Golden PATRIOT GR575 Service Manual Download Page 1

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Patriot

Service Guide

This Service Guide contains:

Troubleshooting

Replacement Instructions

Illustrated Parts Breakdown

Model GR575

Summary of Contents for PATRIOT GR575

Page 1: ...Patriot Service Guide This Service Guide contains Troubleshooting Replacement Instructions Illustrated Parts Breakdown Model GR575 ...

Page 2: ...Patriot_SG_REVA_050714 1 ...

Page 3: ...Voltage 12 BEEP CODE 5 Solenoid Brake Trip 12 13 BEEP CODE 6 Throttle Trip out of neutral 13 BEEP CODE 7 Throttle Trip Speed Control Fault voltage error 13 BEEP CODE 8 Motor Disconnected 14 BEEP CODE 9 Possible Controller Fault 14 COMPONENT REPLACEMENT INSTRUCTIONS 15 23 Controller 15 Drive Wheel 16 Dash 16 Key Switch High Low Switch and Motor Brushes 17 Motor Brake Assembly 18 19 Transaxle 18 19 ...

Page 4: ...r Floor Mat 10 Side Rail 11 Drive Wheel 12 Rear Bumper 13 Freewheel Lever 14 Battery Cover 15 Arm Assembly 16 Hand Brake 17 Tiller Adjustment Lever Figure 1 Patriot Model GR575 Contact Information Golden Technologies 401 Bridge Street Old Forge PA 18518 Toll free 800 624 6374 Fax 800 628 5165 Email parts goldentech com 1 11 2 4 5 7 6 3 8 9 12 15 14 13 16 17 10 ...

Page 5: ...e S Drive controller monitors the systems and displays BEEP codes when it detects a fault in the system The GR575 was designed to operate with between 18 24 volts V of direct current DC The GR575 control system is made up of the following components 12V 75AH Batteries 2 Battery Harness es 2 Main Circuit Breaker Off Board Battery Charger Power Harness Motor Brake P G S Drive Controller Main Harness...

Page 6: ...ing Replace wires as necessary Component Battery Charger Model HP1202B off board charger only Location Off Board Function Recharges batteries There is one LED on the charger The LED is red when the charger is plugged into an electrical outlet If the LED does not go on then check the electrical outlet When the charger is on and plugged into the charger port an orange LED indicates that the batterie...

Page 7: ...wed by a Beep Code BEEP CODES 2 3 and 5 9 Connections Batteries Motor Motor Brake Charging Port and Main Harness Failure Signs Beep Code 9 Tests Test for voltage to motor when paddle is pressed Expected readings Voltage varies Serviceable Replace as necessary Component Main Harness Location Front and rear sections of the scooter Function Connects controller to the dashboard Connections Dashboard H...

Page 8: ...ocation Mounted on top of the tiller Function Provides connectivity between controller and key switch battery meter throttle pot and speed pot Connections Main Harness Lighting Harness es and Throttle Pot Failure Signs Damaged or loose connectors Pins not seated properly in connectors Serviceable Replace as necessary Component High Low Switch Location Mounted on the rear tiller Function Provides c...

Page 9: ...WIRE COLOR 1 Throttle Wiper Yellow 2 Throttle High Reference Orange 3 Audible Alarm Purple 4 Slow Fast Switch Yellow 5 On Off Switch White 6 Inhibit 2 N A 7 24V Red 8 Throttle Low Reference Blue 9 Speed Limiting Potentiometer Gray 10 Status Indicator Green 11 Spare N A 12 Reverse Switch N A 13 0V Black 14 Inhibit 3 N A ...

Page 10: ...Patriot_SG_REVA_050714 9 PATRIOT WIRING DIAGRAM ...

Page 11: ...ction is marked with the symbol Measure the voltage across the red and black wires 24VDC or battery voltage Go to the next step 0VDC Check circuit breaker and wire harnesses for continuity Replace as necessary Check Voltage out of Controller 5 Make sure that the power harness is plugged back into the controller 6 Insert the multimeter probes into the terminal with the red wire pin 7 and the termin...

