About the Compass Sport Service Guide
Contents
1. Right Motor SHARK Power Module SHARK Charging Port Control Unit TX Battery Charger Programmer PC based or Hand Held SHARK Bus Cable Not Used Figure I Compass Sport Electrical System Connector Key Shark 11 Compass Sport SG REVA 041211 Connector Key for Shark Controller Battery Connector Pinout Function Ye Positive 2 Battery Battery Negative Motor Connector Pinout Function Motor Positive Ls Brake Negative 4 Park Brake Positive SHARK Bus Connector Pinout Function Battery Positive ann Communications BUS Low EE See Note The Shark controller and the controller harnesses are keyed eliminating the possibility of the cables from being incorrectly connected to the controller Cabling Diagram Shark Power Module Controller Control Unit Joystick Motor Harness SHARK Bus Cable Note Refer to figure 4 on page 13 Right Motor for the power harness layout on the battery side Battery Harness 12 Volt Battery 12 Volt Battery Motor Harness Left Motor Figure 2 Compass Sport Cabling Diagram Circuit Breaker not shown 12 Compass Sport SG REVA 041211 Wiring Diagrams 2 pin connector female To Brake orange red blue LAWO BLE MOTOR black Left 2 pin connector female To Brake To Dynamic Shark Controller orange red end blue LAWE BLE MOTOR bl2. 3090160020 Bearing Caster 6002 2Z for Compass Sport GP605 WEO3A105 Arm Front Right Caster Arm only for Compass Sport GP605 EN WD2P205A Spacer Caster Wheel White Zinc for Compass Sport GP605 ES WE03E202 Fork Right Caster Assembly w Wheel for Compass Sport GP605 ES Compass Sport SG REVA 041211 Left Rear Arm Assembly WE03E107 qn 6 WD2P205A Spacer Caster Wheel White Zine for Compass Sport GP605 a PO 34 35 Compass Sport SG REVA 041211 Left Forearm Assembly WE03E108 PART NO 3000413041 Washer Flat White Zine 013502092 Dior Compass Sport SG REVA 041211 Wheel Assembly WE03E201 ITEM PART NO DESCRIPTION 31001W3011 Nut Hex White Zinc 5 16 24UNF 3003108011 Washer Spring 8 E 4 3000408011 Washer Flat White Zinc p8 4 p16 1 6 4 WCO9P301A Mag Black for Compass Sport GP605 4 3070100030 Tire Solid Urethane 260 85 For Compass Sport GP605 06 WE03A203 Hub For Compass Sport GP605 36 37 Compass Sport SG REVA 041211 PN 1 Right Caster Assembly WE03E202 ITEM PART NO DESCRIPTION MET WE03P509 Cover Caster Black Plastic for Compass Sport GP605 1 NM WE03A202 Fork Caster Fork only for Compass Sport GP605 EN KH 3110308122 Screw Hex Head Socket Cap Black Zinc M8 82 WC9E112A Wheel Caster for Compass Sport GP605 WC9P202A Spacer White Zinc 012 98 5 4 E
3. 3100308012 Nut Nylon Black Zinc M8 Compass Sport SG REVA 041211 ON IN ON Oy ON S ON NOV Left Caster Assembly WE03E203 ITEM PART NO DESCRIPTION WE03P509 Cover Caster Black Plastic for Compass Sport GP605 WE03A202 Fork Caster Fork only for Compass Sport GP605 EN 3110308122 Screw Hex Head Socket Cap Black Zinc M8 82 EE WC9E112A Wheel Caster for Compass Sport GP605 WC9P202A Spacer White Zinc 012 98 5 4 06 3100308012 Nut Nylon Black Zinc M8 38 39 Compass Sport SG REVA 041211 e a 3 9 5 Seat Assembly WE03E401 ITEM PART NO DESCRIPTION EM WE03E402 rn Joystick Mounting Arm with Joystick for Compass Sport Knob Arm Height Adjustable for Compass GP600M GP620M GP605 ES ME and Companion GC240 340 440 M8 20 ll KH WE03E405 Arm Arm Right Assembly for Compass Sport GP605 Assembly Arm Right Assembly for Compass Sport GP605 Compass Sport GP605 Swivel Seat Assembly for Companion GC221 321 421 240 340 440 04 MBX CSSA2 LiteRider GL 110 Alante GP201R post 2006 High Profile Collar and 1 Compass Sport GP605 3000408031 Washer Flat Zinc 08 4 024 2 Compass Sport SG REVA 041211 E 3110408092 Bolt Outer Hex White Zinc M8 35L 3003108011 Washer Spring White Zinc 8 EN Knob Arm Width Adjustable for Compass ES GP600M GP620M GP605M and Companion GC240 340 440 B EE WE09E403C Arm Arm Lef
4. d GOLDE technologies Compass Sport Service Guide This Service Guide contains Troubleshooting Replacement Instructions Illustrated Parts Breakdown Compass Sport SG REVA 041211 Compass Sport SG REVA 041211 Table of Contents Nomenclature and Contact Mor prin 3 ABOUT THE COMPASS SPORT SERVICE GUIDE nenen n anana nana n anane nana nnns i Compass por E OMI OME IS osos odere yia aa wai ak ad nie a cta nut A tubes un ESO ele 4 6 Ihe SHARK Battery E a a daana adage aia aa aal I SCENARIO I Press the on off button and the LED array does not light up SHARK 8 9 SCENARIO 2 Batteries will not charge Shark Charging Test 9 10 RINNAN 11 Connector Key and Cabling for SO ERTER EEE EE 12 Wine Diagrams and Battery Place He ii seiss apan nana anda aas ang ea ia naa ban da ian di aaa ia cha toc 13 14 TROUBLESHOOTING GUIDE Tor SHARK usen cid 15 21 sien L Checkins Battery Vol ERNEUT 15 SD NN aaa asa gagan raka aa Rte er oe NE baa ee errr M NISA na Na IU E M UR I UM 16 20 Flash ode 1 User Fanit on 17 Haski Codes 2 bate rones 17 ASC OR SAK Moor T ee Ba gag aan de T 17 Flash Code 4 Right Motor Fault nono nn corn arra 18 Flash Coders Let Park Brake Paulo ee ee en ne NIME MM 18 Flach Code Ce Rent Park Brake eeren dpnekenEU brum UE RUP IP OMISIT TUR ORI 19 Fash Coder SARK Control Unit Ed a aga kani naba apapa daa na bab a aa kananga tug aana a i 19 Flash
