IceCar B220 Operating instructions

ICECAT B220 ICE RESURFACER
USER’S AND MAINTENANCE MANUAL

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CONTENTS
1. USER’S MANUAL.........................................................................................4
1.1. General .......................................................................................................................... 4
1.2. Safety Instructions ....................................................................................................... 4
1.3. Dimensions and Values............................................................................................... 5
1.4. Main Parts ..................................................................................................................... 6
1.4.1. Controls ................................................................................................................ 7
1.4.2. Driving Controls .................................................................................................. 8
1.4.3. Meters ................................................................................................................... 9
1.4.3.1. The operating hour meter............................................................................... 9
1.4.3.2. The battery monitor ........................................................................................ 9
1.4.3.3. The shaving depth display ........................................................................... 10
1.4.3.4. The ELCAT display........................................................................................ 10
1.4.3.5. Oil window ..................................................................................................... 11
1.4.3.6. The dirt indicator ........................................................................................... 11
1.4.4. Control Panel ..................................................................................................... 12
1.4.5. Water System..................................................................................................... 15
1.4.5.1. Filling of the Water Tanks ............................................................................ 16
1.4.5.2. Automatic water tank filling (optional)........................................................ 17
1.4.5.3. Wash Water Lever ......................................................................................... 19
1.4.5.4. Speed related ice making water................................................................... 19
1.4.6. Electrical System............................................................................................... 20
1.4.7. Seat ..................................................................................................................... 21
1.5. Use of the Machine..................................................................................................... 21
1.5.1. Recharging the Batteries .................................................................................. 21
1.5.2. Starting of the Machine..................................................................................... 22
1.5.3. Movement........................................................................................................... 23
1.5.4. Movement in Reverse........................................................................................ 23
1.5.5. Ice Maintenance................................................................................................. 23
1.5.5.1. Calibration of the Shaving Depth Display .................................................. 23
1.5.5.2. Side Brush ..................................................................................................... 23
1.5.5.3. Washing Water .............................................................................................. 24
1.5.5.4. Sled................................................................................................................. 24
1.5.5.5. Auger .............................................................................................................. 24
1.5.5.6. Water Spreading Towel ................................................................................ 24
1.5.5.7. Ice Making Water ........................................................................................... 24
1.5.5.8. Emptying of the Snow Tank ......................................................................... 25

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1.5.6. Storage ............................................................................................................... 25
1.5.7. Towing ................................................................................................................ 25
2. MAINTENANCE ..........................................................................................29
2.1. Blade............................................................................................................................ 29
2.2. Hydraulics ................................................................................................................... 30
2.2.1. Oils ...................................................................................................................... 30
2.2.2. Filters .................................................................................................................. 31
2.2.3. Hoses .................................................................................................................. 31
2.2.4. Valves ................................................................................................................. 31
2.2.5. Pumps................................................................................................................. 31
2.2.6. Hub Motors......................................................................................................... 32
2.2.7. Cylinders ............................................................................................................ 32
2.3. Mechanics ................................................................................................................... 32
2.3.1. Bearings ............................................................................................................. 32
2.3.2. Screws and Nuts................................................................................................ 32
2.3.3. Belts and Chain ................................................................................................. 32
2.3.4. Gas Springs ....................................................................................................... 33
2.4. Water System.............................................................................................................. 33
2.5. Electrical System........................................................................................................ 33
2.5.1. Fuses .................................................................................................................. 33
2.5.2. Motor................................................................................................................... 35
2.5.3. Batteries ............................................................................................................. 35
2.5.4. Lights .................................................................................................................. 35
2.5.5. Painted Parts of the Body................................................................................. 35
2.5.6. Stainless Steel Parts ......................................................................................... 35
2.5.7. Plastic Parts ....................................................................................................... 35
2.5.8. Aluminium Parts ................................................................................................ 36
2.6. Removal from Use...................................................................................................... 36

