Golden Buzzaround Carry On Service Manual Download

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Buzzaround Carry On

Service Guide

This Service Guide contains:

Troubleshooting

Replacement Instructions

Multi-meter Instructions

Model: GB120

Summary of Contents for Buzzaround Carry On

Page 1: ...Buzzaround Carry On Service Guide This Service Guide contains Troubleshooting Replacement Instructions Multi meter Instructions Model GB120 ...

Page 2: ...2 ...

Page 3: ... Voltage 14 BEEP FLASH CODE 4 Current Limit Timeout 14 BEEP FLASH CODE 5 Brake Fault 15 BEEP FLASH CODE 6 Paddle Fault out of neutral 15 BEEP FLASH CODE 7 Paddle Fault Speed Control Fault voltage error 16 17 BEEP FLASH CODE 8 Motor Voltage Fault Open Shorted 17 BEEP FLASH CODE 9 Controller Fault 17 BUZZAROUND CARRY ON REPLACEMENT INSTRUCTIONS 18 23 Drive Wheel 18 Anti Tip 18 Throttle Pot 18 Batter...

Page 4: ...nder cover 9 Steering Assembly 10 Front Wheel 11 Rear Wheel Drive 12 Freewheel Switch 13 Dash Upper Lower 14 USB Board Inside 15 Bottle Holder 16 Hand Grip 17 Tiller Adjustment Lever 18 Paddle Throttle Lever 19 LED Head Light 20 LED Tail Light 21 Deck Upper Lower 17 18 19 Contact Information Golden Technologies 401 Bridge Street Old Forge PA 18518 Toll free 800 624 6374 Mobility Tech x501 Lift Cha...

Page 5: ...point during troubleshooting where you cannot continue call Technical Support at 800 624 6374 BUZZAROUND CARRY ON COMPONENTS The Buzzaround Carry On is a battery operated scooter with a controller that monitors the system and flashes beeps when it detects a fault in the system The Buzzaround Carry On was designed to operate within a range of between 22V 30 8V Volts of direct current DC The Buzzaro...

Page 6: ...on page 11 Failure Signs Open fuse corroded wires poor connections and poor spring tension can cause the battery voltage 24 29 volts not to be supplied to the entire electrical system Make sure the fuse is good and all connections are good Note Battery pack will not charge if the inline fuse is blown Tests Test the fuse for continuity Test the harness for continuity See figure 3 Refer to the wirin...

Page 7: ...e 24 29VDC Serviceable Replace as necessary Component Main Harness 5 Location Inside the dash and the plastic upper lower body halves See ﬁgures 5 and 6 Refer to the wiring diagram on page 11 Function Provides connectivity for the tiller components and the controller Connections Connected to the controller and control panel Refer to the wiring diagram on page 11 Failure Signs Scooter will not run ...

Page 8: ...st for voltage and continuity Check connectors Make sure the contacts are not corroded Expected readings Continuity less than 10 ohms Serviceable Replace as necessary Figure 8 Console Board Component Throttle Pot Potentiometer 8 Location Below the control panel See ﬁgure 9 Function The throttle pot uses variable resistance to control speed and direction of travel by varying voltage Connections CN7...

Page 9: ...ed and are seated properly Expected readings Battery voltage 24 29VDC Continuity less than 10 ohms Serviceable Replace the harness as necessary Figure 12 Charger Harness Component Motor Brake Assembly NA Location Mounted on the transaxle See ﬁgure 13 Function Drives the scooter Connections Connected to the controller control board and the transaxle Refer to the wiring diagram on page 11 Failure Si...

Page 10: ...oltage across B a black wire and B a red wire on the controller 4 battery terminals While observing the voltage reading plug the charger into the wall outlet and make sure the voltage reading increases Expected readings Battery voltage 24 29VDC first approximately 29 volts when fully charged Also refer to the charger test on page 13 Test charger harness and fuse for continuity Serviceable Replace ...

Page 11: ...11 Motor Harness 3 5 Figure 14 Buzzaround Carry On Wiring Diagram 8 9 10 Charger Harness 11 Dynamic R Series Controller 4 24 Volt Battery Pack 1 Battery Harnesses 2 Brake Harness 6 5 14 Pin Connector 7 ...

Page 12: ...e battery pack is installed 4 Remove the two thumb screws directly below the seat to remove the controller cover 5 Measure voltage across the red B and black B wires on the controller See ﬁgure 16 24 29VDC or battery voltage Go to the next step 0VDC Check the 35A fuse for continuity battery harness for continuity Replace as necessary Check Voltage Out of Controller 6 Make sure the red B and black ...

