Companion Service Guide
Contents
1. GOLDE technologies N Companion Service Guide This Service Guide contains Troubleshooting Replacement Instructions 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 WWW GOLDENTECH COM info goldentech com PAGE 2 Table of Contents ABOUT THE COMPANION SERVICE 4 Compamomn c omboHe His PUEDE MEME EM 4 SCENARIO 1 TURN THE KEY TO THE ON POSITION AND 2 47 2 13 SCENARIO 2 BATTERIES WON T CHARGE eeessssscecccssscccccsssecoccsssececccsssccocosssececcsssecososssececssssseecesssscessssseese 14 LODES oe E E EEO O Mi 15 FLASH CODE Fl Batteres Low Scooter may drive conus iei Nun eo kni rnrn nE AIT Tg Eara A 15 FLASH CODE 2 Batteries Low Scooter will not operate sci 15 FLASH CODE I AUT Yolla E aee EA r 15 FLASH CODE F4 Current Limit TURO OU 15 PLASH E 16 FLASH CODE Paddle Fauli of Neutral 17 FLASH CODE 7 Paddle Fault Speed Control Fault volta2. Remove the seat Remove the rear shroud Remove the batteries Separate the front and rear frames Turn over the front frame Remove the controller cover Turn the speed pot to full rabbit Set your multimeter to measure resistance Disconnect the main harness from the controller Insert multimeter probes into the main harness connector 9 at pin 8 and pin 2 blue wire and orange wire See figures 13 and 14 e 5k ohm 10 Note the resistance reading and go to the next step e Outside that range Go to step 12 WWW GOLDENTECH COM info goldentech com PAGE 17 11 Insert the multimeter probes into the main harness connector 9 at pin 1 and pin 8 blue wire and yellow wire See figures 13 and 14 Note the resistance reading Insert the multimeter probe into the main harness connector at pin and pin 2 yellow wire and orange wire Note the resistance reading e both readings within 500 ohms of the resistance measured in step 10 Replace the controller e Are either readings outside that range Go to the next step 12 Remove the 8 screws that fasten the back tiller shroud to the front tiller shroud 13 Disconnect the main harness 9b from the throttle pot 14a 14 Insert multimeter probes into the throttle pot connector 14a at the blue wire and the orange wire outside two pins e 5k ohm 10 Note the resistance reading and go to the next step e Outside that range Replace the throttle pot 15 In
3. SE06E605 e Taillights 18 SE06E502 LIGHT L SE06A505 LIGHT R SE06A504 Front Intermediate Light Harness 19 SE06E608 e Rear Intermediate Light Harness 20 SE06E607 e Off Board Battery Charger MBE ASHPC3 WWW GOLDENTECH COM info goldentech com PAGE 4 NOTE number after each component refers to the components position in figure 13 on page 10 Component 50 amp Circuit Breaker 1 Location Mounted on the front frame under the seat See figure 1 Function Protects battery circuit from current overload When the current draw exceeds the breaker rating the circuit breaker will open Connections The circuit breaker is connected to the power harnesses 6b and 7b Failure Signs Opens repeatedly May indicate failed circuit breaker or short in the wiring May also open if the motors are overloaded from excessive weight short in system etc Test Measure the resistance across the circuit breaker Expected reading Less than 10 ohms Serviceable Circuit breaker must be replaced with exact current rating Component 12VDC U 1 Batteries 2 and 3 Location Connected in series under the rear shroud See figure 2 Function Supply 24VDC to the motor and or accessories 12VDC x 2 Connections Positive and negative terminals connect to the Battery Harnesses 4 and 5 Failure Signs Batteries drain quickly Scooter runs slowly or not at all Batteries will not charge but charger is working pro
4. from the rear intermediate motor harness 10b 10 Make sure that the pins are seated properly 10b Check the continuity between 11 114 and 105 e 10 ohms or less Go to step 17 e Open Go the next step 11 Turn the scooter back over 12 Remove the batteries 13 Separate the front and rear sections of the scooter WWW GOLDENTECH COM info goldentech com PAGE 18 14 Inspect the front and rear intermediate motor harness connectors Are they discolored or corroded e Yes Replace as necessary e No Go to the next step 15 Take a quarter and slide into the contacts marked and on the front intermediate motor harness connector See 1 in figure 16 Does each contact hold the quarter firmly in place e No Replace the front intermediate motor harness e Yes Go to the next step 16 Check the front intermediate motor harness and the rear intermediate motor harness for continuity e 10 ohms or less Go to the next step e Open Replace as necessary 17 Make sure that the pins are seated properly on 12a 18 Measure resistance across pin 1 thick red wire and pin 2 thick black wire on 12a 50 ohms or less but not shorted NOTE Can be as low as 0 2 ohms Replace the controller e Out of that range Go to the next step 19 Remove the brushes from the motor and inspect them See figure 17 Indications of a bad brush include broken springs cracked carbon black or discolo
5. 13 15 Disconnect the key switch connector from the control panel harness Make sure that the key 15 in the on position Measure continuity across the two pins on the key switch connector Continuity Replace the control panel wiring harness Open Replace the key switch Scenario 2 Batteries Will Not Charge Most battery chargers need to see least 16 at the charger port Otherwise they may not send a charging current to the batteries This test will ensure that the battery voltage is making it to the charger port You will need to check battery voltage at the batteries at the controller out of the controller and at the charger port Refer to Appen dix D Check Battery Charger Voltage 1 2 3 4 Remove the seat Remove the rear shroud Plug the charger into the charger port and then into a wall outlet Measure voltage across the terminal with the red wire on one battery and the terminal with the black wire on the other battery Does the voltage increase e Yes Load test the batteries and replace as necessary e No But there is voltage If the voltage is lower than 16VDC then replace the batteries If the voltage is 16VDC or greater then go to the next step e No And there is no voltage Check the circuit breaker the wire harnesses and the battery harness fuse for continuity Replace the individual components as necessary Check Voltage Into the Controller 5 6 7 8 9 Make sure the