5. Motor Circuit Breaker Figure 10 Electrical System 24 Compass Sport SG REVA 041211 APPENDIX A HOW TO USE A VOLTMETER Step 1 Plug the probes into the meter Red goes to the positive and black to the negative Step 2 Turn the selector dial or switch to the type of measurement you want To measure direct current a battery for example use DCV To measure alternating current such as a wall outlet use ACV Step 3 Choose the range setting The dial may have options from 5 to 1000 on the DCV side and 10 to 1000 on the ACV side The setting should be the top end of the voltage you are reading Not all voltmeters have this setting Step 4 Turn the meter on Step 5 Hold the probes by the insulated handles and touch the red probe to the positive side of a DC circuit or either side of an AC circuit Touch the other side with the black probe Step 6 Read the digital display or analog dial Figure 35 Multimeter Set to DC Volts 25 APPENDIX B HOW TO USE AN OHM METER Compass Sport SG REVA 041211 Ohm s law breaks down into the basic equation Voltage Current x Resistance Current is generally measured in amps and resistance in ohms Testing the resistance on an electrical circuit in your home or car can help you diagnose problems with that circuit You can use a simple ohmmeter for this task but most professionals now use the ohmmeter function of a multimeter also called multitester or VOM
6. Sport 1 08 WEO3ES04RED Cover Rear Red U1 Battery for Compass Sport GP60 1 0 WEOSESDABLUE Cover Rear Blue Ul Battery for Compass Sport GP605 1 09 WEO3ESOSBLUE Fender Blue Left for Compass Sport Gets 4 09 WEUSESOSRED Fender Red Left for Compass Sport GPS 1 2 Compass Sport SG REVA 041211 Base GP605 Compass Sport WE03E101 ITEM PART NO DESCRIPTION QTY Ol 2310030012 Nut Nylon MIO j 02 SA2P422A Washer ARC P10 pa 03 NAIPSMA Ca PD 04 3110605062 Screw CrossSlotPanHeadM5 10 2 06 WEO3E102 Drive Train Right Includes Caster Arms Wheels and Motor 1 08 WEO3ATIT Strap Battery Right Male for Compass Sport GP605 2 09 3100308082 Nut Nylon Black Zinc Plated M8 2 Footplate Assembly for Compass Sport GP605 3110208082 Bolt Flat Round Hex Black Zinc Plated M8 45 2 L 12 Female for Compass 13 WE03E104 Drive Train Left Includes Wheels and Motor 1 14 300149019 CClaspol9 15 3110611052 Bolt Hex Head Cylinder Black Zinc MIO 65 1 E ME TEE 1 WC5P129A EVA Foam 25 50 5 L 1 amp 300405092 Washer Flat 3381081 a 19 3100305012 Nut Nylon M5 2 3110605052 Screw Cross Slot Pan Head Black Zinc M5 6L WE03P516 Battery Cushion Block 23 30 28 Compass Sport SG REVA 0412
7. for volt ohmmeter Read on for instructions on how to use an ohmmeter and test for resistance e Ohmmeter or Multimeter Volt ohmmeter e Circuit to test with all power OFF e Service manual Step 1 Disconnect completely and or turn OFF all power to the circuit you are testing You must have a completely dead wire or circuit in order to ensure accuracy in measurement as well as your own safety Your ohmmeter will supply the voltage and current for your circuit so NO other power is necessary Testing a powered circuit can cause damage to the meter circuit and you Step 2 Connect testing wires to the ohmmeter The black wire goes to the ground common outlet the red wire to the volt ohms outlet Step 3 Consult a service manual for the normal range of resistance for the circuit you are testing Step 4 Set the dial to the ohms setting with a multimeter On an individual ohmmeter you may have to set a range for the readings in ohms kilohms or megohms Use the range you located in your service manual to set the dial Figure 36 Multimeter Set to Ohms 26 Compass Sport SG REVA 041211 ILLUSTRATED PARTS BREAKDOWN 0 40 E 04 03 05 08 08 GP605 Compass Sport WE03E001 ITEM PART NO DESCRIPTION 02 WE03E501RED Cover Red Right Front Caster for Compass Sport GP605 1 03 WE03E502BLUE Cover Blue Left Front Caster for Compass Sport GP605 1 06 WEOSEIO Base GP605 Compass
8. pin 2 on the power module Greater than 24VDC Test the power harness for continuity and replace as necessary D 5 e OVDC Go to the next step H A A BA am WARNING Prevent damage to the Shark power module Be careful when touching the leads on the power module Do not allow the meter leads to touch each other which will cause a short 7 Reconnect the power harness to the power module Disconnect the bus cable from the power module Measure voltage across pin and pin 4 on the bus cable Greater than 24VDC Replace the power module e OVDC Go to the next step 8 Reconnect the bus cable to the power module Disconnect the bus cable from the joystick Measure voltage across pin 1 and pin 4 on the joystick Greater than 24VDC Replace the bus cable OVDC Replace the control unit A WARNING Before attempting to measure resistance make sure there 15 no power to the circuit Unplug the front and rear battery harnesses from the power harness 9 Measure Resistance across the terminals on the circuit breaker Less than 10 ohms Go to the next step Open Replace the circuit breaker 10 Check continuity across the circuit breaker wires of the power harness and across the battery wires of the power harness Repair or replace the power harness as necessary 10 Compass Sport SG REVA 041211 Electrical System Left Motor 24V Battery Supply m
9. the right motor connections and cabling Left Park Brake Fault ao left park brake connections and BH Right Park Brake Fault Check the right park brake connections and 10 11 cabling Check the SHARK Communications Bus SHARK Control Unit connections and wiring Fault Replace the Control Unit SHARK Power Module Check SHARK connections and wiring Fault Replace the Power Module Check Battery voltage is greater than 17W SHARK Check SHARK Bus Cable Communications Fault Replace the SHARK Power Module Replace the SHARK Control Unit Check all connections and wiring Unknown Fault Consult service agent The Control Unit is incompatible with the Incompatible Control Power Module Unit Ensure the brand of the Power Module matches that of the Control Unit 16 Compass Sport SG REVA 041211 Flash Code 1 User Fault A Possible stall timeout or user error Release the joystick to neutral and try again e Turn the controller off and then on again to clear the fault Flash Code 2 Battery Fault A Try charging the batteries B Check the battery voltage and cabling Refer to step 1 on page 15 C If the battery voltage fault persists after completing step 1 replace the batteries Flash Code 3 Left Motor Fault A Check the resistance of the left motor to determine if the fault is in the motor or the controller e Set your meter to the 20 Ohm scale e Touch the leads together to make sure the ohm me
