on the ice making water tank. Damage to the tank and personal injury may occur. Crushing or Cutting Prevention •... -
Page 18: Lubricants
• Repair any loose or damaged oil lines, tubes and hoses. Leaks can cause fires. Contact the Zamboni Company or your Zamboni machine dealer for repair or replacement. • Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. -
Page 19: Safe Operation
• 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 20: Parking
General Safety Practices Parking • Park the Zamboni machine in authorized areas only • Remove foot from the acceleration foot pedal to place the machine in NEUTRAL • Apply the parking brake • Lower the conditioner onto blocks • Turn the key switch OFF and remove the key •... -
Page 21: 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 22 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 23: 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 24: Electric Machine Operations
Model 650 and a fuel powered Zamboni machine. These differences do not detract from the ability of the Model 650 to perform the operations that produce high quality ice surfaces. These differences do require a slightly different approach to driving the machine. -
Page 25: 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 26 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 27 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 28: Side View
Ice Resurfacer Components Ice Resurfacer Components Side View Snow Tank Maintenance Support Snow Tank Operator's Seat Snow Lid Horizontal screw conveyor Conditioner (inside conditioner) Figure 4.1 Ice Resurfacer Components... -
Page 29: Left View
Ice Resurfacer Components Left View Snow Tank Window Instrument Panel Horizontal Conveyor Drive Motor Board Brush Ice Making Water Distribution Pipe Conditioner Towel Rubber Squeegee (Inside Conditioner) Figure 4.2 Ice Resurfacer Components... - Page 30 Ice Resurfacer Components Wash Water Fill Vertical Screw Conveyor Ice Making Water Fill Hydraulic Oil Fill (under Snow Tank) Hydraulic Oil Level Sight Glass (internal; view through Rear Access Door Conditioner's Chain wheel well on operator's and Pulley Guard side) Hydraulic Oil Level Hydraulic Sight Glass...
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Page 31: Operator's Station
Operator's Station Operator's Station Directional Steering Wheel Control Switch Instrument Panel Blade Adjustment Handwheel Wash Water Fill Wash water Storage Bin sight window Controller Enclosure (inside) Snow Transfer Window Seat Grab Handle Ice Making Water Control Rod Vertical/Horizontal Conveyor Control Valve Lever Conditioner Lift Control Valve Lever Snow Tank Control... -
Page 32: Instrument Panel
Operator's Station Instrument Panel Battery Discharge Indicator Horn Switch Board Brush Switch Lights Switch Wash Water Pump Switch Auto Snow Breaker Key Switch Figure 5.2 Instrument Panel Vehicle Lights Switch This switch activates the machine lighting system. The switch is illuminated when the lights are Horn Switch This switch activates the machine's horn. -
Page 33: Battery Gauge
Operator's Station Battery Gauge BDI (battery discharge indicator) Hour Meter Figure 5.3 Battery Gauge The dash display consists of an alphanumeric LCD display. (See Figures 5.2 and 5.3). The display incorporates the following features: • 10 segment BDI (battery discharge indicator) gauge, with low charge warning; •... -
Page 34: 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 some driving characteristics similar to other machines. It is steered with the steering wheel. It has two pedals, one that controls the acceleration and the other one is a brake pedal. -
Page 35: Stopping The Machine
Operating the Ice Resurfacer To start the machine: • Turn key switch ON to start. • Release the parking brake. • Select a direction (forward or reverse) with the directional control lever. • Be sure dump tank is completely down and conditioner is fully raised. •... -
Page 36: Resurfacing Procedures
• Using a hose, the final coat of water was sprayed or flooded onto the ice surface to complete the resurfacing operation. The Zamboni ice resurfacer performs all of these tasks. The ice is shaved, the shavings are collected into the snow tank, the ice is washed using the wash water system and final coat of water is applies to the ice surface. -
Page 37: Learning To Resurface
• Shaving or cutting • Washing the ice • Distributing ice making water • Use of the board brush, edger, or other Zamboni optional equipment. • Removing excess water from the ice • Removing slush (mixed ice and water) from the ice Shaving or Cutting •... -
Page 38: To Lower The Conditioner
Operating the Ice Resurfacer Note: To avoid catching the towel underneath the conditioner, lower the conditioner only while driving slowly forward. • While on the ice surface and driving slowly forward, lower the conditioner and start the conveyors immediately. To lower the Conditioner: Pull back on the conditioner of valve handle completely. -
Page 39: Reversible Vertical Auger Operating Instructions
Operating the Ice Resurfacer Reversible Vertical 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. Reversing the auger rotation may clear a puck, water bottle, piece of hockey stick or other large objects that do get lodged in the auger flighting. - Page 40 Operating the Ice Resurfacer CAUTION! Never slam the lever back and forth rapidly to unclog something. It is highly likely you will over pressurize the Auger motor and cause breakage. Besides the unnecessary down time associated with this action, the damaged motor will not be covered under warranty. Damage created in this manner is very obvious upon inspection of the motor.
