DELTA-Q RETRO INSTALLATION Instructions

1301 39th Street NW, Suite 2 * Fargo, ND 58102 * Toll Free 866.764.0616 * Fax 701.446.0103 * www.gemcar.com
Service Instructions
DELTA-Q CHARGER RETROFIT INSTALLATION
Models: All pre-2005 72V E825 Models
Part Number: 0606-00723 – Delta-Q Charger Only
* THIS KIT IS DESIGNED FOR THE REPLACEMENT AND UPGRADE OF THE CHARGER
UNIT IN ANY OLDER MODEL GEM VEHICLE EQUIPPED WITH A SCHOTT/SPS OR
ZIVAN CHARGER UNIT. (Refer to Page 6 for kit Part #.) PLEASE REVIEW ALL POSTED
INSTRUCTIONS AND RECOMMENDATIONS THOROUGHLY BEFORE ATTEMPTING
INSTALLATION.
WARNING! TO PREVENT PERSONAL INJURY OR PROPERTY DAMAGE BE SURE TO
TURN THE MASTER DISCONNECT SWITCH (MDS) TO THE ‘OFF’ POSITION BEFORE
ATTEMPTING ANY SERVICE TO THE VEHICLE.
*
BULLETINS 05A1012, 05A3002 & 06A1004 MUST BE PERFORMED BEFORE
INSTALLATION OF THIS KIT.
Parts List: Page 7
Tools List: Page 7
Diagram: Page 6
INSTRUCTIONS:
1. Remove the seat bench to gain access to
the
Master Disconnect Switch located
toward the passenger side above the
batteries. Turn the MDS to the ‘OFF’
position. (See Photo 1)
2. Remove the upper and lower dashes to
gain access to the charger unit. (See
Service Manual Part # 1010-00021,
Section 6 – Body.)
SCHOTT/SPS Conversion (pre-2002):
(If you are converting from a Zivan charger
unit, go to Step 5 below.)
Photo 1
3. Locate the charger unit. Disconnect all
electrical connections located on the
bottom of the charger unit and then
remove the charger from the vehicle.
(See Photo 2, next page)
1
4. Mount the provided aluminum mounting
plate to the vehicle’s ECM plate in the
existing location of the Schott/SPS
charger unit. (This will be used as a
mounting base for the Delta-Q charger
unit.) (See Photo 3) It may be necessary
to relocate the top mounting holes of the
aluminum plate lower when securing it to
the Main ECM plate. Otherwise, the
screws may be in the way of the new
aluminum mounting brackets. (Proceed
with installation following the below
instructions, Step 6.)
Photo 2
Connectors
ZIVAN Conversion:
5. Locate the charger unit. Disconnect all
electrical connections attached to the unit
and then remove the charger from the
vehicle.
The existing orange-colored
power harness attached at the top of the
charger along with the DIN plug type
connector with Temperature Sensor and
Charge Indicator Light can be removed at
this time as well. (See Photo 4)
6. Mount the upper square tubing mount
bracket to the ECM plate in place of the
existing charger location so that the
tubing is 1/8” height higher than the 2” x
3” square tubing frame cross member and
flush mounted to the farthest right
possible toward the Main Contactor
where there is a bend in the ECM plate.
Secure using the provided 2 - 1 ¼” selftapping tek screws. (See Photo 5, next
page)
7. Mount the lower square tuning mount
bracket to the ECM plate in place of the
existing charger flush with the bottom
edge of the plate and to the right most
edge, parallel to the upper mount bracket,
matching the bend in the ECM plate just
as done previously in Step 6. Secure
using the provided 2 - ¾” self-tapping tek
screws. (See Photo 6, next page)
Photo 3
DIN Plug
Orange Power Harness
Photo 4
2
8. Mount the new Delta-Q charger unit
aligning it to the mounting brackets on
top and bottom. Secure the unit using the
provided 4 - ¾” self-tapping tek screws.
(See Photo 7)
Wire Termination
Begin electrical connections starting with the
Interlock Relay circuit.
9. If the charger you are replacing is a
Schott/SPS charger then you will need to
connect the Interlock Retrofit Harness
(Part # 0106-00482) to the Main ECM
Harness first. (See Photo 8, next page)
Mount bracket
Far right
edge
Photo 5
10. For vehicles w/Potted Board Converter
installed - Connect the existing red/green
wire from ECM harness OR red wire
from Interlock Retrofit Harness (Part #
0106-00482) to the yellow wire of the
interlock harness on the Delta-Q charger
unit. Connect the existing green wire to
the black wire of the interlock harness of
the charger unit. (See Photo 9, next page)
11. For vehicles w/Sure Power Converter
installed - Connect the existing red/green
wire from ECM harness OR red wire
from Interlock Retrofit Harness (Part #
0106-00482) to the yellow wire of the
interlock harness on the Delta-Q charger
unit. Connect the existing long green
wire (currently connected to 8-pin Molex
on bottom of Schott/SPS charger) from
the Timer Module Pin 6 to the black wire
w/male spade terminal of the interlock
harness on the Delta-Q charger unit. (See
Photo 10, next page) The Green wire on
harness Part # 0106-00482 is NOT used.
