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diversey TASKI swingo 455 B Installation Manual

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Installation Manual
Retrofit of 50Ah Li-Ion batteries in machines with GEL batteries
Installation of 50Ah/100Ah Li-Ion batteries in new machines
455 B
755 B ECO / 855 R
755 B Power
855 B Power
955 B Power
1255 B Power

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Summary of Contents for diversey TASKI swingo 455 B

  • Page 1 Installation Manual Retrofit of 50Ah Li-Ion batteries in machines with GEL batteries Installation of 50Ah/100Ah Li-Ion batteries in new machines 455 B 755 B ECO / 855 R 755 B Power 855 B Power 955 B Power 1255 B Power...

  • Page 2: Table Of Contents

    12091-66_3 Table of content: Material Matrix for the installation of 50Ah or 100Ah Li-Ion batteries ………………………….. 2 Material inventory ……………………………………………………………………………………………………………. 3 7524718 Basic Kit Lithium 455 – 955 ……………………………………………………………………………………. 3 7524758 Basic Kit Lithium 1255 …………………………………………………………………………………………… 3 7524719 Extension Kit Lithium 455B ……………………………………………………………………………………. 3 7524720 Extension Kit Lithium 755-955B ……………………………………………………………………………..

  • Page 3: Material Matrix For The Installation Of 50Ah Or 100Ah Li-Ion Batteries

    12091-66_3 Material Matrix – Installation of 50Ah or 100Ah Li-Ion batteries swingo Version Basic Kit Extension Kit Battery 50Ah Onboard External Lithium Lithium 50Ah Charger 13A* charger 30A ** 455 B 7524718 7524719 7524716 7523906 EURO 455 B 7524718 7524719 7524716 4131747 755 B...

  • Page 4: Material Inventory

    12091-66_3 Material inventory Prepare material inventory for the corresponding machine. swingo 455/755 Eco/755–955 Power BMS & non-BMS 50Ah/100Ah Basic Kit Lithium 455 – 955 7524718 1 x 4133939 Weight plate A 1 x 4133978 Weight plate B 3 x 4127073 Screw PT Torx KA50x20 (T25) 1 x 4133941 Safety mat (anti-slip) 1 x 4131510 Bypass plug (charger) 2 x 4132094 Label «Charging curve»...

  • Page 5: Extension Kit Lithium 755-955B

    12091-66_3 swingo 755 Eco/755–955 Power/1255 BMS & non-BMS 50Ah/100Ah Extension Kit Lithium 755 – 1255 7524720: 4 x 4133940 Weight block 4 x 4003290 Hex screw M8x90/22 included parts only used for swingo 755 ECO: 1 x 4126957 Support 2 x 4122655 Delta PT-Schr LK AS Torx 50x16 Swingo 755 –...

  • Page 6: 7524716 Lithium-Ion Battery 100Ah (2X)

    12091-66_3 swingo 755–955 Power / 1255 Power BMS & non-BMS 100Ah Lithium battery 24V 50Ah 7524716 (2x) swingo 455 / 755 Eco / 755–955 Power 50Ah Charger 24V 13A CL1 100-240V 4131747 (for 50Ah Lithium battery with charging curve LITHIUM 34 – 70Ah) swingo 455 / 755 Eco / 755–955 Power non-BMS 50Ah/100Ah...

  • Page 7: Installation Instructions Swingo 455 / 755 Eco / 855 R / 755 - 955 Power

    12091-66_3 Installation of ReLion Lithium-Ion battery swingo 455 / 755 Eco / 755–955 Power / 1255 BMS/non-BMS 50Ah/100Ah Handling of batteries involves a risk of electric shock and must be carried out only by authorized personnel. Always charge GEL batteries completely before removal for storage. Always wear appropriate personal protective equipment such as goggles, safety shoes etc.! Installation instructions swingo 455 / 755 Eco / 755 –...
  • Page 8 12091-66_3 Pull out the battery plug. Put a carton on the floor to protect the handle from scratching on the floor. Open the two locking screws M8x20 with an Allen key 5mm on both sides of the chassis. 12091-66_3 17.02.2020 Page 7 of 49...
  • Page 9 12091-66_3 Tilt the tank to get access to the battery compartment. Inspect the batteries visually for corroded contacts, wet spots, side wall deformation and possible damage of the cables, connectors and insulation. Remove the plus (+) connector from the battery with a spanner size 13mm. Risk of electric shock when handling battery cables! Do not touch the battery (+) pole and (-) pole with tools or hands simultaneously.
  • Page 10 12091-66_3 Remove the minus (-) connector from the battery. Remove all battery connecting cables with a 10mm spanner. Place the battery cables safely to the side of the machine. Lift out batteries one by one and place it safely on the ground. A battery weighs up to 28kg! Observe local work safety regulations and use a lifting aid! 12091-66_3...