6. 15 16 17 18 Make sure that the batteries are secure Lower the tiller Turn the scooter over onto its side Remove the controller cover Disconnect the front intermediate motor harness 11 and 11d from the controller Make sure that the pins are seated properly on 1 0b Check the continuity between 11c 11d and 10b e 10 ohms or less Replace the controller e Open Go the next step Turn the scooter back over Remove the batteries Separate the front and rear sections of the S cde scooter Figure 16 Front Intermediate Motor Harness Disassembled for E Inspect the front and rear intermediate motor clarity harness connectors Are they discolored or corroded e Yes Replace as necessary e No Go to the next step Take a quarter and slide into the contacts marked and on the front intermediate motor harness connector See 1 in figure 16 Does each contact hold the quarter firmly in place e No Replace the front intermediate motor harness e Yes Go to the next step Check the front intermediate motor harness and the rear intermediate motor harness for continuity e 10 ohms or less Replace the controller e Open Replace as necessary FLASH CODE 5 BRAKE FAULT This Flash Code appears because the park brake release switch is active or the park brake may be faulty Turn the key to the off position Disengage and then re engage the park brake Turn the key
7. CODE 5 BRAKE FAULT or less but not shorted Shorted or Open 10 Ohms or less WWW GOLDENTECH COM info goldentech com PAGE 34 10 ohms or less 80 ohms or less but not shorted Shorted or open WWW GOLDENTECH COM info goldentech com PAGE 35 FLASH CODE 6 PADDLE FAULT OUT OF NEUTRAL WWW GOLDENTECH COM info goldentech com PAGE 36 FLASH CODE 47 PADDLE FAULT SPEED CONTROL FAULT VOLTAGE ERROR 5k ohm 10 Outside that range Are either readings outside that range WWW GOLDENTECH COM info goldentech com PAGE 37 5k ohm 10 Outside that range 10 ohms or less on each one Open on any wire WWW GOLDENTECH COM info goldentech com PAGE 38 FLASH CODE 8 MOTOR VOLTAGE FAULT OPEN 50 ohms but not shorted NOTE Can be as low as 0 2 ohms Out of that range Open 10 Ohms or less but not shorted WWW GOLDENTECH COM info goldentech com PAGE 39 Not worn or physically damaged Worn or physically dgmaged 50 ohms orjless but not shorted Out of that range NOTE Can be as low as 0 2 ohms WWW GOLDENTECH COM info goldentech com PAGE 40 GOLDE Golden Technologies 401 Bridge Street Old Forge PA 18518 technologies www goldentech com Your Life In Motion GCX40SERVMAN REV50
8. See 1 on figure 26 4 Remove the fuse Ei 5 Install a new fuse Se 6 Reinstall the back shroud onto the tiller Figure 26 Control Panel Fuse WWW GOLDENTECH COM info goldentech com PAGE 22 CIRCUIT BREAKER REPLACEMENT Tools needed Slotted screwdriver Phillips screwdriver adjustable wrench p 10 11 12 13 14 I5 16 17 18 Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the rear shroud Remove the batteries Use a slotted screwdriver to pry off the circuit breaker cover See 1 on figure 27 Slide the plastic covers off of the circuit breaker terminals Remove the two 2 screws that fasten the circuit breaker to the battery connectors See 72 on figure 27 Use a socket or an adjustable wrench to remove the nut that fastens the circuit breaker to the bracket See 3 on figure 27 Use a Phillips screwdriver to disconnect the power harness from the circuit breaker See 4 on figure 27 Install the new circuit breaker onto the bracket Reinstall the bracket onto the battery connectors Figure 27 Circuit Breaker Connect the power harness to the new circuit breaker Reinstall the batteries Insert the key and turn on the scooter to check the circuit breaker function Turn off the scooter Reinstall the shroud Reinstall the seat CONTROLLER REPLACEMENT Tools needed Phillips screwdriver
9. 1522 02 0 oS 10 NOTE Make sure not to mix up the red black motor wires with the red black battery wires 11 12 19 14 Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the rear shroud Remove the batteries Lower the tiller all the way down to its lowest position Separate the front of the scooter from the rear Turn the front frame onto its side Remove the four 4 screws that fasten the controller cover to the frame Unplug the wires from the controller See 1 on figure 28 Figure 28 Controller Remove the two 2 screws that attach the controller to the frame See 2 on figure 28 Install the new controller onto the frame Plug the wires into the controller Reinstall the controller cover WWW GOLDENTECH COM info goldentech com PAGE 23 15 Reconnect the front and rear frames 16 Reinstall the batteries 17 Reinstall the rear shroud 18 Reinstall the seat CHARGER HARNESS FUSE REPLACEMENT 1 Place the freewheel lever in the engaged position Remove the eight 8 screws that fasten the back tiller shroud to the tiller 3 Unplug the charger harness from the main harness 4 Open the fuse holder located on the red wire See 1 on figure 29 5 Remove the fuse 6 Install a new 10A fuse Plug the charger harness back into the main harness 7 Reinstall the back tiller shroud onto the tiller _ MAIN HARNESS REP