10. 0 Unknown Fault A Check all connections and wiring B Call Technical Support Flash Code 11 Incompatible Control Unit A Make sure the brand of the Power Module matches that of the Control Unit Step 3 Check for other conditions displayed by the Shark Control Unit A All LEDs off on the battery gauge indicates the power 1s off V O 3 cy b iy T B All LEDs on steady on the battery gauge indicates the power 15 on Less LEDs imply a reduced battery charge 1e C The left red LED flashing on the battery gauge signifies an extremely low battery charge The batteries should be charged as soon as possible Charge the batteries for 8 hours Refer to step 1 for measuring battery voltage Make sure the correct charger is being used and that it is working properly Make sure the charger is working by check the voltage across pin 1 and 2 on the charger XLR connector z e If after performing the previous tests and the flashing still persists replace the batteries D A right to left LED chase on the battery gauge signifies that the Shark is in a locked state a VE NS ema se S e To unlock the Shark turn the controller on and press the horn button twice within ten seconds 20 Compass Sport SG REVA 041211 E A left to right LED chase on the battery gauge signifies that the Shark is in a charge inhibit The steady LEDs indicate the current state of battery charge gt le ps aR M
11. 11 Right Side Drive Train WE03E102 ITEM PART NO DESCRIPTION Cap Rim for Companion GC240 340 440 and Compass Sport GP605 Washer 910 5 0953 1 5 Hubcap Plastic 10 for Companion GC240 340 LiteRider GL110 and Compass Sport GP605 Wheel Drive Complete Assembly for Compass Sport GP605 05 Motor Right Assembly with Gearbox and Brake for Compass Sport GP605 Cap Brake Handle Yellow for Compass Sport GP605 07 Handle Brake Black for Compass Sport GP605 Screw Cross Head Countersunk White Zinc Plated M4 12 Screw Cross Head Countersunk White Zinc Plated M4 5 10 E 12 13 14 15 16 17 18 19 20 21 Compass Sport SG REVA 041211 Footplate Assembly WE08E103 ITEM PART NO DESCRIPTION WE03P508 Pad Footplate for Compass Sport GP605 TO 02 3110606021 Screw Cross Slot Pan Head Black Zinc M6 16 NE NE h2 03 WCOP107A Footplate Shell ABS LX NONE C EE EE WE03A109 Bracket Footplate Mounting for Compass Sport GP605 1 7 3100110032 Nut Hex Black Zinc M10 1 07 3110310042 Bolt Hex Head Cylinder Black Zinc M10 50 l 08 3110310012 Bolt Hex Head Cylinder Black Zinc M10 35 l 09 WE03A110 Footplate Metal Base Plate Electro Black l 10 3100306012 Nut Nylon Black Zinc M6 2 2 30 3 Compass Sport SG REVA 041211 Left Front Caster Arm Assembly WE08E104 Washer 910 5 0953 1 5 Hubcap Plastic 10 for Companion GC240 340 LiteRider GL110 and Compass Sport GP605 Wheel Drive Complete Assembly for
12. 14 for Compass Sport GP605 NN KA WC9A409B Rail Arm Top for Compass Sport GP605 NN KH 3110108039 Screw Large Hex Head Flat Black Zinc M6 30 EN WC9P415B Nut Hex M8 WC9A416A Spacer Arm Joining For Compass Sport GP605 44 45 Compass Sport SG REVA 041211 Le mee TT Lm summ tm E WC9PA416A Nut Hex Black Zinc M6 o se rs roto Comp ere stage TT NE v ron omme 7000000 D WC9A418A Bracket Arm Joining for Compass Sport GP605 R Compass Sport SG REVA 041211 Seat Swivel Assembly WE03E406 ITEM PART NO DESCRIPTION 3000608012 Spring Pin 9863 5 SE1P413B Lock Handle Group 04 SE1A404C Cross Pan Head screw 1 05 3110605092 Cross Recess Head Screw M5 35 1 06 3100105012 Hex Nut M5 SE1P424A Torsion Spring 6 SE1P530A Cover for Swivel lever 46 47 Compass Sport SG REVA 041211 Right Front Caster Arm Cover WE03E501 ITEM PART NO DESCRIPTION QTY 01 WE03P503 Cover Front Right Caster For Compass Sport GP605 02 WC9P510A Clip Cover Mounting for Compass Sport GP605 OI 02 3 3111103051 Screw Crossed Head Countersunk Self Tapping White Zinc ST3 5 12 l 01 02 N Left Front Caster Arm Cover WE03E502 ITEM PART NO DESCRIPTION QTY WE03P504 Cover Front Left Caster For Compass Sport GP605 WCO9P510A Clip Cover Mounting for Compass Sport GP605 3111103051 Screw Crossed Head Countersunk Self Tapping White Zin
13. 7 SHARK Control Unit Fault A Holding the power switch for a timeframe greater then 4 seconds while powering up will cause the remote to display this flash code This 15 not a fault but a safety feature designed to detect 1f the power button 15 working properly The power button is your emergency stop button for the power chair e Turn the power off and then on again to reset the fault B Check the SHARK Communications Bus connections and wiring C Check that the wiring is not damaged and that all cables are connected properly D Make sure all pins are seated properly in their connectors E If after performing the previous tests and the fault still persists or the remote will not turn off replace the SHARK control unit Flash Code 8 SHARK Power Module Fault A Check the SHARK connections and wiring for continuity B Check that the wiring 15 not damaged C Make sure all pins are seated properly in their connectors D If after performing the previous tests and the fault still persists replace the SHARK power module Flash Code 9 SHARK Communication Fault A Check that the battery voltage is greater than 17VDC Refer to step 1 on page 15 B Check the SHARK bus cable for continuity C Make sure all pins are seated properly in their connectors D If after performing the previous tests and the fault still persists replace both the SHARK control unit and the SHARK power module 19 Compass Sport SG REVA 041211 Flash Code 1