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1. USER’S MANUAL
Congratulations on your purchase of an Icecat ice resurfacer! We hope you enjoy
the product. To ensure long and safe operation, please familiarise yourself with
the use and maintenance of the product by reading this usage and maintenance
manual. Please keep the manual in the operator’s cabin for future reference.
1.1. General
Proper use of the ICECAT B220 requires general knowledge about the use and
functions of the machine. Icecat Jäänhoitokoneet Oy provides basic ICECAT
B220 training for operators.
This manual introduces the structure, use and maintenance of the machine. It is
assumed that the reader is familiar with the basics of ice maintenance and ice
resurfacers.
Read this manual carefully before using the ice resurfacer.
1.2. Safety Instructions
- Familiarise yourself carefully with the controls and monitoring equipment
of the machine.
- Before using the machine, ensure that all of its meters, alarm LEDs and
controls are working normally.
- Do not hesitate to use the emergency stop control to avoid an accident or
damage to the machine.
- Pay special attention and be very careful when using the ice resurfacer
since, as the operator, you have the primary responsibility for the
machine’s effective and safe operation.

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- Even though the ice resurfacer is designed to be as easy to use and safe
as possible, just one mistake by the operator or neglecting a single safety
issue can cause an accident or damage the machine.
- Before using the machine, ensure that all protective covers are in place.
- When the machine is in use, only authorised ice maintenance personnel
may remain on the ice.
- Be very careful when handling the shaving blade.
- Drive carefully.
- If you need to tow the ice resurfacer, see the section 1.5.7. Towing.
1.3. Dimensions and Values
Length: 3,950 mm / 156 in.
Width: 2,350 mm / 93 in.
Height: 2,100 mm / 83 in.
Working width: 2,200 mm / 87 in.
Axle width: 1,950 mm / 77 in.
Wheel track: 1,600 mm / 63 in.
Turning radius: 3,800 mm / 150 in.
Length with snow tank up: 4,600 mm / 181 in.
Height with snow tank up: 3,500 mm / 138 in.
Floor height of the operator’s compartment: 1,185 mm / 47 in.

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Operator’s seat, height from floor: 1,600 mm / 63 in.
Weight, empty: 3,500 kg / 7,720 pounds
Weight, water tanks full: 5,000 kg / 11,023 pounds
Weight of batteries: 1,500 kg / 3,310 pounds
Tires: 225/70 R 15C, 112/110W
Tire pressure: 65 psi
Volume of snow tank: 3 m3/ 106 cu. feet
Volume, cooling water tank: 700 L / 185 USG
Volume, wash water tank: 700 L / 185 USG
Volume, hydraulic oil tank: 60 L / 16 USG
1.4. Main Parts
The ice resurfacer consists of three main parts. The front frame contains the
snow tank, batteries, and the hydraulic unit. The back frame contains the auger,
the wash water tank, and the operator’s compartment and is jointed to the front
frame. The joint enables driving on uneven surfaces – e.g., when emptying the
snow tank outside. The sled, which is the part that takes care of most of the ice
maintenance, is attached to the back frame. The sled contains the shaving blade,
which must be handled with extreme caution.
Figure 1. ICECAT B220 ice resurfacer

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1.4.1. Controls
The controls are located close to the operator so that the operator can use them
very easily during ice maintenance.
Figure 2. Operator’s compartment

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1.4.2. Driving Controls
The operator steers the ice resurfacer with a steering wheel, which turns the front
wheels of the machine to the desired direction. The operator can select the
direction of the machine (forward or backward) with the direction selector. Speed
is controlled by a foot pedal. The operator can apply the brakes by reducing
pressure on the pedal or by removing his foot from it, in which case the hydraulic
system applies the brakes automatically.
Figure 3. Pedal

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1.4.3. Meters
1.4.3.1. The operating hour meter
The operating hour meter shows total machine operating time in hours. The
meter starts running every time the electrical system is turned on by turning the
ignition key.
1.4.3.2. The battery monitor
The battery monitor displays the five most important electrical system values.
Use the < and > buttons to select the desired value:
V Battery voltage
A Current in the electrical system
Ah Amount of charge used from the batteries
% Level of charge in the batteries
h Remaining operating time
Figure 4. Battery monitor
For more information, please contact Icecat Jäänhoitokoneet Oy.