10. IGHT HARNESS 20 REAR INTERMEDIATE MOTOR HARNESS 10 Figure 13 Companion Wiring Diagram WWW GOLDENTECH COM info goldentech com PAGE 10 CONNECTOR 9a 1 5 E D in D BURNT ORANGE ORANGE GREEN BLACK PURPLE LLI gt 1 NC lt e 14 CONNECTOR 9a 7 Front View a gt Lu lt W gt 2 OF lt 5 8 CONNECTOR 9b 1 e e e e 4 Front View RED gt za 5 su TI gt CONNECTOR 9b 7777 j 5 CL I Y E LL CHARGER HARNESS NOTE Color shades vary Figure 14 Companion Wiring Schematic WWW GOLDENTECH COM info goldentech com PAGE 11 8 9 C MOTI3A 3501 NYOH 1 N3385 bU JDNVEO JDNVYO Yov 1d mm 80 Dy 8 1331 HOIIMS 1 9 CHOW 90 Os H2LIMS NYOH HDLIMS NYOH vL n 0418 31IHM NS 9 NMOS aa JONVHO u313W eT aJi 5 1 15 add HOLIMS A3 NOTE Color shades may vary Figur
11. LACEMENT 340 Tools needed Phillips screwdriver adjustable wrench Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the rear shroud Remove the batteries Separate the front and rear frames Remove the eight 8 screws that fasten the back shroud to the tiller 8 Disconnect the main harness from the control panel the charger harness the paddle pot and the headlight LEDs 9 Remove the four 4 screws that fasten the front tiller shroud and the basket bracket to the tiller 10 Remove the carpet 11 Remove the six screws that fasten the floorboard and front shroud to the front frame See 1 on figure 30 i 23 20 du Figure 31 Main Harness Upper Clip WWW GOLDENTECH COM info goldentech com PAGE 24 12 13 14 15 16 17 18 1 20 21 22 23 24 28 26 24 28 29 30 31 225 33 34 23 36 37 38 39 WWW GOLDENTECH COM Remove the upper main harness clip See 1 on figure 31 Remove the lower main harness clip See 1 on figure 32 Unscrew the nut that secures the headlight LEDs See 2 on figure 32 Feed the main harness through the rubber boot and through the front shroud opening Turn the front frame over onto its right side Remove the controller cover Disconnect the 14 pin main harness connector from the controller See 1 on figure 33 Disconnect the 2 pin mai
12. NG DIAGR A E Ea etae EN e Ran Een n ERES MENS RE SU PROS ERE 28 APPENDIX D TROUBLESHOOTING FLOW CHARTS eee ee eee eee eoe eese eo ette ees etes ees ette eese eee eos 29 WWW GOLDENTECH COM info goldentech com PAGE 3 About the Companion Service Guide This service guide provides you with the information necessary to troubleshoot the Golden Technologies Com panion GC 240 GC 340 and GC 440 equipped with the R Series Controller The troubleshooting scenarios in this manual consist of procedures that enable you to systematically trace and correct faults in the system Appendices A and B include instructions on how to use a multimeter to measure voltage and continuity Appendix C includes a copy of figure 13 that may be printed separately Appendix D contains easy to use flow charts of the more complex trouble shooting scenarios Before troubleshooting check the following 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 are in good working order When possible keep sets of known good batteries of various ratings in your shop at all times The Companion uses two 2 35AH UI batteries Problems that surface during troubleshooting are often due to the fact that the batteries are not fully charged or cannot hold their charge Make sur
13. TS 18 FRONT 55 19 Tel e REAR INTERMEDIATE LIGHT HARNESS 20 POWER SEAT TAP CIRCUIT BREAKER 1 FRONT INTERMEDIATE MOTOR HARNESS 11 MAIN HARNESS 9 REAR INTERMEDIATE MOTOR HARNESS 10 WWW GOLDENTECH COM info goldentech com PAGE 28 APPENDIX D TROUBLESHOOTING FLOW CHARTS SCENARIO 1 TURN THE KEY TO THE ON POSITION AND NO POWER 24VDC or battery voltage OVDC p gt More than 16VDC OVDC 24VDC or battery voltage OVDC 24VDC or battery voltage WWW GOLDENTECH COM info goldentech com PAGE 29 24VDC or battery voltage Open Less than 10 ohms Continuity Open WWW GOLDENTECH COM info goldentech com PAGE 30 SCENARIO 2 BATTERIES WILL NOT CHARGE No And there is no voltage No But there is voltage 24VDC or battery voltage 24VDE or battery voltage 24VDC or battery voltage OVDC Open Continuity WWW GOLDENTECH COM info goldentech com PAGE 31 FLASH CODE 4 CURRENT LIMIT TIMEOUT Out of that range 50 ohms or less but not shorted NOTE Can be as low as 0 2 ohms Not worn below 0 26 in or physically damaged Yorn below 0 25 in or physically damaged 10 ohms or less WWW GOLDENTECH COM info goldentech com PAGE 32 10 ohms or less WWW GOLDENTECH COM info goldentech com PAGE 33 FLASH
14. batteries are secure Lower the tiller Turn the scooter over onto its side Remove the controller cover Measure voltage across 6c and 7c 24VDC or battery voltage Go to the next step Check circuit breaker and wire harnesses for continuity Replace as necessary Check Voltage Out of the Controller 10 Insert the multimeter probes into the terminal with the red wire pin 7 and the terminal with the black wires pin 13 on the back of the main harness connector 9a See figure 14 on page 11 e 24VDC or battery voltage Go to the next step e 0VDC Replace the controller Check Voltage at the Main Harness 11 12 13 14 Remove the rear tiller shroud Disconnect the charger harness from the main harness Measure voltage across the terminal with the black wire pin 7 and the red wire pin 4 on the main harness connector 9d See figure 14 on page 11 e 24VDC or battery voltage Go to the next step e 0VDC Replace the main harness Check the charger harness fuse for continuity e Continuity Replace the charger harness e Open Replace the 10A fuse WWW GOLDENTECH COM info goldentech com PAGE 14 FLASH CODES The controller uses an LED on the console to indicate the status of the system When the key is in the key switch and the light 1s solid green the power 15 and the system is running normally When the controller notices that there 15 a malfunction in the system it wil