14. A al ET Fi chase steady e Remove the battery charger from the charging port e Ifthe flashing persists after the charger has been removed replace the controller F When all speedometer LEDs are flashing and the battery gauge LEDs are steady the Shark has detected an Out Of Neutral At Power Up OONAPU condition s Is AL SS 32 ES E in rd e Release the joystick back to the neutral position 21 Compass Sport SG REVA 041211 REPLACEMENT INSTRUCTIONS DRIVE WHEEL 1 Turn off power 2 Place the power chair in drive mode 3 Place a support under the frame so that the drive wheel is off the ground 4 Remove the drive wheel Note Make sure to retain the axle key See figure 7 5 Install the new drive wheel Note Make sure the axle key is installed correctly in the axle slot Also make sure the washer 15 installed facing in the correct direction with the dimples facing toward the hub cap 6 Remove the frame support 7 Power on and test the power chair n p ESD Pa h lt i P rx im a pn oc p r Bn i r Y h MAH Y E SAO ul P LS a Er E a E m F igure 7 Drive Wheel Assembly CASTER 1 Turn off power 2 Place the power chair in drive mode 3 Place a support under the frame so that the caster wheel 1s off of the ground 4 Remove the cap from caster arm See figure 8 5 Remove the nut that fastens the cas
15. Code 8 SHARK Power Module Faut 19 Flash Code 9 SHARK Communications Fault 19 Hash ode LOU RONA Palla AA RANG EM a A aaa a 20 Flash Code 1 Incompatible Control Unt gan aa aan ag ag na padaang pak kg ang an ban aga aan kaa pube estates 20 Step 3 Check for other conditions displayed by the Shark Control Unit 20 21 MED 20 MIDTEN RN a a in 20 DORE D ASI aa 20 KAG O o 206 RR MMM 20 Litio non TAPI GG oases aaa 21 AH sp edometer LEDS ASS rito 21 R PESCEMEN TINS ER CMOS tanana ga sabata a aan ae pa anaa ki an nat a pah aaa aaa aa aja ana aa Pa a ajak ia 22 24 22 22 Drive Train Motor Brake NNN a 23 rower Ma 24 APPENDIX A HOW TO USE A VOLTMETER nn annan nn eee rr nr rn nn nn rra naaa 25 APPENDIX B HOW TO USE AN OHM METER cnc cnn cnn nc 26 ILLUSTRATED PARTS PRE NNN 27 50 Compass Sport Nomenclature Contact Information Golden Technologies 401 Bridge Street Old Forge Pa 18518 Toll free 800 624 6374 Fax 800 628 5165 Lift Chair Bed Tech x645 Mobility Tech x648 VA Tech x647 Email parts goldentech com Compass Sport SG REVA 041211 Seat Assembly Control Unit Shark Right Caster Cover Left Caster Cover Right Fender Left Fender Front Battery Cover Rear Battery Cover Base 10 Right Side Drive Train 11 Front Bat
16. Compass Sport GP605 06 WE03P510 Cap Brake Handle Yellow for Compass Sport GP60s 1 08 3111404012 Screw Hex Socket White Zinc Plated M4 12 1 09 3111004022 Screw Hex Socket White Zinc Plated M4 6 1 10 3110308032 Screw Hex Cap Socket Head Black Zine Plated Mgr 2 11 WEO3P139 LimitSet 1 3000408012 Washer Flat Black Zinc p8 4 p16 1 6 45 5100308072 Nut Nylon Blak Zine MB 15 3110208022 Screw Hex Cap Socket Head M8 35 SSS OA 16 3008108012 Washer Spring WEO3P140 Sliding Pin B XE 3 Washer Flat Black Zinc 910 5 918 1 6 EE 19 WE03A108 Plate Left Connector Front to Rear Caster for Compass Sport GP60S 20 WCopo02A Spar SOS 21 WEO3E108 Caster Front Right Arm with Wheel for Compass Sport GP60S 1 Compass Sport SG REVA 041211 ON UN 1 6 OY ON MI ON y Right Rear Arm Assembly WE03E105 ITEM PARTNO DESCRIPTION WC9P421A Cap Caster Black Plastic for Compass Sport GP605 3100312011 Nut Nylon White Zinc M12 3000413041 Washer Flat White Zinc 13 20 2 Bearing Caster 6002 2Z for Compass Sport GP605 Arm Rear Right Caster Arm Only for Compass Sport GP605 6 WD2P205A Spacer Caster Wheel White Zinc for Compass Sport GP605 Fork Right Caster Assembly w Wheel for Compass Sport GP605 me PR PR rr m 32 33 Compass Sport SG REVA 041211 Right Forearm Assembly WE03E106
17. Place the red and black meter leads on the two middle pins of the motor connector as shown in figure 7 on page 19 e Meter reading should be 80 ohms or less but not shorted e Any reading outside this range replace the park brake C Ifthe reading 15 within range and the controller still displays a flash code check the wiring for visible damage and that all cables are connected properly Make sure all connectors are seated properly in their connectors 18 Compass Sport SG REVA 041211 Figure7 Flash Code 6 Right Park Brake Fault A Make sure the right park brake lever 15 engaged If disengaged re engage the park brake lever and turn the power off and back on to reset flash code UJ Check the resistance of the right park brake to determine if the fault 1s in the park brake or in the controller Set your meter to the 200 ohm scale Touch the leads together to make sure the meter 15 accurate You should have 0 ohms at this point If not your meter needs to be calibrated e Place the red and black meter leads on the two middle pins of the motor connector as shown in figure 7 e Meter reading should be 80 ohms or less but not shorted e Any reading outside this range replace the park brake C If the reading is within range and the controller still displays a flash code check the wiring for visible damage and that all cables are connected properly Make sure all connectors are seated properly in their connectors Flash Code
18. T COMPONENTS The Compass Sport 1s a battery operated power chair controlled by a Dynamic control system The control system monitors and displays flash codes on the LED array when it detects a fault in the system The Compass Sport was designed to operate with between 18 24 volts V of direct current DC The Compass Sport control system is made up of the following components Reference the diagrams on pages 11 and 12 e 12V 35AH Batteries 2 e Battery Harnesses 2 Main Circuit Breaker e Battery Charger e Power Harness e Motors 2 left right e Park Brakes 2 left right e SHARK Dynamic Power Module SHARK Dynamic Control Unit Joystick SHARK Bus Cable NOTE Parts and service must be authorized by the Golden Technologies Service Department Unauthorized parts or service may void the warranty For more information contact the Golden Technologies Service Department at 800 624 6374 or parts goldentech com Component 12VDC 35AH Batteries 2 Location Connected in series inside the battery box Function Supply 24VDC to the power module 12 VDC x 2 Connections Front Battery and Rear Battery Failure Signs Batteries drain quickly Power chair runs slowly or not at all Batteries will not charge but charger 1s working properly Flash Code 2 Compass Sport SG REVA 041211 Tests Load test Fully charge the batteries first Make sure charging system is working Expected Readings 12 14VDC each when fu