  • Page 11: Installation Of Support 4126759 With Screws As Mechanical Block

    12091-66_3 Put the red & black or blue protection caps to cover the blank battery poles on the removed Gel batteries. Observe storage conditions as recommended by the battery manufacturer. Clean the empty battery compartment with a vacuum cleaner. For swingo 755 Eco only: Install the support 4126957 with two screws delta PT Torx 50x16 on the chassis.

  • Page 12: Replacement Of Old Onboard Charger With The New 13A Charger

    12091-66_3 For swingo 455 / 755-955 BMS machines only: Replacement of on-board charger with new 24V 13A charger 4131747 with new charging curve “LITHIUM 34-70Ah” Loosen the two Torx screws with a T25 driver and swing the two cable clamps inwards. Remove the cable tie at the rear cable bundle.
  • Page 13 12091-66_3 Unplug the communication cable from the charger. Loosen the M5 screw with a 4mm Allen key. Lift out the charger from the bottom latch, thread out the disconnected power cable and place the charger safely aside.  You may use the old charger as a spare part for other machines still equipped with GEL batteries.
  • Page 14 12091-66_3 Fix the safety wire to the modified adapter bracket with the new screw M6x12 and the safety nut. Use a 5mm Allen key and a 10mm spanner (torque 5 Nm). Remove the two existing yellow label of the GEL charging curve setting from the battery cable.
  • Page 15 12091-66_3 Check the supplied new 24V 13A on- board charger 4131747 to ensure that it carries the yellow label sticker with the new “LITHIUM 34 – 70Ah” charging curve. Open the cover over the DIP switches and ensure that the correct charging curve “LITHIUM 34- 70Ah”...
  • Page 16 12091-66_3 Plug the communication cable into the new charger. Arrange the communication cable, the charger cable and the charger main cord neatly and tighten the cable tie. 12091-66_3 17.02.2020 Page 15 of 49...

  • Page 17: Installation Of The Weight Plates A & B

    12091-66_3 swingo 455 50Ah swingo 755 – 955 50Ah Always wear appropriate personal protective equipment such as goggles, safety shoes etc.! Arrange the cables neatly and evenly on both sides in the chassis and fix the cable clamps back in position. Connect the black charger main cord with the external main cord.

  • Page 18: Installation Of Weight Blocks And 50Ah Li-Ion Battery With Firmware Update

    12091-66_3 Place the weight plate B on top of plate A and align with the M8 screw holes. swingo 455 50Ah swingo 755 – 955 50Ah Always wear appropriate personal protective equipment such as goggles, safety shoes etc.! Mount the left weight block with two Mount the two weight blocks with screws M8x50.
  • Page 19 12091-66_3 Mount the right side weight block Mount the two weight blocks with with two screws M8x50. Push the two screws M8x90/22 on the left block fully to the right side. side. Push the block fully to the Do not tighten the screws yet! chassis side wall.
  • Page 20 12091-66_3 Ensure that the safety mat is evenly Ensure that the safety mat is evenly covering the side wall so that the covering the side wall so that the battery is not touching the weight battery is not touching the weight blocks directly.
  • Page 21 12091-66_3 Remove the black protection cap Remove the black protection cap from the battery minus (-) pole and from the battery minus (-) pole and fix the black battery cable to the fix the black battery cable to the minus (-) pole. Tighten the M6 nut minus (-) pole.
  • Page 22 12091-66_3 Observe the cable layout as shown. Due to limited space on top of the Ensure the red isolation nut on the battery the connector of battery plus connector is intact and tight (torque (+) must be put to the lowest possible 8Nm).
  • Page 23 12091-66_3 Install the squeegee and plug back the red battery plug. Install the additional safety label on the red battery plug. Update the machine firmware to Update the machine firmware to version V3.17 or higher with the version V1.30 or higher with the TASKI Service Tool version V8.28.