15. continuity Check connectors Make sure the pins are not corroded and are seated properly Expected readings Battery voltage Continuity less than 10 ohms Serviceable Replace as necessary Component Rear Intermediate Motor Harness 10 Location On the right side of the rear frame See figure 6 Function Provides connectivity for Motor Brake Assembly 12 and the Front Intermediate Motor Harness 11 Connections Connects to the Front Intermediate Motor Harness 11a and the Motor Brake Assembly 12a Failure Signs Scooter will run slowly or not at all Tests Test for voltage and continuity Check connectors Make sure the pins are not corroded and are seated properly Expected readings Continuity less than 10 ohms Figure 6 Rear Intermediate Motor Harness Serviceable Replace as necessary WWW GOLDENTECH COM info goldentech com PAGE 6 Component Front Intermediate Motor Harness 11 Location On the right side of the front frame See figure 7 Function Provides connectivity for Rear Intermediate Motor Harness 10 and the Controller 8 Connections Connects to the Rear Intermediate Motor Harness 10a and the Controller 8b 8c and 8d Failure Signs Scooter will run slowly or not at all Tests Test for voltage and continuity Check connectors Make sure the contacts are not corroded See figure 16 on page 16 for quarter test Expected readings Continuity less than 10 ohms Serviceable Replace as nec
16. cts to the charger port on the tiller 13a Charger harness is located inside tiller Connects the charger to the main harness 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 See charger test Test charger harness and 10A 250V fuse for continuity Serviceable Replace if necessary NOTE Some Off Board Battery Chargers may have a switch that enables them to be used with either 110 VAC or 230 VAC This switch is typically located on the end of the charger Some may also have a removable 10A 250V glass fuse Figure 12 Rear Intermediate Motor Harness WWW GOLDENTECH COM info goldentech com PAGE 9 LEFT SPEED POT 15 HORN E 3 BUTTON I 125A Fuse lo THROTTLE POT 14 m mL d HEADLIGHT LEDS 17 125A Fuse BATTERY NA IZ E HARNESS 5 DYNAMICS RHINO POWER CONTROLLER 8 HARNESS 6 CHARGER HARNESS Te TAILLIGHTS 18 POWER SEAT TAP CIRCUIT BREAKER 1 FRONT INTERMEDIATE MAN AARNES 2 MOTOR HARNESS 11 FRONT INTERMEDIATE LIGHT HARNESS 19 REAR INTERMEDIATE L
17. ds on direction of deflection WE Serviceable Replace as necessary Figure 9 Charger Harness WWW GOLDENTECH COM info goldentech com PAGE 7 Component Speed Pot 15 Location Control Panel See figure 10 Function The speed potentiometer pot uses variable resistance to control the top speed of the scooter Connections Control Panel Harness Failure Signs Flash Code 7 Tests Call Tech Support Expected readings Depends speed pot position ES DS KEY SWITCH Serviceable Replace the Control Panel 5 A nc M SPEED POT _ Component Key Switch 16 Location Control Panel See figure 10 Function Completes the circuit to provide power to the motor Connections Control Panel Harness Failure Signs No power when the key is in the ON position Tests Continuity when the key 15 in the position Make sure the connector pins are seated properly Expected readings Less than 10 ohms Serviceable Replace as necessary Component Headlight LEDS 17 Location Tiller Function Provides lighting Connections Main Harness Failure Signs No lights Tests Check voltage to headlights with power switch on Expected readings Battery voltage Serviceable Replace as necessary Component Taillights 18 Location Rear frame Function Provides lighting Connections Rear Intermediate Light Harness E Failure Signs No lights Tests Check voltage to tail lig
18. e 15 Companion Wiring Schematic Control Panel info goldentech com PAGE 12 WWW GOLDENTECH COM Scenario 1 Turn the Key to the On Position and Power Put the key into the key switch and turn to the on position There is no power to the control panel The horn does not work the lights do not work and the battery condition meter does not work Battery voltage travels from the batteries through the controller and the key switch The test below will verify that there is battery voltage at the batteries the controller the main harness and the key switch Refer to Appendix D NOTE Make sure that the batteries are fully charged and connected properly Refer to the battery connection diagram under the rear shroud f the batteries are not fully charged and connected properly then voltage mea surements may produce faulty readings Measure voltage across the battery terminals that have the black wire and the red wire to get total battery voltage approximately 25VDC Reference figure 1 If the batteries will not charge go to Scenario 2 Batteries will not charge Check Battery Voltage 1 Remove the seat 2 Remove the rear shroud 3 Measure voltage across the terminal with the red wire on one battery and the terminal with the black wire on the other battery e 24VDC or battery voltage Go to the next step e More than 16VDC Try to recharge the batteries Load test and replace 1f necessary e 0VDC Check the batte
19. e 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 1f 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 COMPANION COMPONENTS The Companion is a battery operated scooter controlled by a Dynamics R Series controller The R Series controller monitors the system and displays flash codes when it detects a fault in the system The Companion was designed to operate within a range of between 18 24 volts V of direct current DC The Companion control system is made up of the following components NOTE The number after the component refers to the components position on figure 13 on page 10 Circuit Breaker 1 e 12V U 1 Batteries 2 and 3 MBE BATTU 1 e Battery Harnesses 4 and 5 4 SE06A612 BATTERY CABLE LEFT 5 SE06A614 BATTERY CABLE RIGHT Power Harnesses 6 and 7 6 amp 7 sold as set SE06E602 Dynamics R Series Controller 8 3051600100 e Main Harness 9 240 SE06A611240 340 5 06 611340 440 SE06A611440 e Rear Intermediate Motor Harness 10 SE06E604 Front Intermediate Motor Harness 11 SE06E606 e Motor Brake Assembly 12 MBX CMBAR e Charger Harness 13 SE06A610 Throttle Pot 14 SE06E603 e Speed Pot 15 N A e Key Switch 16 SE06A609 Headlight LED 17