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Page 41: 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 6.3 Going onto the Ice... -
Page 42: Using The Snow Breaker
Operating the Ice Resurfacer Using the Snow Breaker The snow breaker (Figure 6.5) will operate automatically. Horizontal Auger Snow Breaker Figure 6.5 Automatic (Hydraulic) Snow Breaker... -
Page 43: Washing The Ice
Operating the Ice Resurfacer Washing the Ice The wash water system removes dirt and debris from the ice surface. Regular use of the wash water system will produce a clean, high quality ice surface. Before using the wash water system, fill the wash water tank with cold water. To use the wash water system: •... -
Page 44: Using The Board Brush
Operating the Ice Resurfacer Using the Board Brush The optional board brush will help you produce a high quality ice surface by sweeping away the snow and ice that gathers at the base of the dasher boards, next to the kick plate, around the perimeter of the ice. -
Page 45: Removing Excess Water From The Ice
Operating the Ice Resurfacer location for best brush performance. The board brush arm has a spring action so that the machine's distance from the dasher boards can vary a little. • After a complete lap of the ice surface next to the boards, retract the board brush by turning off the board brush switch. -
Page 46: Leaving The Ice Surface
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 47: Off Of The Ice
Operating the Ice Resurfacer Off of the Ice • Dumping the snow tank on a level surface if possible Raise the snow tank by operating the snow tank valve lever. After the snow has been • dumped, lower the tank. If the tank is to be left up, the snow tank support stand must be properly placed to support the snow tank and remove excess load from the hydraulic cylinders. -
Page 48: Traction Motor Stalling
Motor or armature replacement is an expensive and time consuming result of stalling the traction motor. The traction motor on the Model 650 Machine can be stalled in several ways, all of them are incorrect operation of the machine. -
Page 49: Water System
Water System Water System A. Pipe A (Figure 8-1) 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 50: 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 51: Used Blade
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. Figure 8.2 Used Blade Blade Controls on Conditioner Side hex head controls level each side of the blade in relation to the runners. Side Controls Down Blade Height... -
Page 52: 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 53: Holding And Securing The Blade
Maintaining the Cutting Blade Holding and Securing the Blade Blade Holding Bar (5K-78890) Bolt Tightening Sequence Blade Holding Bar Blade 0.08" Machined Surface on Blade Holding Bar Blade Figure 8.6 Blade Holding Bar The ends of the blade holding bar are machined upward approximately 0.08" so that one cut of the ice is feathered into the adjoining cut. -
Page 54: 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 8.8) 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 55: 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 8.8). When the blade holding bar is lined up, parallel to the series of lines, the blade angle is approximately 10°. -
Page 56: Using The Edger
Zamboni Bolt-on Edger Attach to conditioner and make one pass around rink next to boards Zamboni Power Edger Walk around boards as required to reduce edge. After edging, use Zamboni machine next to boards and complete resurfacing pattern Figure 8.10 Zamboni Edger... -
Page 57: 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 58: Emergency Operation
Emergency Operation Emergency Operation Emergency Hand Pump The emergency hand pump is located in the rear 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 dump tank in the event the engine will not operate. -
Page 59: Batteries
Batteries Batteries Battery Safety DANGER! Hydrogen and oxygen gas is given off as battery plates get near a full charge condition. These gases are highly explosive and caution must be taken to make sure no arc, spark, or flame come into contact with the generated gases. -
Page 60: Battery Operation
Correct battery charging and use is essential to maintaining the performance of the Model 650 electric ice resurfacer. The Model 650 utilizes lead-acid secondary cell batteries. These batteries are state- of-the-art in design, performance and construction. - Page 61 A “Low Battery Voltage” warning will also be shown on the dash display when the battery’s usable range drops below 8%. During a normal resurfacing, the 650 ice resurfacer uses approximately 30Ah. This 30Ah is approximately 6% to 7% of the available battery capacity. The BDI segments drop in 10% increments.
