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Golden Companion Service Manual Download Page 7

WWW.GOLDENTECH.COM

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PAGE - 7

Component:

 Front Intermediate Motor Harness (11)

Location: 

On the right side of the front frame. See figure 7.

         

 FRONT INTERMEDIATE MOTOR HARNESS

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 necessary.

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 (10b.)

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 is 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:

 Depends on direction of deflection.

Serviceable:

 Replace as necessary.

Figure 7. Front Intermediate Motor Harness

Figure 8. Motor/Brake Assembly

Figure 9. Charger Harness

CHARGER HARNESS

MOTOR/BRAKE ASSEMBLY

Summary of Contents for Companion

Page 1: ...Companion Service Guide This Service Guide contains Troubleshooting Replacement Instructions ...

Page 2: ...o goldentech com PAGE 2 Contact Information Golden Technologies 401 Bridge Street Old Forge PA 18518 Toll free 800 624 6374 Fax 800 628 5165 Lift Chair Bed Tech x502 Mobility Tech x501 VA Tech x505 Email parts goldentech com ...

Page 3: ... FLASH CODE 6 Paddle Fault out of neutral 17 FLASH CODE 7 Paddle Fault Speed Control Fault voltage error 17 FLASH CODE 8 Motor Voltage Fault Open 18 FLASH CODE 9 Controller Fault 19 COMPANION REPLACEMENT INSTRUCTIONS 20 Motor Brake Assembly Replacement 20 Motor Brush Replacement 21 Drivewheel Replacement 21 Battery Replacement 21 Throttle Pot Replacement 22 Key Switch Replacement 22 Control Panel ...

Page 4: ...ing 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 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 Compa...

Page 5: ...ve 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 properly Flash Code 1 or 2 Tests Fully charge the batteries first and load test Make sure charging system is working See Battery Charging Test Expected Readings 12 14VDC each when fully charged Serviceable Replace batteries a...

Page 6: ...s 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 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 ...

Page 7: ...eadings Internal motor resistance is 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 F...

Page 8: ...k 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 Failure Signs No lights Tests Check voltage to tail lights with power switch on Expected readings Battery voltage Check bulbs for discoloration or broken filament Serviceabl...

Page 9: ...ges batteries Connections Connects 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 cha...

Page 10: ...WWW GOLDENTECH COM info goldentech com PAGE 10 Figure 13 Companion Wiring Diagram 24V 5W bulbs ...

Page 11: ...ompanion Wiring Schematic 8 14 7 1 4 5 8 1 GREEN BURNT ORANGE BLACK PURPLE DARK BLUE YELLOW ORANGE GRAY LIGHT BLUE RED YELLOW RED GREEN GRAY BLACK WHITE BROWN CONNECTOR 9b Front View CONNECTOR 9a Front View CONNECTOR 9a CONNECTOR 9b NOTE Color shades may vary ...

Page 12: ...WWW GOLDENTECH COM info goldentech com PAGE 12 Figure 15 Companion Wiring Schematic Control Panel HORN RESISTOR NOTE Color shades may vary ...

Page 13: ...ep More than 16VDC Try to recharge the batteries Load test and replace if necessary 0VDC Check the battery 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 i...

Page 14: ...tteries If the voltage is 16VDC or greater then go to the next step 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 Make sure the batteries are secure 6 Lower the tiller 7 Turn the scooter over onto its side 8 Remove the controller cover 9 Measure v...

Page 15: ...st 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 voltage to fall into the red area on the battery meter 2 Check the battery charger Make sure it is an approved charg...

Page 16: ...ess and the rear intermediate motor harness for continuity 10 ohms or less Replace the controller 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 1 Turn the key to the off position 2 Disengage and then re engage the park brake 3 Turn the key to the on position Did the flash code clear Yes OK ...

Page 17: ...use the throttle control lever is not in the neutral position when the key is turned to the on position 1 Turn the key to the off position 2 Make sure that the paddle pot is not obstructed and it can return to the neutral center position 3 Move the throttle pot forward and then reverse Make sure that it is not obstructed Does it spring back to neutral position Yes Go to the next step No Check for ...

Page 18: ... Are both readings within 500 ohms of the resistance measured in step 14 Go to the next step Are either readings outside that range Replace the throttle pot 16 Check the orange blue and yellow wires on the main harness for continuity 10 ohms or less on each one Replace the speed pot Open on any wire Replace the main harness FLASH CODE 8 MOTOR VOLTAGE FAULT OPEN This Flash Code appears when there i...

Page 19: ...s 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 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 ...

Page 20: ...he drivetrain from the rear frame assembly and stand it up onto its right wheel 12 Use a 5mm hey key to remove the screws that attach the motor brake assembly to the transaxle See 4 on figure 19 13 Remove the motor brake assembly from the transaxle 14 Remove the coupler from the old motor brake assembly See 5 on figure 20 15 Install the coupler onto the new motor brake assembly 16 Install the new ...

Page 21: ...tens the wheel to the axle Make sure you retain the axle key See 1 on figure 22 5 Place a new 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 1 Place the freewheel lever in the engaged position 2 Remove the key from the ke...

Page 22: ... position 2 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 ...

Page 23: ...tors 13 Connect the power harness to the new circuit breaker 14 Reinstall the batteries 15 Insert the key and turn on the scooter to check the circuit breaker function 16 Turn off the scooter 17 Reinstall the shroud 18 Reinstall the seat CONTROLLER REPLACEMENT Tools needed Phillips screwdriver 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Remove the sea...

Page 24: ...Figure 29 Charger Harness Fuse 1 1 Figure 30 Floorboard and Front Shroud Figure 31 Main Harness Upper Clip 1 MAIN HARNESS REPLACEMENT 340 Tools needed Phillips screwdriver adjustable wrench 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Remove the seat 4 Remove the rear shroud 5 Remove the batteries 6 Separate the front and rear frames 7 Remove the eight...

Page 25: ...nector to the controller 24 Connect the 2 pin main harness connector to the taillight connector 25 Feed the main harness through the front shroud opening 26 Secure the main harness to the front frame with the main harness clamp located above the front wheel 27 Turn the front frame over 28 Feed the main harness through the rubber boot 29 Secure the main harness and the headlight LED harness to the ...

Page 26: ... 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 ...

Page 27: ...ual Step1 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 w...

Page 28: ...WWW GOLDENTECH COM info goldentech com PAGE 28 APPENDIX C WIRING DIAGRAM 24V 5W bulbs ...

Page 29: ...Golden Technologies 401 Bridge Street Old Forge PA 18518 www goldentech com Your Life In Motion GCX40SERVMAN_06 11 2013 ...

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