20. eaker 1 6c and 7c connect to the Controller 8 Failure Signs Batteries will not charge but charger 15 working properly No power to the controller Tests Test harnesses for continuity Check connectors Make sure the contacts are not corroded and are seated properly Expected Readings Continuity less than 10 ohms Serviceable Replace as necessary Component Controller 8 Location Under the front frame See figure 4 Function Controls and monitors the system It displays faults through the status light when something in the system is out of range Connections Main Harness 9a Front Intermediate Motor Harness 116 11c and 11d Power Harnesses 6c and 7c Failure Signs Flash Code 9 No power to the Control Panel or the Motor Tests Test for voltage to motor and to the Control Panel Expected readings Battery voltage Serviceable Replace as necessary Component Main Harness 9 Location Inside the tiller shown in figure 5 and under front frame Function Provides connectivity for the tiller components and the controller Connections Connects to the Control Panel the Headlight LEDs the 5 Main Harness Tiller Side Throttle Pot 14a and the Charger Harness 13b in the tiller Con nects to the Controller 8a the Front Intermediate Light Harness and the Optional Power Seat under the front frame Failure Signs Batteries will not charge Scooter will not run Tests Test for voltage and
21. essary Component Motor Brake Assembly 12 Location Rear section of scooter on the transaxle See figure 8 Function Drives the scooter Connections Motor and Brakes 12a to Rear Intermediate Motor Harness 1 0b Failure Signs Scooter runs slowly or not at all Tests Test for internal resistance in motor Test motor wires for continuity See Flash Code 5 and 8 Expected readings Internal motor resistance 15 less than 50 ohms but not shorted Brake resistance is less than 80 ohms but not shorted Serviceable Replace the motor brake assembly or motor brushes Component Charger Harness 13 Location Inside the tiller Function Provides connectivity for the battery charger and the main harness 9 Connections Connects to the battery charger at 13a and to the main harness 9d Failure Signs Batteries will not charge Tests Test for voltage and continuity Check connectors Make sure the pins are not corroded and are seated prop erly Check fuse Expected readings Continuity less than 10 ohms Serviceable Replace the 10A fuse or harness as necessary Component Throttle Pot 14 Location Control Panel See figure 10 Function The throttle potentiometer pot uses variable resistance to control speed and direction of travel by varying voltage Connections Main Harness 9c Failure Signs Flash Codes 6 and 7 Tests Test resistance across the pins 1 and 3 and on 14a Expected readings Depen
22. ge pete es uua uo damduxto Ia 17 FLASH CODE 5 Motor Voltage ODE Md tI MM eM E MEME iN T NM T 18 COD L COMO NCE d UNE m 19 COMPANION REPLACEMENT INST RUC TIONS scscsssccscssscsscesessessvascnesvscseanenssesvoseeenssvsecsntuansevestecsssvseesconsasesns 20 Motor Brake Assembly Replacement ee ne tu sre umm vee M UNA IUE 20 0 21 IDG WC SWING BAC eti DR NIU MM UNIES MAI Ma IE UU NM INE 21 Bale VAC mI HIE eee cadence nup Momentos mum a MEE es ieu IUUENIS BEIM 21 Por E 22 I CCS IR ING AC CIBO HE 22 ConoLPaseL Dnse 6 T 22 ricerca AK ACN Nm 23 R 23 Charmer Fuse 24 Main Harness 0 PRENNE nese 24 APPENDIX HOW USE VOLTMETER be 26 APPENDIX B HOW TO USE AN OHM METER svicsccsescscessuscescnessseesenensevsvsssveneeseyoencossssansencesersneeseensssececeusevtersees 27 APPENDIXC WIRI
23. ge to fall into the red area on the battery meter 2 Check the battery charger Make sure it is an approved charger FLASH CODE 4 CURRENT LIMIT TIMEOUT This Flash Code appears when the motor has been exceeding it s maximum current rating for too long This may be due to a faulty motor poor battery condition excessive uphill driving or excessive weight First turn off the scooter and allow it to cool for ten minutes If this does not work use the following procedure 1 Remove the seat 2 Remove the rear shroud 3 Inspect the connection between the motor brake assembly 12a and the rear intermediate motor harness 10b Are either connectors discolored or melted e Yes Replace motor brake assembly or rear intermediate motor harness as necessary e No Go to the next step 4 Disconnect the motor 12a from the rear intermediate motor harness 106 5 Measure resistance across the two pins on connector 12a that have the thick black wire and the thick red wire internal resistance of the motor 50 ohms or less but not shorted NOTE Can be as low as 0 2 ohms Go to step 7 e Out of that range Go to the next step 6 Remove the brushes from the motor and inspect them e Worn below 0 25 in or physically damaged Replace the brushes e Not worn below 0 25 in or physically damaged Replace the motor brake assembly WWW GOLDENTECH COM info goldentech com PAGE 15 7 8 9 10 11 12 13 14