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1.4.3.3. The shaving depth display
The shaving depth display shows the blade’s cutting depth in millimetres. The
measurement accuracy is 1/10 mm. The meter displays a correct value only
when properly calibrated. To calibrate the meter, follow the instructions in the
section 1.5.5.1. Calibration of the Shaving Depth Display.
Figure 5. Shaving depth display and its reset button
1.4.3.4. The ELCAT display
The ELCAT display shows the status of the electrical system to the operator. The
monitor contains the tachometer for the electric motor, the battery thermometer
(BATT TEMP) and warning and notification LEDs. All LEDs are lit when power is
switched on by turning the ignition key. During starting, the yellow LED of the
ECONOMY display is turned off and a green LED is lit. The warning LEDs
indicate the following: overheating of the motor (MOTOR TEMP), abrasion of the
motor brushes (MOTOR BRUSH) and need to charge the 12-volt battery (12 V
CHG).

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Figure 6. ELCAT display
1.4.3.5. Oil window
There is a window on the side of the hydraulic oil tank for checking the level of oil
in the tank. The oil level must be visible through the window when the machine is
on an even surface. The system contains a total of 60 litres of hydraulic oil.
1.4.3.6. The dirt indicator
The dirt indicator shows how dirty the return oil filter is. Once the indicator
reaches the red area, the filter must be replaced immediately.

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Figure 7. Oil window and the return oil filter’s dirt indicator
1.4.4. Control Panel
The buttons for starting the various functions of the machine are located close to
the operator on the control panel. Check the positions of the buttons before
starting the machine, to avoid unexpected functions.
For emergencies, there is an EMERGENCY STOP button near the operator. Do
not hesitate to use this button. The emergency stop button stops the ice
resurfacer immediately.

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Figure 8. Control panel
1. The ignition key switch has three positions: the main current of the machine
is off when the key is vertical and is switched on when the key is turned to
the right (clockwise). The start-up position of the switch is to the extreme
right.
2. The operator controls the rotational speed of the motor with this knob. The
motor must rotate at maximum speed during operation to produce the
necessary power. During starting, the knob must be turned to the OFF
position.
3. BLADE: use this button to raise or lower the shaving blade. When the button
is in the middle position, the blade does not move. The shaving depth
display shows the shaving depth in use.
4. INTAKE PUMP: The wash water intake pump is used for passing wash
water from the wash compartment of the sled back to the wash water tank.
The pump contains Neopren pump blades and must not be operated when

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dry. Always ensure that the pump is not on when you start the machine. A
red LED indicates that the pump is on.
5. SNOW TANK LIGHT: Light for snow tank
6. CRAWLER GEAR: The crawler gear makes it easier to drive on steep
upslopes.
7. SNOW TANK: open the snow tank cover, and tip up the tank by pressing this
button upwards.
8. PARK BRAKE: use this button to switch on the parking brake. For safety
reasons, brakes are applied when the rotational speed of the motor is less
than 1,000 rpm even if the parking brake is not on.
9. SEAT HEATER: heater for the operator’s seat.
10. LIGHTS: turn on the lights to improve visibility and safety when there may be
other people in the area in which you are using the machine.
11. TIRE WASHER: this button switches on the tire washer.
12. HORN.
13. AUGER: To start the auger, press the button down. To remove snow and ice
that has lodged in the auger apparatus, press the button up.
14. SLED: press this button to raise and lower the sled.
15. TOWEL: press this button to raise and lower the towel that spreads water.
16. BREAKER: this switches on the breaker of the auger to stop blockage of the
auger.
17. SIDE BRUSH: to move the brush to working position and to start rotating the
brush, press the button down. To raise the brush from the ice, press the
button up.
18. WATER: this switches on the ice making water pump and opens the water
valve on the sled to allow ice making water to flow to the ice.
19. This knob regulates the amount of water produced by the water pump from
MIN to MAX. When it is in MIN position, the pump operates very slowly.