19. ack Right Figure 3 Motor Brake wiring harnesses To Battery Harness Connector To Dynamic Shark Controller Power Input BLACK Circuit Breaker To Battery Harness Connector Figure 4 Power Harness 13 Compass Sport SG REVA 041211 Wiring Diagrams continued To Battery Terminals ah EE i E r M o ome iA FG LH uo E L i i i i JEG L M i i VE a pa To Power Harness Connectors ae ha 3 Figure 5 Battery Harnesses Figure 6 Correct Battery Placement 14 Compass Sport SG REVA 041211 Troubleshooting Guide for the Shark Power System Step 1 Battery voltage is always the first thing to check A Check the battery voltage through the 3 pin battery charger port located on the front of the controller as shown in figure 1 e Set voltmeter to the 50 VDC scale e Place the meter leads into the two outside pins of the battery charger port as shown in figure 2 e Meter should read approximately 25 VDC If the voltage is below 25 VDC Recharge the batteries for 8 hours Check wiring for any visible damage and make sure all the cables are connected properly Make sure that the pins are seated in the connectors properly and the fuses are good eeo C If the voltage 15 20 VDC 01 less e The battery charger may not recognize 2 low voltage and thus will not charge the batteries e Boost charge the batteries to bring the voltage up to a level that the charge
20. c ST3 5 12 Compass Sport SG REVA 041211 aa 101 02 w 03 Battery Front Cover Group WE03E503 ITEM DESCRIPTION WC9P528A Sticker Compass Sport WE03P503 Cover Front Battery Plastic Only for Compass Sport GP605 WC9P510A Clip Cover Mounting for Compass Sport GP605 3111103051 Screw Crossed Head Countersunk Self Tapping White Zinc ST3 5 12 Note Item 05 Battery Diagram Label Not Available XL m Battery Back Cover Group WE03E504 ITEM PART NO DESCRIPTION QTY WEO3P505 Cover Rear Battery Plastic Only for Compass Sport GP605 WCO9P510A Clip Cover Mounting for Compass Sport GP605 3111103051 Screw Crossed Head Countersunk Self Tapping White Zinc ST3 5 12 WEO3PS512 Label Black Cover 1 48 40 Compass Sport SG REVA 041211 3 m Left Fender WE03E505 Right Fender WE03E506 ITEM PART NO DESCRIPTION WEO3PS502 Fender Left Plastic Only for Compass Sport GP605 WCO9P510A Clip Cover Mounting for Compass Sport GP605 EFE 3111103051 Screw Crossed Head Countersunk Self Tapping White Zinc ST3 5 12 EN ou WE03P514 Label for Drive Wheel Cap EY Compass Sport SG REVA 041211 Motor Harness al pe gts Eo T LE Eae ribus ODER a S Wiring Diagram WE03E601 2 MBE BATTU Battery U1 9 12V 33AH FS SE06A614 Nut Hex M6 Battery Own 1 3100511010 Nut Waterproof Pr
21. charger A You may damage the charger WARNING Do not touch either of the multimeter probes on the third pin or the XLR connector cover 2 Remove the seat and the battery box covers 3 Make sure that the batteries are connected according to the battery connection diagram on the inside of the battery cover and or figure 6 on page 14 Check the batteries and cables for corroded or loose terminals Clean and tighten if necessary 4 Measure voltage across the rear battery negative black terminal and the front battery positive red terminal Less than 18VDC Load test and replace batteries as necessary e Greater than 18 VDC Go to next step e OVDC Go to step 9 5 Unplug the battery harnesses from the power harness Measure the voltage across the battery connectors on the power harness Place the red meter lead on the positive pin of the front red connector mounted to the frame Place the black meter lead on the negative pin of the rear black connector mounted to the frame Refer to figure 4 on page 13 Note The charger must be plugged in and turned to the on position to perform the testing procedure Greater than 24VDC Test the battery harnesses for continuity and replace as necessary e OVDC Go to the next step Compass Sport SG REVA 041211 SCENARIO 2 Continued 6 Reconnect the battery harnesses to the power harness Unplug the power harness from the power module Measure voltage across the pin and
22. d and black meter leads on the two outside pins of the connector on the motor as shown in figure 5 e Meter reading should be between 0 3 and 5 ohms e Any reading outside this range replace the motor Check the resistance of the M1 motor connector on the controller Disconnect the battery from the controller Set your meter to the 200k ohm scale Touch the leads together to make sure the meter 1s accurate You should have 0 ohms at this point If not your meter needs to be calibrated e Place the red and black meter leads on the two outside pins of the M1 motor connector on the controller as shown in figure 6 e Meter reading should be 22k ohms e Any reading outside this range replace the controller eeo C If the reading 15 within range and the controller still displays a flash code check the wiring for visible damage and that all cables are connected properly Make sure all connectors are seated properly in their connectors Figure 5 Figure 6 Flash Code 5 Left Park Brake Fault A Make sure the left park brake lever 15 engaged If disengaged re engage the park brake lever and turn the power off and back on to reset flash code UJ Check the resistance of the left park brake to determine if the fault is in the park brake or in the controller Set your meter to the 200 ohm scale Touch the leads together to make sure the meter is accurate You should have 0 ohms at this point If not your meter needs to be calibrated e
