56383869 onboard charger kit

56383869 ONBOARD CHARGER KIT
SC750, SC800 Models: ALL US MODELS
CONTENTS OF KIT
ITEM
[]
1
2
3
4
5
6
7
8
9
10
[11]
12
13
14
15
16
17
REF. NO.
56090231
56003426
56003638
56383502
56383503
56383504
56383586
56383587
56383856
56383857
56383866
56478523
9095149000
56009096
964004
56003431
980657
87026A
QTY
1
4
4
1
1
1
1
1
1
1
1
8
1
2
2
4
4
4
DESCRIPTION
Instruction Sheet
Nut, Hex Nyl Loc SS M6-1
Wsh, Flt SS 6mm
Bracket-LED
Decal-Charger LED
Plate-Mounting
Adapter-Charger DeltaQ Power
Adapter-Interlock Pin 1
Charger-Onboard 24VDC 650W
Indicator-Charge LED W/Temp
Cord-AC Nema IEC320 – DeltaQ
Tie-Cable
Battery Cable Support
Wsh Flt .193X.875X.060
Screw M5X16 PN ST PH
Scr Hex SS M6-1.00X16MM
Washer, Lock 1/4
Washer, 1/4 Flat S.S.
[ ] = Not Shown
The purpose of this kit is to either replace an existing SPE Onboard Battery
Charger with the new Delta-Q Battery Charger or perform a fresh install of
the new Delta-Q Battery Charger.
3
Tools needed:
•
•
•
•
•
•
•
10mm socket with extension for most nuts/bolts
½” socket for battery nuts
T30 Torx-driver for IC650 DC terminals
T10 Torx-driver for IC650 cable clamp and cover
PH2 Phillips screwdriver for cord bracket
Small flathead for prying off control panel and IC650 cover
Diagonal cutter for trimming cable ties
4
12
13
14
17
5
16
15
FRONT
8
10
2
9
7
1
6
© 2014 Nilfisk-Advance, Inc.
(page 1 of 19)
4/14 Form No. 56090231 REV A
INSTALLATION INSTRUCTIONS
WARNING!
REMOVE THE BATTERIES AND SQUEEGEE AND DRAIN BOTH TANKS BEFORE STARTING THIS PROCEDURE.
PRE-INSTALL INSPECTION
1 Lay a blanket down to protect the side of the machine and then carefully tip the machine over onto its right side. Observe the underside of the
chassis. If your machine previously had an SPE onboard charger you will require Mounting Plate (5). If your machine did not previously have an
SPE onboard charger you need to inspect the mounting bolt hole pattern(s) on the underside of the chassis to see if your machine has the Delta-Q
mounting hole pattern shown below. If your machine has these mounting holes, you DO NOT need Mounting Plate (5) and can skip Steps 2-3.
If your machine does not have these mounting holes, you DO need Mounting Plate (5) and should proceed to Step 2. NOTE: You can confirm
this by holding the Delta-Q Charger (8) against the underside of the chassis with the wiring connections facing UP to see whether or not all four
mounting holes on the charger line up with four of the holes in the chassis.
Delta-Q mounting holes
© 2014 Nilfisk-Advance, Inc.
(page 2 of 19)
4/14 Form No. 56090231 REV A
PREPARE DELTA-Q BATTERY CHARGER
2 See Figure 1. Position the Charger (8) on the Mounting Plate (5). Make sure the Charger does not block the Screw Slots (A) on the plate.
3 Attach with Nuts and Washers (1 & 2). NOTE: Mounting Plate (5) is only used on machines that do not have the same mounting bolt pattern as
the Delta-Q charger as determined by the “PRE-INSTALL INSPECTION” on the previous page.
FIGURE 1
1
2
8
5
A
4
See Figure 2. Remove DC Connection Cover (B). Lock tabs (one on each side of cover) must be pressed in with a small tool to prevent damage
to cover.
FIGURE 2
B
© 2014 Nilfisk-Advance, Inc.
(page 3 of 19)
4/14 Form No. 56090231 REV A
PREPARE DELTA-Q BATTERY CHARGER
5
6
7
8
See Figure 3. Attach Adapters (6 & 7) as shown. NOTE: Wire from Adapter (7) in the middle. Red wire from Adapter (6) on the right. Black
wire from Adapter (6) on the left.
Install Cable Clamp (C) upside down as shown using the two longer screws.