Page 12: ...lace the individual components as necessary Check Voltage Into the Controller 5 Measure voltage across the B red wire and B black wire of the power harness This is the large black connector on the controller marked with the symbol 24VDC or battery voltage Go to the next step 0VDC Check circuit breaker and wire harnesses for continuity Replace as necessary Check Voltage Out of the Controller 6 Inse...

Page 13: ...n Check the battery connections NOTE The error may only be present when going down hill and power goes back to the batteries 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 charger BEEP CODE 5 SOLENOID BRAKE TRIP...

Page 14: ... wire Note the resistance reading Insert the multimeter probe into the main harness connector at pin 1 yellow wire and pin 2 orange wire Note the resistance reading Readings should be 2 5k ohm 10 Are both readings within 250 ohms Replace the controller Either of the readings outside that range Go to the next step 8 Remove the front basket bracket 9 Remove the 10 screws that fasten the front tiller...

Page 15: ... wire on the motor harness 50 ohms 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 four brushes from the motor and inspect them See figure 10 on page 17 Indications of a bad brush include broken springs cracked carbon black or discolored wire and black or discolored contacts Worn or physically damaged Replace the brushes Not...

Page 16: ...ire ties used to secure the harnesses 5 Remove the two screws that attach the controller to the controller bracket 6 Remove the controller 7 Install the new controller using the two screws removed in step 6 8 Reconnect the harness connectors See figure 3 9 Reinstall the battery cover 10 Reinstall the seat 11 Insert the key into the key switch and operate the scooter Figure 2 Controller Location Fi...

Page 17: ...the center cap Figure 4 Drive Wheel DASH REPLACEMENT To replace the dash 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Remove the 10 Phillips screws in the rear tiller cover See figure 5 4 Remove the 2 Phillips screws securing the basket bracket to the front tiller cover See figure 6 5 Remove the front tiller cover and the dash assembly by lifting them ...

Page 18: ...eplacement instructions above in reverse order to complete the installation Figure 7 Inside Dash Figure 8 Inside Tiller front section MOTOR BRUSH REPLACEMENT To replace the motor brushes 1 Remove the rear shroud See figure 11 on page 18 2 Remove a brush cap with a slotted screw driver 2 Remove brush by gently prying it out of the holder 3 Inspect the brush for discoloration carbon build up rust un...

Page 19: ...ble in the reverse order Figure 11 Rear Shroud Figure 12 Motor Brake Assembly TRANSAXLE REPLACEMENT To replace the transaxle 1 Perform steps 1 7 of the motor brake replacement instructions 2 Place a support under the scooter frame forward of the u brackets to raise the drive wheels off the ground to allow removal of the transaxle See figure 11 3 Remove the center cap 4 Remove the nut and washer th...

Page 20: ...050714 19 Figure 13 Drum Brake Rear Section Figure 14 Scooter Rear Section Transaxle Hand Brake Drum Drum Hand Brake Assembly Hand Brake Cable Place support here Bolts 8mm U Bracket Transaxle Axle Key Axle Key Axle Key ...

Page 21: ...rect when connecting the batteries 9 Attach the RED B and BLACK B wires to each battery 10 Place the two new batteries into the scooter matching the color coded connectors of the battery cables to the connectors in the scooter 11 Tighten down the Velcro strap on each battery 12 Replace the battery cover and secure with the four screws 13 Reinstall the seat 14 Insert the key and test the scooter Th...

Page 22: ... Remove the rubber floor mat by lifting it upward 6 Remove the 6 Phillips screws and 6 7mm lock nuts under the floor mat See figure 17 7 Remove the Phillips screws from each side battery compartment panel 1 on each side forward screws only and lift up on the panels to unlock them from the floor See figure 18 Figure 18 Battery Compartment Panel Left side Figure 19 Wheel Well Right side 8 Remove the...

Page 23: ...e tiller assembly and set it aside for reassembly 8 Disconnect the 4 head light wires underneath the front shroud 9 Remove the Phillips screw located directly behind the front bumper 10 Lift the front shroud upward and over the tiller stem to remove it Note At this point all of the front shroud components can be easily accessed for independent replacement 11 Reassemble in the reverse order To repl...