23. lly charged Serviceable Replace batteries as necessary Component Park Brake 2 Location End of each motor Function Park Brake for the motor Connections Each park brake has a 2 pin male connector which connects to each motor harness Failure Signs Power chair will not move or moves sluggishly No audible click when the chair stops Tests Test for open See Flash Codes 5 and 6 Expected readings Less than 80 ohms but not shorted Serviceable Replace if outside this range Component Circuit Breaker Location Mounted on the front of the power base Function Protects battery circuit from current overload When the current draw exceeds the breaker rating the circuit breaker will open Connections Terminals on the circuit breaker are connected to the batteries through the power harness Failure Signs Opens repeatedly This may indicate a failed circuit breaker or short in the wiring Also may open if the motors are overloaded from excessive weight short in system etc Test Measure the resistance across the circuit breaker Also check for continuity across the power harness from the circuit breaker to each battery Refer to the power harness wiring diagram on page 13 Expected reading Less than 10 ohms Serviceable Circuit breaker must be replaced with exact current rating Replace power harness if no continuity Component Battery Charger Location Stored inside a pouch on the seatback Function Recharges bat
24. lowed to ensure proper fit and function 13 Install the new motor brake assembly 14 Replace either left or right side back onto the frame and reinstall the two snap rings 14 Replace the drive wheel 14 Reconnect motor either left or right to the power module 15 Replace either left or right rear wiring tie wraps 16 Reinstall the batteries 17 Reinstall the center shroud and seat post 18 Reinstall all other shrouds 19 Reinstall the seat 20 Reconnect the bus cable to the control unit Joystick 21 Power on and test the power chair Figure 9 Drivetrain Assembly Left side shown 23 Compass Sport SG REVA 041211 POWER MODULE 1 Turn off power 2 Place the power chair in drive mode 3 Disconnect the bus cable from the control unit Joystick 4 Remove the seat 5 Remove the rear battery cover 6 Disconnect the motor harnesses M2 and M1 the power harness and the bus cable from the power module 7 Remove the power module from the battery box by removing the two screws securing it See figure 10 8 Install the new power module onto the battery box 9 Reconnect the motor harnesses M2 and M1 the power harness and the bus cable to the new power module 10 Reinstall the battery box cover 11 Reinstall the seat 12 Connect the control unit Joystick to the bus cable 13 Power on and test the power chair Battery Cable Motor Harness Power Harness y Motor Harness uf I Left
25. otector LB D 11S Protector Own 0 3000411010 Protector Pads T 0 2 Protector Own 4 05 SE06A612 Cable Battery for the Circuit Breaker Assembly for GC240 GC340 GC440 left Compass 4 GP605 front ree wim Las Los rares EN eee aee puan sarengate NN NEN 50 51 Compass Sport SG REVA 041211 Compass Sport SG REVA 041211 22 Compass Sport SG REVA 041211 d GOLDE technologies N Golden Technologies 401 Bridge Street Old Forge PA 18518 www goldentech com COMPASS SPORT SG REVA 041211 53
26. r will see then plug the battery charger into the charger port and charge for 8 hours e Ifthe batteries will not charge replace both batteries D If the voltage is dropping too quickly perform a load test on the batteries using a load tester If you do not have access to a load tester you can load test by performing the follow steps e Place the meter leads into the outside pins of the battery charger port as shown in figure 2 Sit in the power chair and drive it e After an initial drop the voltage should hold steady at approximately 24VDC or higher when driving with a load on the chair e Ifthe voltage continues to drop while driving replace BOTH batteries Figure I Figure 2 15 Compass Sport SG REVA 041211 Step 2 Check for FLASH CODES Flash Codes Flash codes indicate the nature of an abnormal condition directly from the SHARK Information Gauge Without the use of any servicing tools the condition can be simply diagnosed Note An Amber wrench shaped LED as shown above will display a series of flashes that give the user visual feedback of the current fault condition Flash Code Description Possible stall timeout or user error User Fault Release the joystick to neutral and try again Try charging the battenes Battery Fault Batteries may require replacing Check the batteries and cabling Left Motor Fault Check the left motor connections and cabling Right Motor Fault Check
27. re there is no power to the circuit Unplug the front and rear battery harnesses from the power harness 11 Measure Resistance across the terminals on the circuit breaker e Less than 10 ohms Go to the next step e Open Replace the circuit breaker Compass Sport SG REVA 041211 SCENARIO 1 Continued 12 Check continuity across the circuit breaker wires of the power harness and across the battery wires of the power harness Repair or replace the power harness as necessary 13 Check continuity across both the front and the rear battery harnesses If open check in line fuse and replace fuse or harness as necessary Fuses must be replaced with exact type and rating Note When checking continuity visually inspect wires connectors and pins for any damage and to make sure the pins are seated properly in their connectors SCENARIO 2 Batteries Will Not Charge Shark Charging Test NOTE Battery chargers will not charge the batteries unless the battery voltage is 18 VDC or above and there is a closed circuit between the batteries The circuit breaker completes that circuit Make sure that the circuit breaker is reset If necessary use a set of known good batteries 1 Check the voltage across pin 1 and pin 2 on the charger XLR connector t AM Note The charger must be plugged in and turned to the on position Greater than 24VDC Go to the next step MO Less than 24VDC Try another wall outlet or known good
