Golden Technologies Compass Sport Service Manual
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Golden Technologies Compass Sport Service Manual

Golden technologies compass sport equipped with the dynamic shark controller
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Compass Sport
Service Guide
This Service Guide contains:
Troubleshooting
Replacement Instructions
Illustrated Parts Breakdown

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Summary of Contents for Golden Technologies Compass Sport

  • Page 1 Compass Sport Service Guide This Service Guide contains: Troubleshooting Replacement Instructions Illustrated Parts Breakdown...

  • Page 2: Compass Sport_Sg_Reva

    Compass Sport_SG_REVA_041211...

  • Page 3: Table Of Contents

    Compass Sport_SG_REVA_041211 Table of Contents Nomenclature and Contact Information....................3 ABOUT THE COMPASS SPORT SERVICE GUIDE................4 Compass Sport Components........................4-6 The SHARK Battery Gauge........................7 SCENARIO 1: Press the on/off button and the LED array does not light up (SHARK).......8-9 SCENARIO 2: Batteries will not charge. (Shark Charging Test)............9-10 Electrical System............................11...

  • Page 4: Nomenclature And Contact Information

    Compass Sport_SG_REVA_041211 Compass Sport Nomenclature 1. Seat Assembly 2. Control Unit (Shark) 3. Right Caster Cover 4. Left Caster Cover 5. Right Fender 6. Left Fender 7. Front Battery Cover 8. Rear Battery Cover 9. Base 10. Right Side Drive Train 11.

  • Page 5: About The Compass Sport Service Guide

    Make sure that the batteries are fully charged and in good working order. When possible, keep sets of known good batteries of various ratings in your shop at all times. The Compass Sport uses 35AH (U1) batteries. Problems that surface during troubleshooting are often due to the fact that the batteries are not fully charged or can not hold their charge.
  • Page 6 Compass Sport_SG_REVA_041211 Tests: Load test. Fully charge the batteries first. Make sure charging system is working. Expected Readings: 12 - 14VDC each when fully charged. Serviceable: Replace batteries as necessary. Component: Park Brake (2) Location: End of each motor. Function: Park Brake for the motor. Connections: Each park brake has a 2 pin male connector, which connects to each motor harness.
  • Page 7 Compass Sport_SG_REVA_041211 Component: SHARK Power Module Location: Rear of the power base. Function: Monitors the system and displays faults when something in the system is out of range. These faults are displayed as a series of flashes by the battery meter. Connections: Control unit (joystick), DCI (not used), M1 (right motor), 24V (power harness from batteries), M2 (left motor).

  • Page 8: The Shark Battery Gauge

    Compass Sport_SG_REVA_041211 The SHARK Battery Gauge The Battery Gauge is used to indicate power on and provides an estimate of the remaining battery capacity. Any green LEDs lit indicate well charged batteries. If only amber and red LEDs are lit, the batteries are moderately charged.

  • Page 9: Scenario 1: Press The On/Off Button And The Led Array Does Not Light Up (Shark)

    Compass Sport_SG_REVA_041211 SCENARIO 1: Press the on/off button and the LED array does not light up. Before attempting to troubleshoot the power chair, make sure all connectors are connected and seated properly. Make sure that the batteries are connected properly and fully-charged. Refer to the wiring diagrams on pages 13 and 14 for the correct wiring.

  • Page 10: Scenario 2: Batteries Will Not Charge (Shark Charging Test)

    Compass Sport_SG_REVA_041211 SCENARIO 1 - Continued 12. Check continuity across the circuit breaker wires of the power harness and across the battery wires of the power harness. Repair or replace the power harness as necessary. 13. Check continuity across both the front and the rear battery harnesses. If open, check in-line fuse and replace fuse or harness as necessary.
  • Page 11 Compass Sport_SG_REVA_041211 SCENARIO 2 - Continued 6. Reconnect the battery harnesses to the power harness. Unplug the power harness from the power module. Measure voltage across the pin 1 (+) and pin 2 (-) on the power module. • Greater than 24VDC – Test the power harness for continuity and replace as necessary. •...