Page 24: ...sary to maneuver the panels to gain access to the screws with your screwdriver 4 Disconnect the controller cables 5 Remove the 2 upper shock mating bolts 1 on each shock using a 5mm Allen wrench See figure 24 6 Slide the rear battery compartment panel upward over the shocks and lay the panel flat on the ground See figure 25 Figure 25 Rear Battery Compartment Panel 7 Disconnect the 4 rear light har...

Page 25: ...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 circu...

Page 26: ...isconnect 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 th...

Page 27: ...Patriot_SG_REVA_050714 26 APPENDIX C WIRING DIAGRAMS Power Wiring ...

Page 28: ...Patriot_SG_REVA_050714 27 ...

Page 29: ...Patriot_SG_REVA_050714 28 ...

Page 30: ...Patriot_SG_REVA_050714 29 ILLUSTRATED PARTS BREAKDOWN PATRIOT MODEL GR575 ...

Page 31: ...Patriot_SG_REVA_050714 30 GR575 Complete Vehicle SF06E112 ITEM PART NO DESCRIPTION QTY 01 SF06P543 Logo Front PVC 1 02 SF06E113 Vehicle Complete Assembly 1 03 SF06P542 Label Back Cover PVC 1 ...

Page 32: ... SF06P532 Label Maximum Load Capacity 32 25 PVC 1 07 SF06P544 Label Serial Number 1 08 SF03A502 Screw Knob M5 16L PP 4 09 SF06P505 Cover Back ABS 1 10 SF03A111 Strap Battery 2 11 SF03A112 Strap Single Button Battery 2 12 SE05P144 Pad EVA 8 13 SF06E401 Seat Assembly 1 14 MBB 575D SRFLCT Reflectors for sides with adhesive backing for GR575 SH02A502 2 N A 3052512110 Battery 12V75AH 2 N A MBE 575D BCH...

Page 33: ...00404011 Washer Ø4 Ø9 0 8 10 N A 3003700010 Mirror Left side Rear View M8 1 05 SF03E201 Tiller Delta Handle 1 N A SF03A602 Handbrake Assembly 1 07 SF06E503 Console Cover Assembly 1 08 MBB 575D RTC Rear Tiller Cover complete with cup holders and horn for GR575 1 09 3111005032 Screw Phillips Head M5 30L 2 10 SF06A206 Basket Bracket 1 11 SF06E103 Shroud Body 1 12 SE1P227A Screw Large Flat Head Socket...

Page 34: ...w Hexagon Socket Head Cap M8 25L 4 20 3003108012 Washer Spring Ø8 4 21 300408012 Washer Ø8 4 Ø16 1 6 4 22 3100305012 Nut Nylon M5 2 23 3051600200 Controller S DRIVE 140A 1 24 3110605112 Screw Cross Recessed Pan Head M5 50L 2 25 SF06A104 Bracket Right side Controller Connection 1 26 SF06E501 Back Cover Black 1 27 3110604022 Screw Cross Recessed Pan Head M4 10L 4 28 SF06A103 Bracket Left side Contro...

Page 35: ...y Front Cover PP 1 09 SF03P517 Shroud Battery Left side Cover PP 1 10 3000404021 Washer Ø4 3 Ø12 1 8 11 3110903032 Screw Phillips Pan Head Self Tapping ST3 5 12L 4 12 SF03P516 Shroud Battery Right side Cover PP 1 13 3110803021 Screw Large Flat Head Phillips Self Tapping ST3 5 8L 4 14 MBB 575D CVR BTLA Back Cover Black with Tail Light Assemblies including all wiring for GR575 SF03E506 1 15 31106040...

Page 36: ... Screw Large Flat Head Socket M8 47L 2 09 SF06E202 Complete Rear Wheel Assembly 13x5 for GR575 2 10 3000413052 Washer Ø13 Ø21 1 5 2 11 31003W6012 Nut Nylon 1 2 20UNF 2 12 SE06P517 Cap Wheel ABS 4 13 3110305019 Bolt Hexagon Head M5 12L 2 14 3003105012 Washer Spring Ø5 2 15 3000406022 Washer Ø6 Ø19 1 5 2 16 SF06E201 Complete Front Wheel Assembly 13x4 for GR575 2 17 SF06E117 Frame Front Assembly 1 18...

