Golden Buzzaround XL Service Manual Download

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Buzzaround XL

Service Guide

This Service Guide contains:

Troubleshooting

Replacement Instructions
Multi-meter Instructions

Model GB117

Model GB147

Summary of Contents for Buzzaround XL

Page 1: ...Buzzaround XL Service Guide This Service Guide contains Troubleshooting Replacement Instructions Multi meter Instructions Model GB117 Model GB147 ...

Page 2: ...Buzzaround XL_SG_REVA 1 ...

Page 3: ...13 BEEP CODE 4 Current Limit Timeout 13 14 BEEP CODE 5 Brake Fault 14 15 BEEP CODE 6 Paddle Fault out of neutral 15 BEEP CODE 7 Paddle Fault Speed Control Fault voltage error 16 17 BEEP CODE 8 Motor Voltage Fault Open Shorted 17 18 BEEP CODE 9 Controller Fault 18 BUZZAROUND XL REPLACEMENT INSTRUCTIONS 19 25 Drive Wheel 19 Drive Train 19 Throttle Pot 19 Battery 20 Circuit Breaker 21 Battery Harness...

Page 4: ... 9 Removable Anti Slip Floor Panels Gray Textured 10 Front Wheel 11 Tiller 12 Front Basket 13 Seat Post 14 Bolt Arc Washer and Nut 15 Lockup Handle Figure 1 Buzzaround XL Model GB117 Contact Information Golden Technologies 401 Bridge Street Old Forge PA 18518 Toll free 800 624 6374 Mobility Tech x501 Lift Chair x502 VA Tech x505 Fax 800 628 5165 Email parts goldentech com 5 6 7 8 9 3 4 2 1 10 11 1...

Page 5: ...s in the connectors are seated securely If necessary push any unseated pins back into their connector housings to securely seat them If you get to a point during troubleshooting where you cannot continue call Technical Support at 800 624 6374 BUZZAROUND XL COMPONENTS The Buzzaround XL is a battery operated scooter with a controller that monitors the system and beeps when it detects a fault in the ...

Page 6: ...rminals are connected to the charging port red and black wires and the controller through the power harness 5 Refer to figure 11 on page 10 Failure Signs Batteries drain quickly Scooter runs slowly or not at all Batteries will not charge but charger is working properly Beep Code 1 or 2 Tests Fully charge the batteries first and load test Make sure the contacts are not corroded See figure 4 below a...

Page 7: ...onitors the system Uses a series of beeps when something in the system is out of range Connections Connected to the main harness charger inhibit brake motor M1M2 battery B B See figure 5 Refer to figure 11 on page 10 Failure Signs Beep Code 9 No power to the control panel or the motor Tests Test for voltage coming into and out of the controller Expected readings Battery voltage Serviceable Replace...

Page 8: ...s Make sure the contacts are not corroded Expected readings Continuity less than 10 ohms Serviceable Replace as necessary Component Motor Brake Assembly 10 Location Mounted on the transaxle See 1 on figure 8 Function Drives the scooter Connections Connected to the rear intermediate connector 9 and the brake 11 Refer to figure 11 on page 10 Failure Signs Scooter runs slowly or not at all Figure 7 R...

Page 9: ... Potentiometer 14 Location Below the control panel See 1 on figure 10 Figure 9 Control Panel Back Function The throttle pot uses variable resistance to control speed and direction of travel by varying voltage Connections Connected to the main harness 7 and 1amp in line fuse Refer to figure 11 on page 10 Failure Signs Beep Codes 6 and 7 Tests Test resistance across pins 1 2 and 3 on the throttle po...

Page 10: ...he wall outlet and make sure the voltage reading increases Expected readings Battery voltage first approximately 27 volts when fully charged Then voltage should increase to approximately 29 5 volts with the charger connected and plugged into the wall outlet Also refer to the charger test on page 12 Test charger harness and fuse for continuity Serviceable Replace if necessary Figure 11 Off Board Ba...

Page 11: ...itch 13 Horn LED Light Switch Battery Meter Horn Switch Charger Harness 15 Dynamic R Series Controller 6 30 AMP Circuit Breaker 1 Battery 2 12V Battery 3 12V Battery Box Battery Harness 4 Power Harness 5 Main Harness 7 Front Intermediate Harness 8 Rear Intermediate Connector 9 Motor Brake Assembly 10 Brake 11 ...

Page 12: ... pushing them up from the underside of the scooter frame 4 Remove the four screws fastening the floor shroud 5 Disconnect the power harnesses 5 from the controller 6 Reinstall the battery pack 7 Measure voltage across the red B and black B wires See figure 13 24VDC or battery voltage Go to the next step 0VDC Check power harness for continuity Replace as necessary Figure 13 Check Voltage Out of Con...

Page 13: ...ure voltage across the two outside terminals on connector 4 See figure 16 Does the voltage increase Yes Load test the batteries and replace as necessary 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 No And there is no voltage Open the battery pack and check the circuit breaker battery harnesses and ...

