Shockwave ICE, Operation & Service Manual

Page 1: ...rations Service Manual with Illustrated Parts Breakdown SW 07441 REV01 SHOCKWAVE MARINE SUSPENSION SEATING 2074 Henry Avenue Sidney BC Canada V8L 5Y1 Tel 1 250 656 6165 Fax 1 250 655 4334 SHOCKWAVESEATS COM ...

Page 2: ...roubleshooting Autotune Overview Autotune 1 Troubleshooting Electrical Diagram Autotune 1 Troubleshooting Flow Diagram Troubleshooting Autotune Troubleshooting Finding an Air Leak Troubleshooting Fixing an Air Leak Troubleshooting Solenoid Orientation Check Shock Configuration Warranty Warranty Claim Form Warranty Claim Procedure Service and Repair Procedure 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 3: ... can be requested by contacting support shockwaveseats com Tell us what the concern is Be sure to answer all the Who What When Where and Whys of the situation so we have a clear understanding and can provide the best advice Please identify the SHOCKWAVE product by supplying the serial number which is typically located inside the front hatch on the helm side Tell us who you are and what your relati...

Page 4: ...roughout the Operations and Service Manual to prolong the appearance and service life of your SHOCKWAVE ICE Console WARNING Do not modify the equipment by drilling extra holes removing material or adding extra equipment Serious injury can result Do not use the ICE if it is or appears to be damaged Serious injury can result Do not use seating if the seat to ICE attach ments are loose Serious injury...

Page 5: ...as not specifically designed for the curved deck by SHOCKWAVE Do not mount the ICE in the middle of an unsupported deck plate Ensure that the movement of the ICE does not interfere with the vessel structure or equipment Check operation of the ICE after installation by filling and draining the system It must not bind or stick Do not attach any equipment to the ICE without first consulting SHOCKWAVE...

Page 6: ...M8 M10 M12 5 16 5 8 3 8 3 4 7 16 1 10 1 4 1 2 32 0 8 32 1 0 1 25 1 5 1 75 18 11 16 10 14 8 24 20 13 32 28 20 10 in lbs 45 in lbs 21 in lbs 6 ft lbs 15 ft lbs 31 ft lbs 54 ft lbs 11 ft lbs 96 ft lbs 20 ft lbs 131 ft lbs 32 ft lbs 299 ft lbs 23 in lbs 6 ft lbs 45 ft lbs 33 in lbs 8 ft lbs 47 ft lbs 9 in lbs 40 in lbs 17 in lbs 6 ft lbs 14 ft lbs 27 ft lbs 48 ft lbs 9 ft lbs 82 ft lbs 17 ft lbs 111 f...

Page 7: ...s provided as a general checklist Do not operate the ICE if The shock ride height is incorrect Any components are loose broken or missing The ICE makes a strange noise when being operated USE SEAT BELTS IF SUPPLIED Seat belts prevent occupants from being ejected from the vessel and the seat When not in use the seat belt buckle clasp should be fastened to prevent damage to the ICE SET FORE AND AFT ...

Page 8: ...Set the ICE console to SET height by holding the switch in the SET position This generally takes 5 10 seconds STEP 1 Ensure the ICE console is set up with its full occupants and gear weight STEP 2 Lift the ON OFF toggle switch to the up position The FILL light should be blinking STEP 3 Lift the FILL toggle switch to the up position and wait until the FILL light has stopped blinking STEP 4 When the...

Page 9: ... might have been placed under the ICE Before sitting in the ICE raise the zip tie travel indicators up on the exposed shock until they rest against the upper shock body Setup the ICE as per instructions on page 8 Once the console is SET check to see if there is a gap between the shock body and the zip tie If a gap exists there is a potential for an air leak in the system which has caused the ICE t...

Page 10: ...ricate Link Ends LPS 3 triple guard grease or equivalent EVERY 40 HOURS AFTER SEATS HAVE DRIED FROM CLEAN Protect Metal Surfaces and Fasteners LPS 1 or equivalent EVERY 125 HOURS Check Fastener Torques EVERY 200 HOURS Use Soapy water to check for air leaks AS REQUIRED REMOVING ANY BUILDUP OF DIRT OR SALT Clean Upholstery Boat or Automotive Detail Spray Cleaner AFTER EVERY EXPOSURE TO SALTWATER SPR...

Page 11: ...m and lubricate bearing area with heavy duty marine grease Follow Finding an air leak on the subsequent pages Remove excess weight from the console Clunking Noise During Operation Loose bolts or cracked components Check bolt torques and inspect for loose cracked or bent parts Start by checking the upper shock bolts and work your way down to the deck checking all fasteners and brackets CONDITION CA...

Page 12: ...set port is used to automatically drain a certain amount of air from the shock to provide the correct ride height The compressor tank and water separator are typically located in the rear lower section of the ICE The fill and set solenoid valves are typically located just inside the body of the ICE near the shock mounts Each shock has its own FILL and SET solenoid valve The main fill solenoid valv...