  • Page 24: Machine Preparations

    12091-66_3 swingo 755 – 955 Power 100Ah (any existing on-board charger is replaced with a new external charger) Always wear appropriate personal protective equipment such as goggles, safety shoes etc.! Place the machine on a lifting table or on solid floor. Pull out the suction hose and remove the squeegee.
  • Page 25 12091-66_3 Put a carton on the floor to protect the handle from scratching on the floor. Open the two locking screws M8x20 with an Allen key 6mm on both sides of the chassis. Tilt the tank to get access to the battery compartment.

  • Page 26: Removal Of Gel Batteries

    12091-66_3 Remove the plus (+) connector from the battery with a spanner size 13mm. Risk of electric shock! Do not touch the battery plus (+) pole and minus (-) pole with tools or hands simultaneously. Remove the minus (-) connector from the battery.

  • Page 27: Removal Of The Onboard Charger (If Bms)

    12091-66_3 Lift out batteries one by one and place it safely on the ground. A battery weighs up to 28kg! Observe local work safety regulations and use a lifting aid! Put the red & black / blue protection caps to cover the blank battery poles on the removed Gel batteries.
  • Page 28 12091-66_3 Cut the cable tie at the back of the chassis to loosen the charger cables. Unplug both the grey charger cable and the black charger power supply cable. Loosen the cable holding latches and turn them inwards. Unplug the communication cable from the charger.
  • Page 29 12091-66_3 Use a 4mm Allen key to loosen the M5 screw of the charger. Lift out the charger from the bottom latch, thread out the disconnected power cable and place the charger safely aside. You may use the old charger as a spare part for other machines still equipped with GEL batteries.

  • Page 30: Installation Of The Weight Plates A & B

    12091-66_3 Place back the rubber membrane and fix the cable clamp back. Place the charger communication cable and the charger cable end in the pocket of the chassis and fix them with a black cable tie. Arrange all cables on both sides of the chassis evenly and neatly and put the cable holding latches back in position.

  • Page 31: Adjustment Of The Battery Connection Cable

    12091-66_3 Fix the two hollow distance bolts with the hex socket screw M8x55/28 through plate B and tighten them to the lower plate A. Place the safety mat over the bolts onto the top plate. Separate the two cables of the wire harness by cutting the cable tie.

  • Page 32: Installation Of The Batteries 100Ah And Battery Cables

    12091-66_3 Fix the ring connector of the red wire to the battery plus (+) connector. Take the black wire of the wire harness and thread it through the rubber protection cap of the black minus (-) pole battery cable. Fix the black cable to the battery minus (-) pole connector.
  • Page 33 12091-66_3 Connect the black battery minus (-) cable to the battery’s minus (-) pole. Tighten the screw with an 10mm spanner with a torque of 8Nm. Unprotected battery terminals may get short circuit. Only remove safety caps when required. Install the battery connection cable to the minus (-) pole of the other battery and tighten with a 10mm spanner with torque 8Nm.
  • Page 34 12091-66_3 Complete the cable connection to both batteries and put the rubber protection caps over the poles. Connecting battery terminals is posing the risk of short cirucit. Always observe the correct polarity. Fix the red and black protection caps together with a cable tie to the battery cable.

  • Page 35: Setup Of The New External Charger

    12091-66_3 Mount the squeegee but leave the battery plug disconnected. Install the additional safety label with a cable tie to the battery plug. Plug in the new external 30A charger to power supply to access the setting menu. The charger is NOT connected to the machine! Adjust the correct Lithium battery charging curve LITHIUM 91-180Ah.

  • Page 36: Charging Of The Batteries

    12091-66_3 Plug the charger to power supply. The charger turns ON. Batteries will start charging. Complete the charging cycle of the batteries. Check machine firmware. Service Tool Version 8.28 Use Service Tool 8.28 to update to FW version V1.30 or higher. Machine is now ready to use! Important: Always disconnect first the charger from power supply before connecting or disconnecting the charger to or from the machine!

  • Page 37: Installation Instructions Swingo 1255 B Power

    12091-66_3 swingo 1255 B Power 100Ah (any existing on-board charger is replaced with a new external charger) Always wear appropriate personal protective equipment such as goggles, safety shoes etc.! Replacement of existing 180Ah Gel batteries with 100Ah Lithium batteries Place the machine on a lifting table or on solid floor.