24. hts with power switch on Expected readings Battery voltage Check bulbs for discoloration or broken filament Figure 11 Front Intermediate Light Harness Serviceable Replace with 24 volt 5 watt bulbs as necessary Component Front Intermediate Light Harness 19 Location On the left side of the front frame See figure 11 Function Provides connectivity for the Rear Intermediate Light Harness and the Main Harness Connections Connects to the Rear Intermediate Light Harness and the Main Harness Failure Signs Rear lights will not go on Tests Test for voltage and continuity Check connectors Make sure the pins are not corroded and are seated properly Expected readings Less than 10 ohms Serviceable Replace as necessary WWW GOLDENTECH COM info goldentech com PAGE 8 Component Rear Intermediate Light Harness 20 Location On the left side of the rear frame Function Provides connectivity for the Front Intermedi ate Light Harness and the Rear Lights Connections Connects to the Front Intermediate Light Harness and the Rear Lights Failure Signs Rear lights will not go on Tests Test for voltage and continuity Check connectors Make sure the pins are not corroded and are seated properly Expected readings Continuity less than 10 ohms Serviceable Replace as necessary Component Off Board Battery Charger Location Stored inside a pouch on the seatback Function Recharges batteries Connections Conne
25. l flash a code when the key 15 inserted into the key switch For ex ample when it flashes five times and stops that indicates flash code 5 Brake Fault Refer to Appendix D The following flash codes are used to help diagnose system errors Flash Code 1 Batteries Low Scooter will operate Flash Code 2 Batteries Very Low Scooter will not operate Flash Code 3 High Battery Voltage Flash Code 4 Current limit timeout Flash Code 5 Motor Brake Fault Flash Code 6 Paddle Fault out of neutral Flash Code 7 Paddle Voltage Fault Flash Code 8 Motor Voltage Fault Open Flash Code 9 Controller Fault FLASH CODE 1 BATTERIES LOW SCOOTER MAY DRIVE SLOWLY This Flash Code appears when the battery voltage drops below a certain level Recharge the batteries immedi ately If they batteries will not recharge then load test them or refer to Scenario 2 Batteries will not Charge FLASH CODE 2 BATTERIES LOW SCOOTER WILL NOT OPERATE This Flash Code appears when the battery voltage drops lower than Flash Code 1 Recharge the batteries immediately If the batteries will not recharge load test them or refer to Scenario 2 Batteries will not Charge FLASH CODE 3 HIGH BATTERY VOLTAGE This Flash Code appears when the battery voltage climbs above 26VDC 1 Insert the key into the key switch and turn it to the on position Allow the battery level to drop Do not allow the battery volta
26. lug the probes into the meter Red goes to the positive and black to the negative Step2 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 Step3 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 Step4 Turn the meter on Step5 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 Step6 Read the digital display or analog dial Figure 35 Multitester Set to DC Volts WWW GOLDENTECH COM info goldentech com PAGE 26 APPENDIX HOW USE OHM METER 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 for volt ohmmeter Read on for instructions on how to use an ohmmeter and test for resistance e Ohmmeter or Multimeter Volt ohmmeter e Ci
27. m the old motor brake assembly See 5 on figure 20 15 Install the coupler onto the new motor brake assembly 16 Install the new motor brake assembly onto the transaxle Use the existing hardware 17 Reinstall the transaxle onto the rear frame 18 Reassemble the rear frame assembly 19 Connect the new motor brake assembly to the rear intermediate motor harness 20 Usea wire tie to fasten the motor brake assembly harness to the rear frame 2 Reassemble the front and rear scooter frames 22 Reinstall the batteries 23 Reinstall the rear shroud 24 Reinstall the seat Figure 18 Rear Frame Assembly ar prof nas fedar 722 15 UCU WWW GOLDENTECH COM info goldentech com PAGE 20 MOTOR BRUSH REPLACEMENT Tools needed Slotted screwdriver 0 1 Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the rear shroud Remove the motor brush cap See 1 on figure 21 Remove the brush Install the new brush Reinstall the motor brush cap Repeat for the other brush Reinstall the rear shroud Reinstall the seat DRIVEWHEEL REPLACEMENT Tools needed 19mm socket frame blocks 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Place the rear of the scooter onto blocks 4 Remove the nut and washer that fastens the wheel to
28. n harness connector from the 2 pin taillight connector See 2 on figure 33 Loosen the main harness clamp located just above the front wheel on the front frame See 1 on figure 34 Remove the main harness Install the new main harness under the floor board Make sure that it 1s placed in the channel on the front frame Connect the 14 pin main harness connector to the controller Connect the 2 pin main harness connector to the taillight connector Feed the main harness through the front shroud opening Secure the main harness to the front frame with the main harness clamp located above the front wheel Turn the front frame over Feed the main harness through the rubber boot Secure the main harness and the headlight LED harness to the tiller with the lower main harness clip Secure the main harness and the headlight LED harness to the tiller with the upper main harness clip Reinstall the front tiller shroud Connect the main harness to the control panel the charger harness the paddle pot and the headlight LEDs Reinstall the rear tiller shroud Reinstall the six screws that fasten the front shroud and floorboard to the frame Reinstall the carpet Reconnect the front and rear frame sections Reinstall the batteries Reinstall the rear shroud Reinstall the seat Figure 34 Harness Frame Clamp info goldentech com PAGE 25 APPENDIX A HOW TO USE A VOLTMETER Step P
