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+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 02/26/2025 The manual and all related safety and service materials are available online at www.zamboni.com...
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 Maintenance Information...
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Contents Travel on Highways Safe Operation Front View Rear View Operator's Station Instrument Panel - 552AC Instrument Panel - 552AC Lithium Ion Horn Switch Vehicle Lights Switch Board Brush Switch Wash Water Pump Switch Key Switch Dash Display Hours Counted...
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Blade Controls on Conditioner Side Controls Hand Wheel Holding and Securing the Blade Using The Zamboni Blade Angle Tool Procedure for Setting Blade Angle and Depth of Cut Blade Angle Adjustment Decal Conditioner Down Pressure Assessing and Measuring Down Pressure...
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Contents Keeping the Batteries Clean and Dry 10-6 Battery Inspection (Lead Acid batteries) 10-7 Open Circuit Voltage Test 10-7 Specific gravity test 10-7 Record Keeping 10-7 Status Codes (Lithium-ion batteries) 11-1 Warning, Fault and Automatic Shut-down Modes 11-1 Storage Information 12-1 Storage Room Information 12-1...
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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.
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.
Battery Symbols Battery Symbols The following symbols are used to differentiate the two types of batteries used in the Model 552AC and the Model 552AC+LI, respectively. Battery Types Model 552AC uses a Lead Acid battery Model 552AC+LI uses a Lithium Ion battery...
Ice Resurfacer Guards Ice Resurfacer Guards The safety guards used on the Zamboni ice resurfacer are illustrated in Figures 1.1 and 1.2. Snow Tank Safety Stand Figure 1.1 Ice Resurfacer Guards - Snow Tank Safety Stand...
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.
• 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.
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.
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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.
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 •...
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 •...
• 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.
• 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.
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 •...
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.
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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.
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...
8 hours (Model 552AC+LI has a total charge time approximately 2.5-3 hours, from no charge at all to 100%) The recommended way to achieve the best performance and the longest battery life is to connect the machine to the charger after each use.
The battery pack is also a sealed unit and should only be opened by a trained and authorized technician. It is also recommended that the new owner contact the local Zamboni Authorized Dealer to acquaint themselves with the service policy.
• 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.
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...
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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.
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The Model 552AC machine operates on 80 VDC (nominal). The batteries contain either 600AH or 510AH capacity. The Model 552AC + LI operates at 83.2V with a capacity of 300Ah. This is a potentially lethal amount of electrical energy if the batteries were to directly discharge.
Operator's Station Operator's Station Directional Control Switch Snow Tank Vent Manual Snow Breaker Steering Wheel Parking Instrument Panel Brake Ice Making Lever Control Rod Wash Water Control Rod Blade Adjustment Handwheel Snow Tank Control Valve Lever Conditioner Lift Brake Pedal Horizontal and Control Valve Lever Vertical Conveyor...
Wash Water Pump Switch Options Switches Key Switch Figure 5.3 552AC + LI Instrument Panel Horn Switch This switch activates the machine's horn. Vehicle Lights Switch This switch activates the machine lighting system. The switch is illuminated when the lights are on.
• Traction Motor Hours (T) • Pump Motor Hours (P) 552AC: The BDI, Battery Discharge Indicator appears as 10 segments on the display (See Figure 5.4). When the batteries are fully charged, all 10 segments will be lit. When the batteries are fully discharged, all segments will be unlit.
Operator's Station Hours Counted 552AC: A six digit hours counter is provided to indicate traction motor, pump motor and key switch hours. At power up the hours count display initially indicates traction motor hours for approximately three seconds, followed by pump motor hours for three seconds, followed by key switch hours which remains permanently displayed.
Do not operate the machine if the guards are not in place or broken. Machine Controls Some aspects of the Zamboni ice resurfacing machine are very similar to other industrial machines. Like most, the machine is steered via usage of the steering wheel, and forward/ reverse movement is accomplished via usage of a combination of the directional control lever with the acceleration and brake pedals.
• 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.
• 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 •...
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 completely back on the conditioner valve handle.
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 BACKWARDS, as shown by the information decal located near the valve operating lever. 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.
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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.
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...
Operating the Ice Resurfacer Using the Snow Breaker The operator should use the manual snow breaker (Figure 6.5 and Figure 6.6) 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.
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: •...
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.
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.
Operating the Ice Resurfacer Turn off and remove the ignition key before adjusting, repairing, cleaning, or servicing the conveyors. If any part of the conveyor system becomes plugged or clogged, or appears plugged or clogged, the conveyor must be flushed out with water.
Operating the Ice Resurfacer Off of the Ice • Dump the snow tank on a level surface if possible WARNING! 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.
Motor or armature replacement is an expensive and time consuming result of stalling the traction motor. The traction motor on the 552AC Machine can be stalled in several ways, all of them are incorrect operation of the machine.
Operating the Ice Resurfacer A simple rule is this: If the machine is moving, you cannot stall the traction motor. If the machine is not moving, you can stall the traction motor by holding the accelerator pedal down while the machine does not move. Please review your driving and operational patterns to see if you may be stalling the motor.