Page 14: ...ge 12 BEEP CODE 3 HIGH BATTERY VOLTAGE This Beep Code occurs 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 charger BEEP CODE 4 CURRENT LIMIT TIMEOUT This Beep Code oc...

Page 15: ...ext step 11 Check the rear intermediate connector 9 and the motor brake harnesses connected to connector 9 No damage or discoloration Replace the controller Damaged or discolored Replace as necessary Figure 19 Quarter Test Connector 8 BEEP CODE 5 BRAKE FAULT This Beep Code occurs because the park brake release switch is active or the park brake may be faulty Check the Park Brake Position 1 Turn th...

Page 16: ...rk Brake 14 Measure resistance across the two inside pins on the intermediate harness connector 9 with park brake engaged See figure 21 45 ohms 52 ohms Replace the controller Out of range Replace the motor brake assembly Open Check the connections at connector 9 Shorted Replace the motor brake assembly Figure 21 Connector 9 BEEP CODE 6 PADDLE FAULT OUT OF NEUTRAL This Beep Code means that the thro...

Page 17: ...nnector 7 at pin 1 and pin 8 gray wire and orange wire See figure 23 Note the resistance reading Insert the multimeter probe into the main harness connector at pin 1 and pin 2 gray wire and yellow wire See figure 24 Note the resistance reading Figure 23 Connector 7 Are both readings within 500 ohms of each other Replace the controller Are either of the readings outside that range Go to the next st...

Page 18: ...rside of the scooter frame 4 Remove the four screws fastening the floor shroud 5 Disconnect the M1 and M2 connections on the front intermediate harness 8 from the controller Refer to figure 11 on page 10 6 Measure resistance across the front intermediate harness M1 and M2 See figure 28 45 ohms 52 ohms replace the controller Out of that range Go to the next step Check for Continuity on the Front In...

Page 19: ...29 0 8 ohms 1 5 ohms Replace the controller Out of range Replace the motor brake assembly Open Check the connections at connector 9 Shorted Replace the motor brake assembly BEEP CODE 9 CONTROLLER FAULT This Beep Code means that the controller has an internal fault 1 Remove the key from the key switch and allow the controller to cool down If the code continues then replace the controller Figure 29 ...

Page 20: ...t sides which fasten the wheels to the axle 6 Separate the front and rear frames 7 Remove the drive wheels Make sure you retain the axle keys 8 Remove the drive train from the rear frame 9 Install the drive wheels onto the new drive train 10 Install the new drive train onto the rear frame 11 Connect the rear and front frames 12 Reinstall the battery pack 13 Reinstall the seat THROTTLE POT REPLACEM...

Page 21: ...d wires from one battery 10 Remove the battery from the pack 11 Repeat steps 9 and 10 for the opposite battery 12 Place a new battery into the bottom half of the battery pack Make sure that the terminals are facing as shown See figure 33 13 Connect the and wires and tighten securely 14 Place the second new battery into the bottom half of the battery pack with the terminals facing as shown See figu...

Page 22: ...into the fuse holder Fuse s must be replaced with exact type and rating 9 Reassemble the battery pack halves together 10 Reinstall the battery pack 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 seat 4 Remove the battery pack 5 Remove the 2 gray textured floor inserts by lifting them up ...

Page 23: ... harness all connections from the control panel Refer to the wiring diagram on page 10 8 Remove the 2 gray textured floor inserts by lifting them up from each side of the floor shroud 9 Remove the floor shroud by removing the 4 screws securing it to the frame 10 Disconnect the main harness connections from the controller 11 Remove the 4 screws securing the front shroud Two are located in the front...

Page 24: ...th the four screws removed in step 9 14 Install the rear shroud 15 Reinstall the color panels 16 Connect the front and rear frames Figure 39 Motor Brake Removal 17 Reinstall the battery pack FRONT INTERMEDIATE HARNESS REPLACEMENT Tools needed Phillips screwdriver 7mm wrench Figure 40 Connector Front View 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Rem...

Page 25: ...0 Reconnect the front and rear frames 22 Reinstall the battery pack 23 Reinstall the seat REAR INTERMEDIATE CONNECTOR REPLACEMENT Tools needed Phillips screwdriver 7mm wrench Figure 41 Connector Front View 1 Place the freewheel lever in the engaged position 2 Remove the key from the key switch 3 Remove the seat 4 Remove the battery pack 5 Separate the front and rear frames Please note the placemen...

Page 26: ...ws securing the connector to the battery tray Please note the placement of all wiring prior to removal At this time the entire harness can be removed by simply disconnecting the red and black battery wires and the green wire from the controller At this time to replace only the connector or harness separately continue to step 10 10 Remove the 4 bolts securing the wires to the back of the connector ...

Page 27: ...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 28: ...sconnect 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...

Page 29: ...Buzzaround XL_SG_REVA 28 ...

Page 30: ...Buzzaround XL_SG_REVA 29 BUZZAROUND XL_SERVMAN_REVA_110915 Golden Technologies 401 Bridge Street Old Forge PA 18518 www goldentech com Model GB147S Model GB117S ...

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