29. ntrol lever bracket See 2 on figure 24 and lift off the throttle lever Install the throttle lever onto the new throttle pot Install the new throttle pot onto the tiller shroud Connect the new throttle body to the main harness Reinstall the back tiller shroud onto the tiller Figure 24 Throttle Pot E UP E KEY SWITCH REPLACEMENT Tools needed Phillips screwdriver adjustable wrench 1 Place the freewheel lever in the engaged position Remove the key from the key switch 3 Remove the eight 8 screws that fasten the back tiller shroud to the tiller 4 Remove the two screws that fasten the control panel to the front tiller shroud 5 Disconnect the key switch from the control panel harness See 1 on figure 25 6 Remove the nut that fastens the key switch to the control panel See 2 on figure 25 7 Install a new key switch onto the control panel 8 Use the existing nut to fasten the new key switch to aes the control panel Figure 25 Key Switch 9 Connect the new key switch to the control panel harness 10 Reinstall the control panel onto the back tiller shroud 11 Reinstall the back tiller shroud onto the tiller owes SN ev OM NN ET dee CONTROL PANEL FUSE REPLACEMENT Tools needed Phillips screwdriver 1 Place the freewheel lever the engaged position 2 Remove the eight 8 screws that fasten the back shroud to the tiller 3 Open the fuse holder
30. or harness and the rear intermediate motor harness for continuity e 10 ohms or less Go to the next step e Open Replace as necessary Check the pins on the motor brake assembly harness connector 12a Make sure they are seated properly Measure resistance across pin 1 and pin 2 small black wires on the motor brake assembly harness 12a with park brake engaged 80 ohms or less but not shorted Replace the controller e Shorted or open Replace the motor brake assembly FLASH CODE 6 PADDLE FAULT OUT OF NEUTRAL This Flash Code appears because the throttle control lever is not in the neutral position when the key is turned to the on position 1 2 3 4 Turn the key to the position Make sure that the paddle pot 1s not obstructed and it can return to the neutral center position Move the throttle pot forward and then reverse Make sure that it is not obstructed Does it spring back to neutral position e Yes Go to the next step e No Check for obstructions Adjust if necessary Replace if the adjustment does not work or if there are no obstructions Turn the key to the on position Does the code return e No OK e Yes Goto FLASH CODE 77 to test the paddle pot FLASH CODE 77 PADDLE FAULT SPEED CONTROL FAULT VOLTAGE ERROR This Flash Code appears because there 15 a fault with the throttle pot the speed pot or the associated wiring 1 2 3 4 5 6 7 9 10
31. perly Flash Code 1 or Z2 Tests Fully charge the batteries first and load test Make sure charging system 15 working See Battery Charging Test Expected Readings 12 14VDC each when fully charged Serviceable Replace batteries as necessary Component Battery Harnesses 4 and 5 Location Connected to the positive and negative terminal on the batteries See figure 2 Function Connects the batteries to the Power Harnesses 6 and 7 Connections 4a and 4b connect to the neg and pos terminals on Battery 2 5a and 5b connect to the neg and pos terminals on Battery 3 and 5c connect to the Power Harnesses Failure Signs Corroded wires may cause the batteries not to work properly Make sure connector pins are seated properly Tests Check the inline fuse on the battery harness Test the harnesses and the 125A fuse for continuity Expected Readings Less than 10 ohms Serviceable Replace 125A fuse and or harnesses as necessary Figure 1 Circuit Breaker UNIVE Al 3 WWW GOLDENTECH COM info goldentech com PAGE 5 Component Power Harnesses 6 and 7 Location Mounted to the front frame under the rear shroud See figure 3 Function Connects the Batteries Harnesses 4 and 5 to the Circuit Breaker 1 and the Controller 8 Connections 6a and 7a connect to the Battery Harnesses 4 and 5 6b and 7b connect to the Circuit Br
32. rcuit to test with all power OFF e Service manual Step 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 Step2 Connect testing wires to the ohmmeter The black wire goes to the ground common outlet the red wire to the volt ohms outlet Step3 Consult a service manual for the normal range of resistance for the circuit you are testing Step4 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 your service manual to set the dial Figure 36 Multitester Set to Ohms WWW GOLDENTECH COM info goldentech com PAGE 27 APPENDIX WIRING DIAGRAM 2 KEY SWITCH 16 LEFT SPEED POT 15 5 BATTERY HORN HORN jE 3 BUTTON BUTTON Wir 125A Fuse lo THROTTLE POT 14 2 E IJ A __ PANEL FUSE HEADLIGHT 125A Fuse LEDS 17 BATTERY HARNESS 4 BATTERY HARNESS 5 DYNAMICS RHINO POWER CONTROLLER 8 HARNESS 6 CHARGER TAILLIGH
33. red wire and black or discolored contacts e Worn physically damaged Replace the brushes e Not worn or physically damaged Replace the motor brake assembly FLASH CODE 9 CONTROLLER FAULT This Flash Code appears when the controller has an internal fault Remove the key from the key switch and allow the controller to cool down If the code continues then replace the controller WWW GOLDENTECH COM info goldentech com PAGE 19 COMPANION REPLACEMENT INSTRUCTIONS MOTOR BRAKE ASSEMBLY Tools needed 13mm socket 5mm hex key 6mm hex key wire cutters 1 Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the rear shroud Remove the batteries Separate the front and rear frames Cut the wire tie that fastens the motor harness to the rear frame See 1 on figure 18 8 Disconnect the motor brake assembly from the rear intermediate motor harness See 2 on figure 18 9 Use the 13mm socket and 6mm hex key to remove the hardware that fastens the two rear frame assembly sections together See 3 on figure 18 10 Separate the rear frame assembly 11 Remove the drivetrain from the rear frame assembly and stand it up onto its right wheel 12 Usea 5mm hey key to remove the screws that attach the motor brake assembly to the transaxle See 74 on figure 19 13 Remove the motor brake assembly from the transaxle 14 Remove the coupler fro