  • Page 12: Electrical System

    Compass Sport_SG_REVA_041211 Electrical System Charging Port SHARK Bus Cable Not Used Circuit Breaker Figure 1. Compass Sport Electrical System Connector Key (Shark)

  • Page 13: Connector Key And Cabling For (Shark)

    Note: Refer to figure 4 on page 13 for the power harness layout on the battery side. Battery Harness 12 Volt 12 Volt Battery Harness Battery Battery Motor Harness Left Motor Figure 2. Compass Sport Cabling Diagram (Circuit Breaker not shown)

  • Page 14: Wiring Diagrams And Battery Placement

    Compass Sport_SG_REVA_041211 Wiring Diagrams 2 pin connector (female) To Brake orange blue black To Dynamic Shark Controller Left 2 pin connector (female) To Brake orange blue black Right Figure 3. Motor/Brake wiring harnesses To Battery Harness Connector To Dynamic Shark Controller Power Input BLACK Circuit Breaker To Battery Harness Connector...
  • Page 15 Compass Sport_SG_REVA_041211 Wiring Diagrams – continued To Battery Terminals To Power Harness Connectors BLACK To Battery Terminals Figure 5. Battery Harnesses Figure 6. Correct Battery Placement...

  • Page 16: Troubleshooting Guide For (Shark)

    Compass Sport_SG_REVA_041211 Troubleshooting Guide for the Shark Power System Step 1: Battery voltage is always the first thing to check. A. Check the battery voltage through the 3-pin battery charger port located on the front of the controller as shown in figure 1. ...

  • Page 17: Step 2: Checking "Flash Codes

    Compass Sport_SG_REVA_041211 Step 2: Check for “FLASH CODES” Flash Codes Note: An Amber wrench shaped LED as shown above will display a series of flashes that give the user visual feedback of the current fault condition.

  • Page 18: Flash Code 1: User Fault

    Compass Sport_SG_REVA_041211 Flash Code 1: User Fault A. Possible stall timeout or user error – Release the joystick to neutral and try again.  Turn the controller off and then on again to clear the fault. Flash Code 2: Battery Fault A.

  • Page 19: Flash Code 4: Right Motor Fault

    Compass Sport_SG_REVA_041211 Flash Code 4: Right Motor Fault A. Check the resistance of the right motor to determine if the fault is in the motor or the controller.  Set your meter to the 20 Ohm scale.  Touch the leads together to make sure the ohm meter is accurate. You should have 0 ohms at this point. If not, your meter needs to be calibrated.

  • Page 20: Flash Code 6: Right Park Brake Fault

    Compass Sport_SG_REVA_041211 Figure7 Flash Code 6: Right Park Brake Fault A. Make sure the right park brake lever is engaged.  If disengaged, re-engage the park brake lever and turn the power off and back on to reset flash code. B.

  • Page 21: Flash Code 10: Unknown Fault

    Compass Sport_SG_REVA_041211 Flash Code 10: Unknown Fault A. Check all connections and wiring. B. Call Technical Support. Flash Code 11: Incompatible Control Unit A. Make sure the brand of the Power Module matches that of the Control Unit. Step 3: Check for other conditions displayed by the Shark Control Unit. A.

  • Page 22: Left To Right Led Chase

    Compass Sport_SG_REVA_041211 E. A left to right LED chase on the battery gauge signifies that the Shark is in a charge inhibit. The steady LEDs indicate the current state of battery charge.  Remove the battery charger from the charging port. ...

  • Page 23: Replacement Instructions

    Compass Sport_SG_REVA_041211 REPLACEMENT INSTRUCTIONS DRIVE WHEEL 1. Turn off power. 2. Place the power chair in drive mode. 3. Place a support under the frame so that the drive wheel is off the ground. 4. Remove the drive wheel. Note: Make sure to retain the axle key. See figure 7. 5.