Page 37: ...3A113 Buffer Plastic Head Ø18 M8 43 2 07 SF03P149 Bracket Rear Bottom 2 Q235 2 08 3001003010 Zip Ties 3 150mm Black 3 09 SF03E207 Steering Arm Right side Assembly 1 10 SF03E208 Lower Arm Assembly 2 11 3110408012 Bolt Hex M8 100L 1 12 SE1P213A Slug Yoke Mounting A3 1 13 3000408031 Washer Ø8 4 Ø24 2 2 14 SE06A207 Tiller Yoke 1 15 SF03E209 Arm Assembly Top Right side 1 16 SF06P103 Bracket Battery Cov...

Page 38: ...n Assembly 1 34 SF03P161 Screw Hexagon Socket Head Cap M8 75L 2 35 SF03E210 Arm Assembly Top Left side 1 36 SF03E206 Steering Arm Left side Assembly 1 37 3100308012 Nut Nylon M8 19 38 3110108112 Bolt Large Flat Head Hex M8 50L 2 39 SE3P120B Spacer Paddle Ø8 Ø14 24 A3 2 40 SF03E205 Connecting Rod Assembly II 1 41 WC5P210A Bushing Beam Tube A3 1 42 3090432070 Bracket Lower Bearing Ø37 1 43 309043206...

Page 39: ...5 04 3003108011 Washer Spring Ø8 5 05 3000408011 Washer Ø8 4 Ø16 1 6 5 06 3100306012 Nut Nylon M6 12 07 3000406012 Washer Ø6 Ø12 1 6 20 08 SF03P230 Rim 13 Front Wheel Q235B 2 09 SF06P528 Tire 13 Front PU 1 10 3110306089 Screw Hexagon Socket Head Cap M6 16L 8 11 3090162020 Bearing 6202 2Z 2 12 SF03A212 Hub Front Wheel Assembly 1 13 SF03P229 Spacer Bearing Q235B 1 14 3110306049 Screw Hexagon Socket ...

Page 40: ...F 5 04 3003108011 Washer Spring Ø8 5 05 3000408011 Washer Ø8 4 Ø16 1 6 5 06 3100306012 Nut Nylon M6 12 07 3000406012 Washer Ø6 Ø12 1 6 20 08 SF03P231 Rim 13 Wheel Q235B 2 09 SF06P529 Tire 13 Rear PU 1 10 3110306089 Screws Hexagon Socket Head Cap M6 16L 8 11 3090162020 Bearing 6202 2Z 2 12 SF03A212 Hub Front Wheel Assembly 1 13 SF03P229 Spacer Bearing Q235B 1 14 3110306049 Screw Hexagon Socket Head...

Page 41: ...07 3110308089 Screw Hexagon Socket Head Cap M8 25L 2 08 3003108012 Washer Spring Ø8 2 09 3000408012 Washer Ø8 4 Ø16 1 6 10 10 SF03A108 Bracket Transaxle Bottom Left side 1 11 3100308012 Nut Nylon M8 5 12 RA07E101 Transaxle Assembly 1 13 SF06P519 Plug D type Pipe PP 2 14 3051400010 Brake 71001 1 15 SF03A217 Brake Drum Q235B 1 16 WE03P510 Handle PP 1 17 SF03P249 Spacer Bearing Q235B 1 18 3110306079 ...

Page 42: ... SF06P518 Grill Front Lower PP 1 03 WE03P512 Plug Ø38 Pipe PP 4 04 3110903071 Screw Phillips Pan Head Self Tapping ST3 5 14L 2 05 3000404031 Washer Ø4 Ø8 0 8 2 Side Rail Left Right with mounting hardware for GR575 MBB 575d SRAIL SF06E108 ITEM PART NO DESCRIPTION QTY 01 SF06P519 Plug D type pipe PP 2 02 SF06A102 Rail Side Tube Assembly 1 Note Hardware not shown ...

Page 43: ...1 SF06P502 Cover Taillights PP 1 02 SF06P504 Shade Rear Left side PMMA 1 03 SF06P503 Shade Rear Right side PMMA 1 04 SF06P523 Light Reflective Rear Left side Housing ABS 1 05 SF06P522 Light Reflective Rear Right side Housing ABS 1 06 3110902011 Screw Phillips Pan Head Self Tapping ST2 6 10L 6 ...