34. ry fuse for continuity Replace with 125A fuse if necessary Check main circuit breaker 1 and main power harnesses for continuity 6a to 6b 6c and 7a to 7b 7c Replace as necessary Check Voltage at Controller 4 Make sure that the batteries are secure 5 Lower the tiller 6 Turn the scooter over onto its side 7 Remove the controller cover 8 Measure voltage across 6c and 7c on each power harness e 24VDC or battery voltage Go to the next step e 0VDC Check circuit breaker and wire harnesses for continuity Replace as necessary Check Voltage out of Controller 9 Make sure that the power harness is plugged back into the controller 10 Insert the multimeter probes into the terminal with the red wire pin 7 and the terminal with the black wires pin 13 on the back of the main harness connector 9a See figure 14 on page 11 e 24VDC or battery voltage Go to the next step e 0VDC Replace the controller Check Voltage at Main Harness 11 Remove the rear tiller shroud 12 Disconnect the main harness 9b from the control panel harness 13 Measure voltage across the main harness terminals with the red wire and the black wire e 24VDC or battery voltage Go to the next step e 0VDC Replace the main harness Check Key Switch 14 Open the control panel fuse holder Check the fuse for continuity e Open Replace the fuse e Less than 10 ohms go to the next step WWW GOLDENTECH COM info goldentech com PAGE
35. sert the multimeter probes into the throttle pot connector 14a at the blue wire and the yellow wire Note the resistance reading Insert the multimeter probe into the main harness connector at the yellow wire and the orange wire Note the resistance reading e both readings within 500 ohms of the resistance measured in step 14 Go to the next step e Are either readings outside that range Replace the throttle pot 16 Check the orange blue and yellow wires on the main harness for continuity e 10 ohms or less on each one Replace the speed pot e Open on any wire Replace the main harness FLASH CODE 8 MOTOR VOLTAGE FAULT OPEN This Flash Code appears when there is an internal problem with the motor or its wiring 1 Remove the seat 2 Remove the rear shroud 3 Make sure that the batteries are secure 4 Lower the tiller 5 Turn the scooter over onto its side 6 Remove the controller cover 7 Disconnect the front intermediate motor harness 11 and 114 from the controller 8 Measure resistance across the front intermediate motor harness 11c and 114 50 ohms but not shorted NOTE Can be as low as 0 2 ohms replace the controller e Out of that range Go to the next step 2 12 M c i y AAA NNI a oe 5 atte 9 a Le a E 090 3 Figure 17 Motor Brush Conditions 9 Unplug the motor brake assembly 12a
36. the axle Make sure you retain the axle key See 1 on figure 22 5 Place anew wheel onto the axle Make sure that the axle key is reinstalled in its original position 6 Reinstall the wheel cover and wheel hardware 7 Tighten securely BATTERY REPLACEMENT Tools needed Phillips screwdriver adjustable wrench pep nd nen 9 10 Il 12 19 WWW GOLDENTECH COM Place the freewheel lever in the engaged position Remove the key from the key switch Remove the seat Remove the shroud Remove the velcro strap Unplug and remove the battery Remove the battery harness See 1 on figure 23 Reinstall the battery harness onto the new battery Tighten the harness hardware securely Place the new battery onto the frame Plug the battery harness into the battery connector Secure the battery and the harness with the Velcro Strap Reinstall the shroud Reinstall the seat Figure 22 Drive Wheel Axle Key UNIVE lt A _ info goldentech com PAGE 21 THROTTLE REPLACEMENT Tools needed Phillips screwdriver 1 Place the freewheel lever in the engaged position Remove the eight 8 screws that fasten the back tiller shroud to the tiller 3 Disconnect the throttle pot from the main harness 4 Remove the two 2 screws that fasten the throttle body to the tiller shroud See 1 on figure 24 5 Remove the two screws that fasten the throttle lever to the throttle co
37. to the on position Did the flash code clear Yes OK e No Go to the next step Remove the seat and the rear shroud Make sure that the batteries are secure Lower the tiller Turn the scooter over Remove the controller cover Disconnect 11b from the controller Make sure that the pins on 11b are seated properly Measure resistance across pin 1 and pin 2 on the front intermediate motor harness 11b with park brake engaged e 80 ohms or less but not shorted Replace the controller e Shorted or open Go to the next step 11 Unplug the motor brake assembly 12a from the rear intermediate motor harness 1 0b 12 Make sure that the pins are seated properly on 10b Check the continuity between 11b 10b e 10 ohms or less Go to step 18 e Open Go the next step WWW GOLDENTECH COM info goldentech com PAGE 16 13 14 15 16 17 18 19 Turn the scooter back over Remove the batteries Separate the front and rear frames Inspect the connection between the front intermediate motor harness 11a and the rear intermediate motor harness 10a Make sure the contacts not corroded Take a quarter and slide into the contacts on 11a not marked and on the connector Similar to 1 in figure 16 Does each contact hold the quarter firmly place e No Replace the front intermediate motor harness e Yes Go to the next step Check the front intermediate mot
Download Pdf Manuals
Related Search