See Figure 4. Reinstall DC Connection Cover (B). NOTE: If a third screw was provided with clamp (C), secure cover with it.
BEFORE INSTALLING CHARGER ON MACHINE YOU MUST SET THE CHARGE PROFILE: REFER TO THE Delta-Q IC650 PRODUCT
MANUAL FOR INSTRUCTIONS REGARDING SETTING THE CORRECT CHARGE PROFILE. REFER TO THE LAST PAGE OF THIS
INSTRUCTION SHEET FOR CHARGE PROFILES.
FIGURE 3
6
7
6
C
FIGURE 4
B
© 2014 Nilfisk-Advance, Inc.
(page 4 of 19)
4/14 Form No. 56090231 REV A
PREPARE LED BRACKET
9
See Figure 5. Attach LED Decal (4) to LED Bracket (3). NOTE: Line up the LED window (D) in the decal with the hole in the bracket.
FIGURE 5
4
D
3
REMOVE SPE ONBOARD CHARGER (IF APPLICABLE)
10
See Figure 6. Disconnect and remove the original onboard charger (E). NOTE: It is only necessary to remove the top two bolts. The bottom
two bolts (F) only need to be loosened.
FIGURE 6
F
E
© 2014 Nilfisk-Advance, Inc.
(page 5 of 19)
4/14 Form No. 56090231 REV A
INSTALL DELTA-Q BATTERY CHARGER
11
See Figure 7. Install the Delta-Q Charger (8) as shown. NOTE: If your machine previously had an SPE onboard charger you can reuse the four
mounting bolts and washers. If your machine did not previously have an SPE onboard charger you will need to use hardware items (15-17).
FIGURE 7
8
ROUTE AC POWER CORD
12
See Figure 8. Route the AC Cord (10) through the chassis as shown (back to front).
FIGURE 8
10
© 2014 Nilfisk-Advance, Inc.
(page 6 of 19)
4/14 Form No. 56090231 REV A
ROUTE CHARGE INDICATOR HARNESS
13
See Figure 9. Route the Charge Indicator Harness (9) through the chassis as shown (front to back).
FIGURE 9
(9) Remote LED
(9) Battery
Temp Sensor
ROUTE CABLES (CONTINUED)
14
15
See Figure 10. Pull AC Cord (10) through (back to front) enough to reach the plugin on the charger.
Pull the Charge Indicator Harness (9) through (front to back) enough so its plug just reaches the plugin on the charger. NOTE: Newer machines
will have a jumper cap installed on the 3 wire connector that needs to be removed.
FIGURE 10
10
9
3 wire connector
© 2014 Nilfisk-Advance, Inc.
(page 7 of 19)
4/14 Form No. 56090231 REV A
CONNECT CHARGER WIRING
16
17
See Figure 11. Connect AC Cord (10), Charge Indicator Harness (9) and DC Adapter Connections (6 & 7).
Tuck the DC Connectors away behind the AC Cord (10) and secure all wires as needed with Cable Ties (11).
FIGURE 11
10
6
7
9
ROUTE CABLES (CONTINUED)
18
See Figure 12. Carefully tip the machine back upright and gently pull the cables to the rear to remove any slack.
FIGURE 12
© 2014 Nilfisk-Advance, Inc.
(page 8 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
19
See Figure 13. Secure the cables to the existing harness using a Cable Tie (11).
FIGURE 13
11
20
See Figure 14. Remove cord bracket and set aside. NOTE: This step is only required for machines that previously had an SPE onboard
charger.
FIGURE 14
© 2014 Nilfisk-Advance, Inc.
(page 9 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
21
See Figure 15. Route LED wire behind vacuum tubes and other harnesses so that it comes out near the AC cord bracket.
FIGURE 15
22
See Figure 16. Remove the top part of the Bezel (H1) from the LED. Leave the Nut (I) on as shown.
FIGURE 16
I
© 2014 Nilfisk-Advance, Inc.
H1
(page 10 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
23
24
See Figure 17. Push the top part of the Bezel (H1) through the front of the LED Bracket (3).
Insert the LED (J) from the back through the Bezel (H1).
FIGURE 17
H1
J
25
3
See Figure 18. Thread the top part of the Bezel (H1) onto the bottom (H2), then thread the Nut (I) onto the top part of the Bezel (H1) and gently
tighten.
FIGURE 18
H1
I
H2
© 2014 Nilfisk-Advance, Inc.