Page 44: ...movable PP 1 05 SF03A618 Receptacle Charger Cord Port 1 06 3111003012 Screw Phillips Head M3 12L 2 07 SF03P504 Bottle Holder Left side Removable PP 1 08 3000325160 Velcro Hook 25 40 2 09 3000325170 Velcro Loop 25 40 2 10 SF06P521 Tiller Rear side Cover PP 1 11 SF03A604 Switch High low Speed 15A250V 1 12 SF03A611 Switch Key 1 13 SF06A621 Key 44 23 5 1 8 1 14 SE06P539 Washer Key 20 26 mm 1mm 1 15 SB...

Page 45: ...2 08 SF03A626 Cable Upper and Lower Panel Adapter 1 09 SF06P512 Console Top side Cover ABS 1 10 3053100140 Button Headlight 5A 250VAC No Lock 1 11 3053100130 Button Turn Signal 5A 250VAC No Lock 2 12 3053100120 Button Horn 2 13 SF03E601 Paddle TOCOS 5KVR Assembly 1 14 3110903042 Screw Phillips Pan Head Self Tapping ST3 5 20L 2 15 3053100110 Button Emergency Flashers 5A 250VAC No lock 1 16 SF03P535...

Page 46: ... 1 02 SF06P514 Lens Front right side Turn Signal PMMA 1 03 SF03A613 Turn Signal Front Right 1 04 SF06P516 Shade Front Right side Turn Signal ABS 1 05 3110903031 Screw Phillips Pan Head Self Tapping ST3 5 12L 8 06 3100304012 Nut Nylon M4 4 07 SF06P515 Lens Front Left side Turn Signal PMMA 1 08 SF06P517 Shade Front Left side Turn Signal ABS 1 09 SF03A606 Turn Signal Front Left 1 ...

Page 47: ...side Front Head Light PMMA 1 11 SF06P510 Holder Front Left side ABS 1 12 SF03P537 Label Non slip Right side PVC 1 13 SF03P538 Label Non slip Center PVC 1 14 MBB 575D SHRD FOS Front Shroud Red for GR575 with Scuff Guards SF03P512 1 14 MBB 575D SHRD FRS Front Shroud Orange for GR575 with Scuff Guards SF03P512 1 15 SF03P539 Label Non slip Left side PVC 1 N A MBB 575D SGS Scuff guard set 3 pieces for ...

Page 48: ...ar Shroud Cover ORANGE MBB 575D CVR RSO SF06E506 13 Wheel Cover Assembly SF06E511 ITEM PART NO DESCRIPTION QTY 01 SF03P524 Cover 13 Wheel ABS 1 02 300360602B Pad EVA 6 2 5 750L 1 ITEM PART NO DESCRIPTION QTY 01 SF06P501 Shroud Rear ABS 1 02 SF03P358 Barrier Motor Noise Cotton 1 ...

Page 49: ...Assembly 1 07 SF03E402 Armrest Right side Assembly 1 08 WE03E406 Swivel Seat Assembly 1 09 3000408032 Washer Ø8 4 Ø24 2 4 10 3110408092 Bolt Hex M8 35L 4 11 3003108012 Washer Spring Ø8 8 12 SA2P420A Plug Square Tube 25 2 2 N A WD6A402A Receiver Accessory Tube 1 N A WC9P453A Plug Square Pipe 32 32 2 5 1 N A 3110108042 Screw Large Flat Head Socket M8 45L 2 N A 3100308012 Nut Nylon M8 2 N A SE1P529A ...

Page 50: ...ide Note P5 and P6 are internal connections only Handbrake Throttle Pot Light Switch Horn Horn Turn Signal Switch Turn Signal Switch Hazard Switch Speed Pot Hand Brake P1 P3 Horn P2 P4 Status LED P5 P6 Hand Brake Hand Brake Switch Paddle Paddle ...

Page 51: ...Patriot_SG_REVA_050714 50 Wiring Diagram ...

Page 52: ...Patriot_SG_REVA_050714 51 Golden Technologies 401 Bridge Street Old Forge PA 18518 www goldentech com PATRIOT_SG_REVA_050714 ...

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