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20. Shaving depth display reset button (see 1.5.5.1. Calibration of the Shaving
Depth Display).
21. Direction selector: use this button for selecting the driving direction desired –
i.e., forward or backward. The button must remain in the central (neutral)
position when power is on but you do not intend to move the machine.
Whenever backing up, you should hear the back-up signal.
Figure 9. Direction selector and shaving depth display reset button
1.4.5. Water System
The water system of the ice resurfacer contains four parts. Filling pipes are used
for filling the water tanks. An immersion pump pumps ice making water from the
lower water tank to the water spreading towel on the sled. Wash water flows by
its own pressure from the wash water tank to the wash compartment of the sled.
The intake water system uses suction and filters to move the water back to the
wash water tank from the wash compartment.

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1.4.5.1. Filling of the Water Tanks
There is a fire hydrant connector and a main water valve under the operator’s
seat for filling the water tanks. The operator’s footwell contains a three-position
filling valve lever for filling both the wash and ice making water tanks. During
operation, the operator can use this lever for adding water from the wash tank to
the ice making water tank.
The water must be less than 80 °C (176 °F). Hotter water makes the hoses soft,
which can inhibit water flow.
To fill the ice making lower water tank, turn the filling valve lever left from the
driving direction. To fill the wash water tank, turn the lever so that it faces
backward. To transfer water flow under its own pressure from the wash water
tank to the ice making water tank, turn the lever right. Remember that once the
ice making water tank is full, the overflow tube releases water under the
machine.
Figure 10. Filling valve lever

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To fill the water tanks, do the following:
1. Attach a hose from the pipeline network that has a suitable connector to
the fire hydrant connector of the machine.
2. Open the main water valve of the machine.
3. Select which water tank to fill by turning the filling valve lever.
4. Open the pipeline network tap.
5. Close the tap once water flows from the overflow tube or when the tank
contains the desired amount of water.
6. Fill the other tank as above (steps 3 to 5).
7. Close the main water valve.
8. Detach the filling hose from the fire hydrant connector of the machine.
Figure 11. Fire hydrant connector and main water valve
1.4.5.2. Automatic water tank filling (optional)
For automatic water tank filling, both water tanks of the ice resurfacer contain
surface switches. The filling valve lever has two limits, which recognises the
position of the lever. There is a plug above the main water valve and the fire
hydrant connector for connecting a conduit from the magnetic valve of the
pipeline network.

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To fill the cooling water tank, turn the filling valve lever left from the driving
direction. To fill the wash water tank, turn the valve backwards. To transfer water
from the wash water tank to the ice making water tank, turn the lever right.
To use automatic water tank filling, do the following:
1. Attach a hose from the pipeline network that has a suitable connector to
the fire hydrant connector of the machine.
2. Open the main water valve of the ice resurfacer.
3. Select which water tank to fill by turning the filling valve lever.
4. Attach the conduit from the pipeline network magnetic valve to the plug in
the ice resurfacer. The desired water tank is filled.
5. The surface switch of the water tank automatically closes the magnetic
valve of the pipeline network once the water tank is full.
6. Fill the other tank as above (steps 3 to 5).
7. Remove the conduit of the pipeline network’s magnetic valve from the
plug.
8. Close the main water valve.
9. Detach the filling hose from the fire hydrant connector of the machine.
Figure 12. Fire hydrant connector, main water valve and plug for automatic
water tank filling

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1.4.5.3. Wash Water Lever
The amount of wash water is controlled by the wash water lever, situated on the
right side of the control panel. To open the wash water valve, push the lever
forward. Water then flows to the wash compartment of the sled. Switch on the
intake pump required for washing the ice by pressing the control panel’s INTAKE
PUMP button.
Figure 13. Wash water lever
1.4.5.4. Speed related ice making water
Speed related ice making water is an extra option. You can toggle the speed
related ice making water with a switch on the control panel (see figure 14.)

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Figure 14. Speed related ice making water
1.4.6. Electrical System
The electrical system consists of the following parts:
- charger, which charges and maintains the batteries
- black box, which controls the main motor and monitors the batteries
- 12-V battery, which maintains the black box and the control panel
- batteries for powering the electric motor
- 24-V hydraulic control unit, which controls the hydraulic pump
- control panel for controlling the machine