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
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