(page 11 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
26
See Figure 19. Attach LED Bracket (3) and AC cord bracket with original screws. NOTE: Machines that did not previously have an onboard
charger will require the use of items (12, 13, 14).
FIGURE 19
12
13
14
3
27
See Figure 20. Gather and cable tie the excess LED cable behind the harness and vacuum tubes.
FIGURE 20
© 2014 Nilfisk-Advance, Inc.
(page 12 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
28
See Figure 21. Route the temp sensor forward into the battery compartment.
FIGURE 21
29
See Figure 22. Cable Tie the temp sensor to the negative battery cable.
FIGURE 22
© 2014 Nilfisk-Advance, Inc.
(page 13 of 19)
4/14 Form No. 56090231 REV A
ROUTE CABLES (CONTINUED)
30
See Figure 23. Gather and Cable Tie slack in the temp sensor cable to the negative battery cable as shown.
FIGURE 23
31
See Figure 24. Wrap AC Cord (10) as neatly as possible, passing in front of vacuum tubes to allow as much cord length as possible.
FIGURE 24
10
© 2014 Nilfisk-Advance, Inc.
(page 14 of 19)
4/14 Form No. 56090231 REV A
REWIRE KEY SWITCH (IF APPLICABLE)
32
See Figure 25. Remove the Control Panel (K) and observe the key switch wiring. NOTE: If your key switch is wired as shown on the right
(two brown wires on one terminal and one black wire on the other terminal), you do not need to perform any rewiring on the key switch and can
skip to step 36. Otherwise, if your machine previously had an SPE battery charger, proceed to step 33 and skip step 34. If your machine did not
previously have an SPE battery charger, skip step 33 and proceed to step 34.
FIGURE 25
K
33
See Figure 26. If the machine originally had an SPE battery charger, the key switch will be wired as shown. Remove the Yellow Wire (L) and
replace with the Brown Wire (M). Connect the Yellow Wire (L) to the now free Brown Wire (N).
FIGURE 26
L
© 2014 Nilfisk-Advance, Inc.
N
(page 15 of 19)
M
4/14 Form No. 56090231 REV A
REWIRE KEY SWITCH
34
See Figure 27. If the machine originally had no onboard charger, the key switch will be wired as shown. Remove the Yellow Wire (L) and replace
with White/Brown Wire (O). Connect the Yellow Wire (L) to the Brown Wire (N).
FIGURE 27
N
L
O
35
See Figure 28. Regardless of original key switch wiring, after rewiring your key switch should look like this.
FIGURE 28
© 2014 Nilfisk-Advance, Inc.
(page 16 of 19)
4/14 Form No. 56090231 REV A
REINSTALL CONTROL PANEL AND TEST
36
37
38
See Figure 29. Reinstall the Control Panel (K) and the batteries and reconnect the batteries.
Make sure the machine turns OFF when the key switch is OFF. Make sure the machine turns ON when the key switch is ON.
Plug in the battery charger and verify that the charge LED begins flashing green. Verify that the control panel is OFF and that the machine will
not propel while the battery charger is plugged in regardless of key switch position.
39 See Figure 30. If the charger doesn’t charge, verify battery connections. Big and small red wires on the positive battery stud (P). Big and small
black wires as well as the temp sensor on the negative battery stud (Q).
NOTE: IF YOUR MACHINE WAS ORIGINALLY EQUIPPED WITH AN SPE ONBOARD CHARGER, PROCEED TO THE NEXT PAGE FOR
INSTRUCTIONS TO DISABLE THE ONBOARD CHARGER.
FIGURE 29
K
FIGURE 30
P
Q
© 2014 Nilfisk-Advance, Inc.
(page 17 of 19)
4/14 Form No. 56090231 REV A
DISABLE ON-BOARD CHARGER IN MACHINE SOFTWARE
a) Enter the Hidden Menus on the machine control panel.
I.
Press and hold the Scrub On/Off and Vacuum buttons simultaneously.
II.
Turn the machine Key Switch ON, still pressing the 2 buttons.
III.
When the top line of the LCD reads “PROGRAM OPTIONS”, release the two buttons.
nd
IV.
Press the Solution Decrement button until the 2 line of LCD reads “5. CHARGER SELECTION”.
V.
Press the Solution On/Off button to enter the mode.