28. ripped but does not reset Remove the seat and front battery box cover Go to step 12 2 Measure voltage across pin B and pin 2 B on the control unit Joystick charging socket Co OVDC Go to the next step Q e 25VDC or battery voltage Replace the control unit A socket Do not allow the meter leads to touch each other which will cause a short WARNING Prevent damage to the Joystick Be careful when inserting the meter leads into the charging 3 Disconnect the bus cable from the control unit Joystick 4 Measure voltage across pin 1 and pin 4 on the bus cable e OVDC Go to the next step e 25VDC or battery voltage Replace the control unit Joystick 5 Remove the seat 6 Remove the rear battery box cover 7 Disconnect the bus cable from the power module 8 Measure voltage across pin and pin 4 on the power module e OVDC Go to the next step e 25VDC or battery voltage Replace bus cable A power module Do not allow the meter leads to touch each other which will cause a short WARNING Prevent damage to the Shark power module Be careful when touching the leads on the 9 Disconnect the power harness from the power module 10 Measure voltage across the pin 1 and pin 2 on the power harness e OVDC Go to the next step e 25VDC or battery voltage Replace the power module A WARNING Before attempting to measure resistance make su
29. splay for any given state Display Description This means All LEDs OFF Power is OFF All LEDs ON Power is ON Less LEDs imply a steady reduced battery charge Left RED LED Battery charge is low The batteries should be is flashing charged as soon as possible a ES e Right to left SHARK is being To unlock SHARK press N Gage chase brought out of Lock the Horn button twice Nu mode within 10 seconds ur E chases Sah alternating and or charging of battery charge steady with steady mode display 10 Left to right SHARK is in The steady LEDs mz chase programming inhibit indicate the current state Compass Sport SG REVA 041211 SCENARIO 1 Press the on off button and the LED array does not light up Before attempting to troubleshoot the power chair make sure all connectors are connected and seated properly Make sure that the batteries are connected properly and fully charged Refer to the wiring diagrams on pages 13 and 14 for the correct wiring If the batteries are not fully charged or connected properly then voltage measurements may produce faulty readings Measure the voltage across the rear battery negative black terminal and the front battery positive red terminal to get battery voltage If the batteries will not charge go to Scenario 2 Batteries will not charge 1 Check the circuit breaker e fitis tripped Reset it e Not tripped Go to the next step T
30. t Assembly for Compass Sport GP605 Arm Left Assembly for Compass Sport GP605 for Compass Sport GP605 SMH GRC 1818 18x18 High Back Seat Raw me mr Lm eem sement WC9PSIIA Plastic Clamp ET EN TI NE Lu soo see tete E 40 41 Compass Sport SG REVA 041211 Controller Assembly WE03E402 an l l 01 MBC DYNSJ1 Joystick Dynamic Shark REMD Drive black no cable pushbutton controls MBH A3SA Arm Straight fits into joystick mount for Alante GP201R GP202R En 03 04 Compass GP600M GP620M and Compass Sport GP605 03 3003105012 Washer Spring Black Zinc 5 04 3110105012 Screw Large Hex Head Flat Black Zinc M5 16 Compass Sport SG REVA 041211 Right Arm Assembly WE03E405 3110108032 Screw Large Hex Head Flat Black Zinc M8 40 see ame RCE CT EN Lo voan Lasagnes worse messe worse rimar 42 43 Compass Sport SG REVA 041211 3110604041 Screw Crossed Pan Head White Zinc M4 8 3111804012 EN pe Head Countered sunk Self Tapping White Zinc worse o ET 0000000 3 WC9P419A Adjustable Knob WC9P418A Tube Arm Bottom Bent For Compass Sport GP605 m mes ies SRE a NE 0 1 Lm worms esto O OOOO OOOO O O 3111804012 o e Head Countered sunk Self Tapping White Zinc Compass Sport SG REVA 041211 fi fa Lay CS Ch Left Arm Assembly WE03E403C ITEM PART NO DESCRIPTION Qe EM 3100208012 Pad Arm
31. ter is accurate You should have 0 ohms at this point If not your meter needs to be calibrated e Place the red and black meter leads on the two outside pins of the connector on the motor as shown in figure 3 e Meter reading should be between 0 3 and 5 ohms e Any reading outside this range replace the motor B Check the resistance of the M2 motor connector on the controller e Disconnect the battery from the controller e Set your meter to the 200k ohm scale e Touch the leads together to make sure the meter 15 accurate You should have 0 ohms at this point If not your meter needs to be calibrated e Place the red and black meter leads on the two outside pins of the M2 motor connector on the controller as shown in figure 4 e Meter reading should be 22k ohms e Any reading outside this range replace the controller C If the reading 15 within range and the controller still displays a flash code check the wiring for visible damage and that all cables are connected properly Make sure all connectors are seated properly in their connectors Figure 3 Figure 4 17 Compass Sport SG REVA 041211 Flash Code 4 Right Motor Fault A Check the resistance of the right motor to determine if the fault is in the motor or the controller e Set your meter to the 20 Ohm scale e Touch the leads together to make sure the ohm meter is accurate You should have 0 ohms at this point If not your meter needs to be calibrated e Place the re