Water System Water System A. Pipe A (Figure 7.2) supplies water from the wash water tank to the conditioner. B. Hose B (Figure 7.1) carries water picked up in the conditioner, via Pipe B (Figure 7.3), from the water pump back to the wash water tank. The water flows through the filtering screen (Figure 7.5) at which point the water can be recirculated.
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Water System Hose (C) Wash Water Pipe (A) Ice Making Water Pipe (C) Figure 7.2 Wash Water Pipes Pipe (B) Wash Water Distribution Pipe Blade Adjustment Screw & Greasable Clevis Wash Water Pickup (Suction) Wash Water Outlet (Both Ends Of Conditioner) Figure 7.3 Conditioner Underside Figure 7.4 Water Water Transfer Valve (Optional)
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Water System Ice Making Water Tank Cover Ice Making Water Tank Figure 7.5 Ice Making Water System Wash Water Wash Water Filter Return Figure 7.6 Wash Water System...
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.
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 3.5" wide. Discard blade. Figure 8.2 Used Blade Blade Controls on Conditioner Blade Height Adjusting Screws level each side of the blade in relation to the runners. Side Controls Blade Level Adjusting Screw Blade Level Adjusting Screw...
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...
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 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.
Maintaining the Cutting Blade Using The Zamboni Blade Angle Tool The Blade Angle Tool can be used to set the proper blade angle after a blade change or anytime to check that the blade angle and height is properly set.
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Maintaining the Cutting Blade 1. Turn the conditioner blade height adjustment screws (Figure 3) until the edge of the blade is even with the bottom surface of the runner. 2. Confirm that the blade corner is at the same level as the runner by sliding the upside-down Blade Angle Tool along the runner.
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 8.7) 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.
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°.
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. Assessing and Measuring Down Pressure Proper down pressure helps your machine’s conditioner to make exceptional ice. There are a number of factors which affect your machine’s down pressure.
Maintaining the Cutting Blade Down Pressure Adjustment 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 •...
Maintaining the Cutting Blade Leaf Spring Tension - US and Canada Proper tension on the leaf springs ensures that the machine and blade system are working optimally. Determine where your machine was manufactured via the serial number plate. REFERENCE THE TABLE BELOW FOR THE SPECIFIC NUMBER OF TURNS RECOMMENDED BY MANUFACTURED LOCATION, MACHINE, MODEL, AND SERIAL NUMBER.
With ice buildup at edges, blade cannot shave properly Zamboni Power Edger ® Walk around boards as required to reduce edge. After edging, use Zamboni ® machine next to boards and complete resurfacing pattern Figure 8.14 Zamboni Edger 8-12...
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 hydraulic pump motor will not operate/the machine is powered down.
Batteries Batteries Battery Types LEAD ACID BATTERY LITHIUM-ION BATTERY Battery Safety DANGER! FOR LEAD ACID MODELS ONLY: 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.
Correct battery charging and use is essential to maintaining the performance of the Model 552AC electric ice resurfacer. Battery chargers used with the model 552AC machine feature computer control &...
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DON'T LET THIS HAPPEN TO YOU! Battery State of Charge Percentage Figure 10.2 552AC + LI For Lithium-ion Batteries: Lithium Ion Batteries are displayed as a solid bar and reflect actual percentage of the battery charge.
Batteries The battery harness connector is located on the driver’s side of the vehicle at the front and is accessible when the snow tank is raised and safety stand is in place. Battery harness connector can also be accessed without the snow tank raised via the side access door. NOTE: This location is the same for Lead acid and Lithium-ion batteries.
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 •...
Batteries Adding Water to the Battery Adding too much water, especially to a cold battery will cause the battery to overflow. This will lead to a loss in battery capacity, shortened battery life and corrosion to the battery tray and to the machine.
Batteries Battery Inspection ( Lead Acid batteries) Download 552AC Lead Acid Inspection Report In addition to inspecting the batteries electrolyte level and exterior condition, two additional measurements are required. These are a battery Open Circuit Voltage (O.C.V.) test and the Specific Gravity (S.G) test.
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Batteries Daily: • Record the battery charging activity, cycles and service activities. Weekly: • Record the Open Circuit Voltage (O.C.V.) for each cell in the entire battery. • Use the Lead Acid Battery Inspection Report • Record the results from the specific gravity test on five cells from each battery. Different cells should be tested each week so that over the course of a month, all cells in both trays have been tested.
The main cause of a automatic shut-down on the Model 552AC 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.
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Status Codes The Sevcon Gen4™ AC controllers used on the Model 552AC provide advanced onboard 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.
• If possible, raise the machine onto blocks thereby taking the weight off the tires • Please reference the documentation for the specific battery installed in your Zamboni Machine for long term storage and maintenance instructions...
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Zamboni Quebec Robert Boileau Inc. ZAMBONI and the configuration of the Zamboni ice resurfacer ® 4255 Rue Hickmore Saint-Laurent, Québec H4T 1S5 Canada 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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