  • Page 24: Drive Train (Motor/Brake And Gearbox)

    Compass Sport_SG_REVA_041211 DRIVETRAIN 1. Turn off power. 2. Place the power chair in drive mode. 3. Disconnect the bus cable from the control unit (Joystick). 4. Remove the seat and seat post. 5. Remove the battery box covers. 6. Remove the center shroud and either the right or the left side shrouds from the frame. Note: Only the center shroud requires screw removal (qty.2).

  • Page 25: Power Module

    Compass Sport_SG_REVA_041211 POWER MODULE 1. Turn off power. 2. Place the power chair in drive mode. 3. Disconnect the bus cable from the control unit (Joystick). 4. Remove the seat. 5. Remove the rear battery cover. 6. Disconnect the motor harnesses M2 and M1, the power harness, and the bus cable from the power module. 7.

  • Page 26: Appendix A - How To Use A Voltmeter

    Compass Sport_SG_REVA_041211 APPENDIX A - HOW TO USE A VOLTMETER Step 1 Plug the probes into the meter. Red goes to the positive (+) and black to the negative (-). Step 2 Turn the selector dial or switch to the type of measurement you want. To measure direct current - a battery, for example - use DCV.

  • Page 27: Appendix B - How To Use An Ohm Meter

    Compass Sport_SG_REVA_041211 APPENDIX B - HOW TO USE AN OHM METER Ohm’s law breaks down into the basic equation: Voltage = Current x Resistance. Current is generally measured in amps, and resistance in ohms. Testing the resistance on an electrical circuit in your home or car can help you diagnose problems with that circuit.