12. Route the 3-color LED charge indicator
light harness up the steering column to the
Instrument Panel and install in the same
location as the existing LED, or if the car
was not equipped with one before,
remove the center screw from the face
plate. The LED will mount here.
Photo 6
Align edges w/ bend
Photo 7
3
13. Next, connect the power harness from the
DC Voltage output side of the Delta-Q
charger. Connect the red wire to the Fuse
Stand-off (+72V). (See Photo 11, next
page)
14. Connect the black wire to B- (72V GND)
of the Motor Controller Unit. Also,
connect the one end with the 5/16” ring
terminal of the provided black 2-wire
temperature sensor harness to B- (72V
GND). Connect the white wire to the
other end of the provided black 2-wire
temperature sensor harness. (See Photo
12, next page)
Interlock Retro – Schott/SPS
Photo 8
* The black wires for the Temperature
Sensor harness will need to be cut and
terminated for this installation. Use the
provided 18 gauge black wires and
terminals included in this kit.
*
The green wire will NOT be used for
this application. Please disregard this
wire during the installation process. It
should already be capped with black
electrical tape or heat shrink tubing.
15. Route the black 2-wire temperature sensor
harness from Step 14 to the front battery
compartment under the hood. Route the
wires down below the charger unit, under
the firewall and back up to the battery
tray, Battery 6.
16. Attach the provided Temperature Sensor
to Battery Six Positive, B6+, battery post.
Tighten the securing nylok nut with a
9/16” socket wrench. (If attaching to a
Trojan battery with a 5/16” stud torque
to 95-105 inch/lbs. If you are attaching
to a GEL battery with a 3/8” stud
torque to 120-180 inch/lbs.) Then route
the temperature sensor harness to the
temperature sensor and attach the 2 black
wires. (See Photo 13, next page)
Interlock Retro - Zivan
Photo 9
Interlock Retro – Delta-Q
Photo 10
Green wire NOT used in this application
4
17. Connect the AC power cord from the new
charger unit to the existing charger cord.
(See Photo 14, next page) (If you are
installing this kit on any pre-2003 model
GEM, the AC power cords may be too
short to complete the connection and a
short AC jumper cord, provided in kit,
may need to be installed.
18. Installation complete.
ALGORITHM SELECTION
See also Product Manual included in charger
kit – Charge Algorithm Selection and
attached documents along with Flow Chart.
19. Install upper and lower dashes.
Service Manual, Section 7 - Body)
72V + Fuse Stand-off
Photo 11
72V GND Controller B-
(See
20. Turn MDS to the ‘ON’ position and
verify vehicle and charger operation.
(See Product Manual included in this kit –
Operating Instructions.)
Charge the
vehicle.
21. Done.
Temp Sensor
Harness
Photo 12
White Wire
Black wire
Photo 13
Temp Sensor
5
Photo 14
6
TOOLS LIST:
-
Cordless or Electric drill
3/8” driver and/or wrench, ratchet wrench and socket
½” wrench and/or ratchet wrench and socket
13mm wrench
9/16” wrench or ratchet and socket
Phillips driver or screw driver
T27 Torx driver
Wire Stripper
Wire Crimp Tool
7/16” wrench and/or ratchet wrench and socket
PARTS LIST:
QTY.
DESCRIPTION
PART NO.
Zivan Conversion Kit: (Part # 1206-00026)
1 – CHARGER, 72 VOLT – DELTA-Q (PRE-2005) 10/05
1 -- SENSOR, BATTERY TEMP - DELTA-Q CHARGER
2 – BRACKET, DELTA-Q – MOUNT, ALUMINUM 1”X1”X1/8” TUBING
2 – TERMINAL, FEMALE SPADE ‘FAST-ON’ ¼” 22-18 GA.
3 – TERMINAL, MALE SPADE ‘FAST-ON’ ¼” 22-18 GA.
1 – TERMINAL, RING 5/16” 14-16 GA.
2 – SCREW, HEX ¼” x 1 ½” TEK SELF-TAPPING
6 – SCREW, HEX ¼” x ¾” TEK SELF-TAPPING
2 – WIRE, BLACK – INSULATED ELECTRICAL 18 GA. – 3 FEET
3 – TIE, CABLE – BLACK 9”
1 – CORD, CHARGER – DELTA-Q RETROFIT EXTENSION 24”
0606-00623
0606-00681
0351-02024
0606-00403
0606-00117
0606-00406
0523-00122
0523-00032
0406-00134
0510-00137
0306-02031
Schott Conversion Kit: (Part # 1206-00027)
* Includes ALL parts listed above, plus…
1 – HARNESS, ZIVAN CHARGER (For Schott upgrade only)
1 – PLATE, ZIVAN MOUNT (For Schott upgrade only)
0106-00482
0306-00799
7