- Page 62 Batteries READ AND FOLLOW THE SAFETY, OPERATION AND MAINTENANCE INSTRUCTIONS DESCRIBED IN THE SERVICE MANUALS FOR YOUR BATTERIES AND CHARGER. Low battery operation must be prevented. Operation with a low battery may cause damage to the battery. Low battery operation will cause higher than normal current in the electrical system.
- Page 63 Batteries Powerhouse IHF Charger Green Charger 10-5...
- Page 64 Batteries Many chargers have an automatic equalizing charge feature, however the charge occurs at the end of the full charging cycle. A “cycle charge” will completely charge the battery. The typical charge for a fully discharged battery usually is an eight hour charge. The battery must be recharged before it has been over discharged.
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Page 65: Opportunity Charging
Batteries WARNING! Never charge a battery with frozen electrolyte. Opportunity Charging The battery charging schedule depends upon the use-schedule of the machine. It should be noted that when the batteries reach a level below 2 segments or 20% on the BDI gauge (Figure 10.1), charging time may be as long as 6 to 8 hours. -
Page 66: Battery Maintenance
Batteries Battery Maintenance Maintaining proper battery condition is important for long battery life. Proper maintenance includes: • Maintaining the electrolyte (battery acid/water mixture) at the recommended levels in each battery cell; • “Watering the battery” at the correct times and to the correct level; •... -
Page 67: Keeping The Batteries Clean And Dry
Batteries Battery watering gun Figure 10.5 Battery Watering Gun Keeping the Batteries Clean and Dry Most dirt and dust picked up by the battery can usually be blown off with low pressure compressed air. “Washing down” the batteries regularly with water will reduce the chance of “grounds” caused by electrolyte spills and corrosion. -
Page 68: Battery Inspection
Different cells should be tested each week so that over the course of a month, all cells in both trays have been tested. Use the sheet on Page 10-13. Note: If you find very hot or dry cells, contact Zamboni. Follow the 10 commandments of good battery care listed in Table 10-1. -
Page 69: Cold Storage Applications
Cool before charging or operating if battery is above 1150F. Charge only at proper voltage and ampere-hours. Keep dump tank raised, maintenance supports in place and battery cover open during charging. When in doubt, call the Zamboni Company or your Zamboni Authorized Distributor. Table 10-1 10-11... -
Page 70: Status Codes
Status Codes Status Codes The Sevcon Gen4™ AC controllers used on the Model 650 provide advanced on-board diagnostics, troubleshooting and vehicle management capabilities. The dash display (Figure 11.1) shows a graphic indication of the batter state of charge via the Battery Discharge Indicator (BDI), and shows controller hour information via an hour meter. -
Page 71: Common Operational Status Codes
Status Codes Common Operational Status Codes Status Fault Description Remedy Code Any drive switch (direction, Return the directional F22004 Sequence Fault accel pedal) active at control lever to neutral and/ power up or release accel pedal Handbrake Handbrake is active when F12001 Release the parking brake Fault... -
Page 72: 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 73: Battery Summer Maintenance
Storage Information Battery Summer Maintenance • Before storing the machine, make sure the batteries are fully charged and that the battery electrolyte is at the correct level. • Charge the batteries every four weeks using the equalize charge setting. Allow the charger to shut OFF automatically. - Page 74 Zamboni Quebec Robert Boileau Inc. ZAMBONI and the configuration of the Zamboni ice resurfacer ® 1425 Boulevard Pitfield, Saint-Laurent, Quebec, Canada H4S 1G3 are registered trademarks of Frank J. Zamboni & Co., Inc. (514) 333-8420 (877) 333-8420 www.zamboni.com Part Number DM-20080...
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