32. ter wheel to the caster arm See figure 8 Note Make sure you retain the hardware used to secure the caster assembly 6 Install the new caster assembly 7 Remove the frame support 8 Power on and test the power chair Figure 8 Front Left Caster Assembly shown 22 Compass Sport SG REVA 041211 DRIVETRAIN 1 Turn off power 2 Place the power chair in drive mode 3 Disconnect the bus cable from the control unit Joystick 4 Remove the seat and seat post 5 Remove the battery box covers 6 Remove the center shroud and either the right or the left side shrouds from the frame Note Only the center shroud requires screw removal qty 2 All other shrouds are the snap on type Simply lift up to remove 7 Disconnect and remove the batteries 8 Disconnect the motor either left or right from the power module 9 Cut and remove either left or right rear wiring tie wraps only Note Left side qty 3 Right side qty 2 10 Prop up the center of the power chair so the casters and wheels are off the ground 11 Remove the drive wheel See drive wheel replacement and figure 7 on page 22 Note Drive wheel removal is NOT required if replacing only the brake 11 Remove the two snap rings from either left or right side and pull drive assembly towards you to remove 12 Remove the motor brake assembly See figure 9 Note Motor Brakes are Left Right side specific The instructions you received with the parts MUST BE fol
33. teries Connections XLR connector connects to the charger port on the front of the control module Failure Signs Charger power LED does not go on Batteries will not charge Tests Charger tests vary Some chargers may be tested by measuring positive and negative leads on the charger connector Other chargers need to see battery voltage before charging Expected reading Varies with charger Serviceable Replace if necessary Component Motors 2 Location Left and right sides of the power base Function Drives the power chair Connections The right motor harness connects to M1 on the power module and the left motor harness connects to M2 on the power module Failure Signs Power chair runs slowly or not at all Tests Test for internal resistance in motor Test motor wires for continuity See Flash Codes 3 and 4 Expected readings Internal resistance is less than 5 ohms but not shorted Note Can be as low as 0 3 ohms Serviceable Replace motor if outside range Compass Sport SG REVA 041211 Component SHARK Power Module Location Rear of the power base Function Monitors the system and displays faults when something in the system 15 out of range These faults are displayed as a series of flashes by the battery meter Connections Control unit joystick DCI not used M1 right motor 24V power harness from batteries M2 left motor Refer to figures 1 and 2 on pages 11 and 12 Failure Signs Flash Code 8 Tests Meas
34. tery 12 Footplate 13 Power Harness with Circuit Breaker 14 Left Side Drive Train 15 Power Module Shark 16 Bus Cable 17 Rear Battery 18 Control Unit Joystick D IN m Compass Sport SG REVA 041211 About the Compass Sport Service Guide This service guide provides you with the information necessary to troubleshoot the Golden Technologies Compass Sport equipped with the Dynamic Shark controller The troubleshooting scenarios in this manual consist of procedures that enable you to systematically trace and correct faults in the system Before troubleshooting check the following e Make sure that the circuit breaker is reset e Visually check terminals for corrosion Check wires for missing insulation Make sure that the batteries are fully charged and in good working order When possible keep sets of known good batteries of various ratings in your shop at all times The Compass Sport uses 35AH U1 batteries Problems that surface during troubleshooting are often due to the fact that the batteries are not fully charged or can not hold their charge Make sure that the electrical connections are secure Unplug the connectors and make sure all of the pins are seated properly Push the pins back into the connector housing if necessary Make sure that the battery terminals are tight NOTE If you get to a point during troubleshooting where you cannot continue call tech support at 800 624 6374 COMPASS SPOR
35. ure voltage at SHARK Bus Connector pin battery positive and pin 4 battery negative Expected readings Battery voltage Serviceable Replace as necessary Component SHARK Control Unit Joystick Location End of the armrest Function Provides user interface to the power chair Also shows battery charge and status of control system Connections XLR charger programming port on the front of the control module Bus cable connection on the back of the control module Failure Signs Flash Code 7 Tests Measure voltage at pin 1 battery positive and pin 2 battery negative Expected readings Battery voltage Serviceable Replace as necessary Component SHARK Bus Cable Location Rear of SHARK Control Unit Joystick Function Provides connectivity to the SHARK power module Connections 4 pin quick connect bus cable Failure Signs Flash Code 9 Tests Measure continuity Expected readings Less than 10 ohms Serviceable Replace if open Compass Sport SG REVA 041211 The SHARK Battery Gauge The Battery Gauge 15 used to indicate power on and provides an estimate of the remaining battery capacity Any green LEDs lit indicate well charged batteries If only amber and red LEDs are lit the batteries are moderately charged Recharge before undertaking a long trip If only red LEDs are lit the batteries are running out of charge Recharge as soon as possible The following table indicates what the gauge will di
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