  • Page 38: Removal Of Gel Batteries

    12091-66_3 Inspect the batteries visually for corroded contacts, wet spots, side wall deformation and possible damage of the cables, connectors and insulation. Always charge the battery before removal and for storage! Always wear your PPE goggles & safety shoes when working with batteries! To minimize the risk of short circuits do not deposit any tools on the batteries! First remove the secondary battery...
  • Page 39 12091-66_3 Remove the secondary battery minus (-) cable using a 10mm spanner. Risk of electric shock! Do not simultaneously touch the battery plus (+) pole and minus (-) pole with tools or hands. Remove the primary battery minus (- ) cable using a 10mm spanner. Risk of electric shock! Do not simultaneously touch the battery plus (+) pole and minus (-)

  • Page 40: Removal Of The Onboard Charger (If Bms)

    12091-66_3 Remove all batteries and store them safely with the protection caps put on the battery poles! A battery weighs up to 28kg! Observe local work safety regulations and use a lifting aid! Observe storage conditions as recommended by the battery manufacturer.
  • Page 41 12091-66_3 Remove the cable tie near the charger connection plugs. Unplug the charger main cord. Unplug the charger connector Anderson SB50. Unplug the charger communication cable. Loosen the two screws holding the charger underneath the chassis with a 10mm spanner. 12091-66_3 17.02.2020 Page 40 of 49...
  • Page 42 12091-66_3 Carefully pull out the charger from underneath the chassis. Store the charger safely to be used as spare part on other machines. Open the two pan head Torx screws of the cable clamp. Pull the charger power supply cable out of the chassis.

  • Page 43: Installation Of The Weight Plates A & B And Blocks

    12091-66_3 Place back the rubber membrane and fix the cable clamp back. Connect the charger bypass connector (Jumper). Place the cables and connectors in the pocket of the chassis and close the cable clamps again. Place weight plate A into the chassis and align properly to the screw holes.

  • Page 44: Installation Of The Batteries 100Ah And Battery Cables

    12091-66_3 Place the weight plate B on top of the plate A and align it to the M8 screw holes. Install two weight blocks at the rear end of the weight plates and tighten the two M8x90/22 screws first only by hand.
  • Page 45 12091-66_3 Carefully place the rear battery between the weight blocks. Observe the plus (+) pole of the battery to be on the right side of the machine. Carefully place the front battery between the weight blocks. Observe the plus (+) pole of the battery to be on the right side of the machine.

  • Page 46: Marking The Electronics With The New Charging Curve Lithium 91-180Ah

    12091-66_3 When tightening the M8x90/22 hex screw press the weight blocks against the battery. Use a 13mm spanner (torque 20-25Nm). When tightening the two M8x90/22 hex screw press the weight blocks against the battery. Use a 13mm spanner (torque 20-25Nm). When tightening the four M8x90/22 screws of the middle blocks with a 13mm spanner, put a screw driver...
  • Page 47 12091-66_3 Mount the primary battery minus (-) connector and tighten with a 10mm spanner (torque 8Nm). Risk of electric shock! Do not simultaneously touch the battery plus (+) pole and minus (-) pole with tools or hands. Mount the secondary battery minus (-) connector and tighten with a 10mm spanner (torque 8Nm).
  • Page 48 12091-66_3 Put all protection rubber hoods over the battery connectors. Bundle the pole protection caps with a cable tie on the battery cables. Remove any existing yellow label for GEL battery charging curve from the battery cables. Attach the new yellow labels for LITHIUM charging curve setting with white cable ties near the battery pole connectors.

  • Page 49: Setup Of The New External Charger

    12091-66_3 On the right side place the foam inserts between chassis and batteries. Close the tank and put back the two tank locking screws on the side of the chassis with a 5mm Allen key. Put back the squeegee and connect the suction hose.

  • Page 50: Charging Of The Batteries

    12091-66_3 Adjust the correct Lithium battery charging curve LITHIUM 91-180Ah. Remove the external charger from power supply. The charger is OFF! Connect the charger to the charger plug of the machine. Plug the charger to power supply. The charger turns ON. Batteries will start charging.

This manual is also suitable for:

Taski swingo 755 b eco / 855 rTaski swingo 755 b powerTaski swingo 855 b powerTaski swingo 955 b powerTaski swingo 1255 b power

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