  • Page 28: Illustrated Parts Breakdown

    Highback Grey Charcoal 18x18 (Arms and Joystick Sold Separately) SMH-COS-1818-C21 Highback Coffee Sand 18x18 (Arms and Joystick Sold Separately) WE03E501BLUE Cover, Blue Right Front Caster for Compass Sport GP605 WE03E501RED Cover, Red Right Front Caster for Compass Sport GP605 WE03E502BLUE...
  • Page 29 NA1P504A 3110605062 Screw, Cross Slot Pan Head M5*10 WE03P506BLUE Plate, Battery Cover Connection w/ Ledge Blue for Compass Sport GP605 WE03P506RED Plate, Battery Cover Connection w/ Ledge Red for Compass Sport GP605 WE03E102 Drive Train, Right Includes Caster Arms, Wheels and Motor...
  • Page 30 Cap, Rim for Companion GC240/340/440 and Compass Sport GP605 WE03P204 Washer φ10.5*φ53*1.5 SE07E502 Hubcap, Plastic 10" for Companion GC240/340, LiteRider GL110 and Compass Sport GP605 WE03E201 Wheel, Drive Complete Assembly for Compass Sport GP605 RA03E103 Motor, Right Assembly with Gearbox and Brake for Compass Sport GP605...
  • Page 31 Screw, Cross Slot Pan Head Black Zinc M6*16 WC9P107A Footplate Shell ABS 3100310012 Nut, Nylon Black Zinc M10 WE03A109 Bracket, Footplate Mounting for Compass Sport GP605 3100110032 Nut, Hex Black Zinc M10 3110310042 Bolt, Hex Head Cylinder Black Zinc M10*50 3110310012...
  • Page 32 Cap, Rim for Companion GC240/340/440 and Compass Sport GP605 WE03P204 Washer φ10.5*φ53*1.5 SE07E502 Hubcap, Plastic 10" for Companion GC240/340, LiteRider GL110 and Compass Sport GP605 WE03E204 Wheel, Drive Complete Assembly for Compass Sport GP605 RA03E102 Motor, Left Assembly with Gearbox and Brake for Compass Sport GP605...
  • Page 33 Washer, Flat White Zinc (Ø13*Ø20*2) 3090160020 Bearing, Caster (6002-2Z) for Compass Sport GP605 WE03A104 Arm, Rear Right Caster Arm Only for Compass Sport GP605 WD2P205A Spacer, Caster Wheel White Zinc for Compass Sport GP605 WE03E202 Fork, Right Caster Assembly w/ Wheel for Compass Sport GP605...
  • Page 34 Washer, Flat White Zinc (Ø13*Ø20*2) 3090160020 Bearing, Caster (6002-2Z) for Compass Sport GP605 WE03A105 Arm, Front Right Caster Arm only for Compass Sport GP605 WD2P205A Spacer, Caster Wheel White Zinc for Compass Sport GP605 WE03E202 Fork, Right Caster Assembly w/ Wheel for Compass Sport GP605...
  • Page 35 Washer, Flat White Zinc (Ø13*Ø20*2) 3090160020 Bearing, Caster (6002-2Z) for Compass Sport GP605 WE03A103 Arm, Rear Left Caster Arm Only for Compass Sport GP605 WD2P205A Spacer, Caster Wheel White Zinc for Compass Sport GP605 WE03E203 Fork, Left Caster Assembly w/ Wheel for Compass Sport GP605...
  • Page 36 Washer, Flat White Zinc (Ø13*Ø20*2) 3090160020 Bearing, Caster (6002-2Z) for Compass Sport GP605 WE03A106 Arm, Front Left Caster Arm Only for Compass Sport GP605 WD2P205A Spacer, Caster Wheel White Zinc for Compass Sport GP605 WE03E203 Fork, Left Caster Assembly w/ Wheel for Compass Sport GP605...
  • Page 37 DESCRIPTION 31001W3011 Nut, Hex White Zinc (5/16-24UNF) 3003108011 Washer, Spring (8) 3000408011 Washer, Flat White Zinc (φ8.4*φ16*1.6) WC9P301A Mag, Black for Compass Sport GP605 4’’ 3070100030 Tire, Solid Urethane φ260*85 For Compass Sport GP605 WE03A203 Hub, For Compass Sport GP605...
  • Page 38 Compass Sport_SG_REVA_041211 Right Caster Assembly (WE03E202) ITEM PART NO. DESCRIPTION WE03P509 Cover, Caster Black Plastic for Compass Sport GP605 WE03A202 Fork, Caster Fork only for Compass Sport GP605 3110308122 Screw, Hex Head Socket Cap Black Zinc (M8*82) WC9E112A Wheel, Caster for Compass Sport GP605 WC9P202A Spacer, White Zinc (Ø12*φ8.5*4)
  • Page 39 Compass Sport_SG_REVA_041211 Left Caster Assembly (WE03E203) ITEM PART NO. DESCRIPTION WE03P509 Cover, Caster Black Plastic for Compass Sport GP605 WE03A202 Fork, Caster Fork only for Compass Sport GP605 3110308122 Screw, Hex Head Socket Cap Black Zinc (M8*82) WC9E112A Wheel, Caster for Compass Sport GP605 WC9P202A Spacer, White Zinc (Ø12*φ8.5*4)