VI.
vi. Press the Solution Increase and/or Solution Decrease buttons as many times as necessary until it reads NONE.
rd
rd
VII.
vii. Press the Scrub On/Off button to lock in your selection. Success will be confirmed by the 3 line going away on the LCD (the 3 line
will now be blank).
b) Turn the Key Switch off to exit the Hidden Menus.
BATTERY CHARGER OPERATION
1
Plug the power cord for the battery charger into the appropriate style electrical outlet.
2
The Charge Status LED will begin flashing green. This indicates that the charging cycle has begun. As the charging cycle continues, the flashing
of the LED will become more rapid.
3
When the LED is steady on, the charging process has completed. This may take several hours depending upon the condition of the batteries
before charging.
4
Disconnect the power cord from the outlet and wrap around the cable support.
NOTE: The machine Key Switch may be on ON or OFF during the charging cycle. If left ON, all machine functions will be disabled and the machine
will not be allowed to move until the power cord is unplugged from the outlet.
© 2014 Nilfisk-Advance, Inc.
(page 18 of 19)
4/14 Form No. 56090231 REV A
A)
B)
BATTERY CHARGER PROFILE SELECTION CHART FOR USE WITH Delta-Q ON-BOARD CHARGER (N-A P/N 56383856)
AVAILABLE CHARGING PROFILES ARE AS FOLLOWS:
N-A P/N
Battery
Manufacturer
Battery
Model #
Voltage
20 Hour
Rating
56383856 Charge Profile to use
331318
US BATTERY
US-125
6
235
P-0-1-1
871334
US BATTERY
US-185
12
195
P-0-1-1
871335
US BATTERY
US-185
12
195
P-0-1-1
881317
US BATTERY
US-125
6
235
P-0-1-1
891384
US BATTERY
US-305
6
305
P-0-7-2
891385
US BATTERY
US-305
6
305
P-0-7-2
56026200
TROJAN
J-250-2992-41
6
250
P-0-0-3
56026200
US BATTERY
US250HC
6
275
P-0-1-1
56112545
DISCOVER
EVGT6A
6
255
P-0-4-3
56112545
FULL RIVER
DC 250-6
6
250
P-1-5-1
56112546
DISCOVER
EV305A-A
6
312
P-0-4-3
56112546
FULL RIVER
DC 335-6
6
335
P-1-4-1
56206078
TROJAN
J185-2292-42
12
195
P-0-0-3
56206078
US BATTERY
US-185
12
195
P-0-1-1
56206079
TROJAN
T-125LPT
6
235
P-0-0-3
56206079
US BATTERY
US-125
6
235
P-0-1-1
56206117
TROJAN
T-605LPT
6
195
P-0-0-3
56206117
US BATTERY
US1800
6
201
P-0-1-1
56206987
EAST PENN MFG. CO.
8GGC 2/T881 (GEL CELL)
6
180
P-0-2-6
56206988
EAST PENN MFG. CO.
8G27MM/T876
12
86.4
P-0-2-6
56315772
DISCOVER
EVGT6A
6
255
P-0-4-3
56315959
DISCOVER
EV305A-A
6
312
P-0-4-3
56317154
US BATTERY
US-14 5XC
6
251
P-0-7-2
56388582
DISCOVER
EVL 16A-A
6
390
P-0-4-3
56388582
US BATTERY
L16HC
6
415
P-0-7-3
56391391
TROJAN
J -305G
6
285
P-0-0-7
56391391
US BATTERY
US-305
6
305
P-0-7-2
56393912
DISCOVER
EV185A- A
12
234
P-0-4-3
40070A
US BATTERY
UB27
12
86
P-0-0-6
40136A
US BATTERY
US-125
6
235
P-0-1-1
40136B
US BATTERY
US-125
6
235
P-0-1-1
40602A
US BATTERY
L16
6
375
P-0-7-3
40605A
US BATTERY
US-31TMX
12
130
P-0-7-1
40606A
US BATTERY
US-31TMX
12
130
P-0-7-1
40704A
US BATTERY
L16
6
375
P-0-7-3
40953A
DISCOVER
EV250A-AGM
6
260
P-0-4-3
40964A
DISCOVER
EV305A-AGM
6
312
P-0-4-3
41023A
DISCOVER
EV185A-A
12
234
P-0-4-3
56388582
TROJAN
L16-5592-41
6
395
NOT RECOMMENDED
56380239
DISCOVER
EV12A-A
12
140
P-0-4-2
© 2014 Nilfisk-Advance, Inc.
(page 19 of 19)
4/14 Form No. 56090231 REV A