Page 13: ... wiring diagram on page 11 24 29VDC or battery voltage on pack Go to the next step More than 22VDC on pack Try to recharge the battery pack Load test and replace if necessary 0VDC Replace the battery pack 2 Open the controller cover directly under the seat 3 Plug the charger into the XLR charger port and then into a wall outlet 4 Measure voltage across the B and B connections on the controller 4 S...

Page 14: ...y pack will not recharge load test it or refer to Scenario 2 Battery Pack will not Charge on page 13 BEEP FLASH CODE 3 HIGH BATTERY VOLTAGE This Beep Flash Code occurs when the battery voltage climbs above 29 6VDC 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 Chec...

Page 15: ... at the Controller 6 Remove the two screws securing the controller 7 Lift the controller to expose the control board underneath it 8 Measure continuity across the purple brake harness CN4 and yellow brake harness CN3 See figure 23 Refer to the wiring diagram on page 11 Continuity Yes Replace the control board No Replace harness es as needed Figure 22 Connection from Brake BEEP FLASH CODE 6 PADDLE ...

Page 16: ... pin 1 and pin 8 yellow wire and white wire See ﬁgure 25 Note the resistance reading Insert the multimeter probes into the main harness connector 5 at pin 1 and pin 2 yellow wire and light green wire See ﬁgure 26 Note the resistance reading Are both readings within 500 ohms of each other Replace the controller Are either of the readings outside that range Go to the next step Check Throttle Pot Res...

Page 17: ...ere is an internal problem with the motor or its wiring Check Motor Resistance at Motor 1 Remove the battery pack 2 Remove the controller panel by loosening the 2 thumb screws on the scooter deck directly below the seat 3 Disconnect the M and M connections from the controller Refer to the wiring diagram on page 11 4 Measure the internal resistance of the motor across M and M See ﬁgure 30 0 8 ohms ...

Page 18: ...4 Remove the battery pack 5 Stand the scooter up as shown See figure 32 Tip Hazard Make sure the scooter is stable before attempting any repairs 6 Remove the left or right anti tip assembly by removing the 1 lock nut and 1 Phillips screw shown inside the small circles See figure 32 7 Install the new anti tip assembly by reversing steps 1 6 Note If needed repeat step 6 for the opposite side THROTTL...

Page 19: ...eplacement and warnings 3AMP Mini Glass Fuse shown Good Fuse Bad Fuse Fault The XLR charging port is not functioning causing the battery pack not to charge when the off board battery charger is connected Remedy Check the fuse F3AL250V inside the fuse holder located on the tiller below the control panel Replace the fuse with the same type and rating if the fuse is bad FUSES MUST BE REPLACED WITH SA...

Page 20: ...e holder Fuse s must be replaced with exact type and rating Refer to the wiring diagram on page 11 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 battery pack from the scooter 4 Loosen the two thumb screws securing the controller cover by turning them counterclockwise 5 Remove the cover ...

Page 21: ...ustment cable See figure 39 Note At this point you can replace the upper lower dashes and or any of their components 6 Complete steps 1 5 in reverse to reassemble UPPER MAIN HARNESS REPLACEMENT 1 Complete steps 1 5 above 2 Remove the 2 screws securing the cable clamp located in front of the battery release button to allow access to the upper main harness Note The screws must be removed from the un...

Page 22: ...e wiring diagram on page 11 See figure 41 9 Install the new transaxle assembly by reversing steps 1 8 LOWER MAIN HARNESS REPLACEMENT Tools needed Phillips Screwdriver 8mm Allen Wrench Before attempting repairs engage the brake turn off the key switch and remove the battery pack 1 Remove the 2 screws securing the cable clamp located in front of the battery release button to allow access to the uppe...

Page 23: ...emove roll pin with a punch and hammer See figure 45 2 Remove tiller locking bracket Take note of the tiller cable position in relation to the tiller shock The tiller will not operate properly if the cable is routed incorrectly 3 Remove the 1 6mm Allen bolt See figure 45 4 Remove the 2 5mm Allen bolts on either side of the tiller uprights and remove uprights See figure 45 5 Loosen the locking nut ...

Page 24: ...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 th...

Page 25: ...mpletely 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 T...

Page 26: ...26 Golden Technologies 401 Bridge Street Old Forge PA 18518 www goldentech com BUZZAROUND CARRY ON_SERVMAN_07 01 2021 Model GB120 ...

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