Page 13: ...80 12V 4MM Panel Mount LED Red 6 1 SW 04982 SPDT Harsh Environment Toggle Switch 7 1 SW 04985 Seadog 30A Push Button Switch 8 1 SW 05071 VIAIR 480C Air Compressor 9 2 SW 05098 Resistor 680 Ohm 1 Watt 10 1 NOT SUPPLIED 4 Position ATD ATC Fuse Block 11 2 NOT SUPPLIED 4 Position Common Bus Bar 12 1 NOT SUPPLIED 8 Position Terminal Block No Common 13 1 NOT SUPPLIED ATD ATC Fuse 5A 14 1 NOT SUPPLIED AT...

Page 14: ...INISH TOGGLE PUSH SWITCH TO DRAIN START DOES ICE CONSOLE LIFT UNTIL AT FULL HEIGHT TOGGLE SWITCH TO SET DOES ICE DROP TO SAG HEIGHT TOGGLE SWITCH TO FILL CHECK CONNECTIONS AND 12VDC AT SWITCH 2 PROBLEM FIXED CONFIRM OPERATION OF SOLENOIDS 5 8 AND CONNECTIONS TO GROUND DOES ICE CONSOLE LOWER TO THE GROUND CONFIRM OPERATION OF SOLENOID 9 AND CONNECTIONS TO GROUND CHECK CONNECTIONS AND 12VDC AT SWITC...

Page 15: ...ystem cannot reach maximum operating pressure MIN 190 PSI System has not detected signifi cant air flow during SET process Console was not able to get above the SET point Status light shave burnt out Dimmer switch turned down Check Autotune fuse Ensure wiring is not damaged pinched or corroded Check for air leaks around the tank compressor and shocks Re calibrate the system Reduce weight in the IC...

Page 16: ... possible Do not allow anyone to enter or add gear to the ICE during this time STEP 4 Measure all the shocks on the ICE and record the extended length as well as the tank pressure Tank pressure has dropped but shocks are still measuring the same extended length Tank is still at max pressure but extended length of one or more shocks has dropped Potential air leak between compressor and FILL solenoi...

Page 17: ... onto the adapter c Using a wrench rotate the fitting to tighten by turning the fitting the 1 1 2 to 1 3 4 hex flat rotations STEP 8 If the leak continues replace the fittings or hoses and repeat steps 6 8 WARNING When removing combined fittings always hold both fittings so you only loosen the required fitting I e Removing Fitting 2 from 1 hold Fitting 1 with a wrench and loosen fitting 2 See draw...

Page 18: ...rn off the compressor this might require the vessel power to be turned off depending on how the system is powered STEP 4 Pull the pressure relief valve on the tank Extended shock length has been reduced Potential incorrect orientation of the FILL or SET solenoids Install solenoid in the correct orientation see AUTOTUNE Installation Instructions at the back of this manual CONDITION CAUSE REMEDY TRO...

Page 19: ...NOID HIGH PRESSURE JIC FLARE HOSE MEGAFLOAT SHOCK HIGH PRESSURE JIC FLARE HOSE SHOCK CONFIGURATION SET SOLENOID TYPICALLY LOCATED INSIDE CONSOLE NEAR THE SHOCK FILL SOLENOID TYPICALLY LOCATED INSIDE CONSOLE NEAR THE SHOCK LOW PRESSURE PUSH TO CONNECT HOSE PRESSURE RELIEF VALVE AIR WATER SEPERATOR AIR COMPRESSOR MAIN DRAIN SOLENOID LOW PRESSURE PUSH TO CONNECT HOSES TANK GAUGE TANK MAIN FILL SOLENO...

Page 20: ...he manual provided There is damage to the ICE caused during installation or unpacking There is damage to the cushions and covers caused by cuts burns or abuse The above expressed warranties shall be the exclusive warranties and SHOCKWAVE seats makes no other warranties expressed or implied SHOCKWAVE seats expressly disclaims any implied warranties or merchantability and implied warranties of fitne...

Page 21: ...Name Fax Number Email Serial Number Boat or Project Identification Type of Seat Date Vessel in Service Number of Seats Affected Nature of Problem Comments Date Invoice Number Ship to Address City Province State Postal Zip Code Country Mailing Address City Province State Postal Zip Code Country ADDRESS PHONE FAX EMAIL HOURS WEBSITE 2074 Henry Avenue Sidney BC Canada V8L 5Y1 1 778 426 8544 1 250 655...

Page 22: ...l case number is used to create a service technician request if deemed necessary by TSE C Defective parts are to be returned unless waived by the TSE 4 The Technical Case is used to create a warranty Sales Order SO A A warranty Work Order WO is created which creates demand for the product B If product is in stock it will ship within 24 hours of dispatch from technical support C Notification of shi...

Page 23: ...d are subject to change C Sales order confirmations will be provided upon customer approval of the assessment Sales orders may be changed upon completion of the work if previously unknown issues are discovered that require repair or part replacement D Customer will be provided with updates on progress 5 Should the customer require repairs anywhere in the world a quotation including logistical cost...