Golden Companion Service Manual

Text of Golden Companion User Guide:

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 4 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. Before troubleshooting, check the f

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 15 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 is solid green, the power is on and the system is running normally. When the controller notices that there is a malfunction in the system, it will flash a code when the key is inserted into the key switch. For ex- ample, when it flashes five times and stops, that indicates flash code #5 – Brake Fault. 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 �

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 17 13) Turn the scooter back over. 14) Remove the batteries. 15) Separate the front and rear frames. 16) Inspect the connection between the front intermediate motor harness (11a) and the rear intermediate motor harness (10a.) Make sure the contacts are 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 in place? • No? - Replace the front intermediate motor harness. • Yes? - Go to the next step. 17) Check the front intermediate motor harness and the rear intermediate motor harness for continuity. �

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 24 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. 2. 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. Figure 29. Charger Harness Fuse 1 1

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 26 APPENDIX A - HOW TO USE A VOLTMETER Step1 Plug 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

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 13 Scenario 1: Turn the Key to the On Position and No 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. NOTE: Make sure that the batt

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 5 NOTE: The 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 b

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 3 Table of Contents ABOUT THE COMPANION SERVICE GUIDE .................................................................................................... 4 Companion Components ............................................................................................................................................................... 4 SCENARIO 1: TURN THE KEY TO THE ON POSITION AND NO POWER ................................................ 13 SCENARIO 2: BATTERIES W

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 21 Figure 22. Drive Wheel Axle Key MOTOR BRUSH REPLACEMENT Tools needed: Slotted 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 rear shroud. 5. Remove the motor brush cap. (See #1 on figure 21.) 6. Remove the brush. 7. Install the new brush. 8. Reinstall the motor brush cap. 9. Repeat for the other brush. 10. Reinstall the rear shroud. 11. Reinstall the seat. DRIVEWHEEL REPLACEMENT Tools needed: 19mm socket, frame blocks. 1. Place the freewheel lever in the engaged position. 2. Remove the key

• WWW.GOLDENTECH.COM [email protected] PAGE - 9 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 cont

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 6 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 Breaker (1). 6c and 7c connect to the Controller (8). Failure Signs: Batteries will not charge, but charger is working properly. No power to the controller. Tests: T

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 14 15) Disconnect the key switch connector from the control panel harness. Make sure that the key is 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 16VDC at the charger port. Otherwise, they may not send a charging current to the batteries. This test will ensure that the battery vol

• WWW.GOLDENTECH.COM [email protected] PAGE - 11 Figure 14. Companion 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.

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 16 7) Make sure that the batteries are secure. 8) Lower the tiller. 9) Turn the scooter over onto its side. 10) Remove the controller cover. 11) Disconnect the front intermediate motor harness (11c and 11d) from the controller. 12) Make sure that the pins are seated properly on 10b. Check the continuity between 11c/11d and 10b. • 10 ohms or less? – Replace the controller. • Open? – Go the next step. 13) Turn the scooter back over. 14) Remove the batteries. 15) Separate the front and rear sections of the scooter. 16) Inspect the front and rear intermediate motor harness connectors. Are they discolored or corroded? • Yes? - Replac

• Golden Companion, WWW.GOLDENTECH.COM [email protected] PAGE - 25 12. Remove the upper main harness clip. (See #1 on figure 31.) 13. Remove the lower main harness clip. (See #1 on figure 32.) 14. Unscrew the nut that secures the headlight LEDs. (See #2 on figure 32.) 15. Feed the main harness through the rubber boot and through the front shroud opening. 16. Turn the front frame over onto its right side. 17. Remove the controller cover. 18. Disconnect the 14-pin main harness connector from the controller. (See #1 on figure 33.) 19. Disconnect the 2-pin main harnes

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