  • Page 40 Compass Sport_SG_REVA_041211 Seat Assembly (WE03E401) ITEM PART NO. DESCRIPTION Extension, Joystick Mounting Arm with Joystick for Compass Sport WE03E402 GP605 Knob, Arm Height Adjustable for Compass GP600M/GP620M/GP605 MBH-COAHAK and Companion GC240/340/440 ( M8*20) WE03E405 Arm, Right Assembly for Compass Sport GP605...
  • Page 41 Bolt, Outer Hex White Zinc (M8*35L) 3003108011 Washer, Spring White Zinc (Ø8) Knob, Arm Width Adjustable for Compass MBA-COKAWA GP600M/GP620M/GP605M and Companion GC240/340/440 WE09E403C Arm, Left Assembly for Compass Sport GP605 SMH-GRC-1818 18x18 High Back Seat Raw 3111308030 Knobs 3110108122 Socket Screw, Black Zinc Plated 3003108012 Spring Washer (Ø8)
  • Page 42 Joystick, Dynamic Shark REMD Drive (black, no cable, pushbutton MBC-DYNSJ1 controls) Arm, Straight(fits into joystick mount) for Alante GP201R/GP202R, MBH-A3SA Compass GP600M/GP620M and Compass Sport GP605 3003105012 Washer, Spring Black Zinc (5) 3110105012 Screw, Large Hex Head Flat Black Zinc M5*16...
  • Page 43 Nut, Cap Shaped Black Zinc M8 3110308032 Screw, Large Hex Head Flat Black Zinc (M6*40) 3100108012 Socket Screw (M8) WC9P415B Adjusting Block WC9A416A Rail, Arm Top for Compass Sport GP605 WC9P489A Armrest Shell Fixed Cotton I WC9P488A Armrest Shell Fixed Cotton II...
  • Page 44 Screw, Crossed Pan Head White Zinc (M4*8) WC9P416A Shell Screw, Crossed Head Countered sunk Self Tapping White Zinc 3111804012 (M4*8) WC9P421A Tube Plug WC9A417A Bracket, Arm Joining for Compass Sport GP605 (L) WC9P420A Bayonet WC9P454A Label for Bayonet 3111004031 Flat Phillips Head Screw WC9P419A Adjustable Knob...
  • Page 45 Compass Sport_SG_REVA_041211 Left Arm Assembly (WE03E403C) ITEM PART NO. DESCRIPTION 3100208012 Pad, Arm 14" for Compass Sport GP605 WC9A409B Rail, Arm Top for Compass Sport GP605 3110108039 Screw, Large Hex Head Flat Black Zinc (M6*30) WC9P415B Nut, Hex M8 WC9A416A...
  • Page 46 WC9P417A Screw, Hex Head Socket Set Black Zinc M6*12 WC9P416A Nut, Hex Black Zinc M6 3111804012 Tube, Arm Bottom Bent For Compass Sport GP605 WC9P419A Screw, Hex Head Socket Cap Black Zinc M8*30 3111004031 Nut, Cap Shaped Black Zinc M8...
  • Page 47 Compass Sport_SG_REVA_041211 Seat Swivel Assembly (WE03E406) ITEM PART NO. DESCRIPTION WE03A406 Sear Swivel 3000608012 Spring Pin (φ8*63.5) SE1P413B Lock Handle Group SE1A404C Cross Pan Head screw 3110605092 Cross Recess Head Screw ( M5*35) 3100105012 Hex Nut ( M5) SE1P424A Torsion Spring SE1P530A Cover for Swivel lever...
  • Page 48 Right Front Caster Arm Cover (WE03E501) ITEM PART NO. DESCRIPTION WE03P503 Cover, Front Right Caster For Compass Sport GP605 WC9P510A Clip, Cover Mounting for Compass Sport GP605 3111103051 Screw, Crossed Head Countersunk Self Tapping White Zinc ST3.5*12 Left Front Caster Arm Cover (WE03E502) ITEM PART NO.
  • Page 49 PART NO. DESCRIPTION WC9P528A Sticker, Compass Sport WE03P503 Cover, Front Battery Plastic Only for Compass Sport GP605 WC9P510A Clip, Cover Mounting for Compass Sport GP605 3111103051 Screw, Crossed Head Countersunk Self Tapping White Zinc ST3.5*12 Note: Item (05) Battery Diagram Label – Not Available.
  • Page 50 Compass Sport_SG_REVA_041211 Left Fender (WE03E505) ITEM PART NO. DESCRIPTION WE03P501 Fender, Left Plastic Only for Compass Sport GP605 WC9P510A Clip, Cover Mounting for Compass Sport GP605 3111103051 Screw, Crossed Head Countersunk Self Tapping White Zinc ST3.5*12 WE03P514 Label for Drive Wheel Cap...
  • Page 51 Compass Sport_SG_REVA_041211 Joystick Motor Harness Motor Harness Wiring Diagram (WE03E601) ITEM PART NO. DESCRIPTION MBE- Battery, U1 9 12V/33AH) BATTU1 SE06A614 Nut, Hex (M6 Battery Own) 3100511010 Nut, Waterproof Protector LB-D-11S Protector Own 3000411010 Protector Pads (T=0.2 Protector Own) Cable, Battery for the Circuit Breaker Assembly for GC240, GC340, GC440 (left) Compass SE06A612 GP605 (front) WE03A603...
  • Page 52 Compass Sport_SG_REVA_041211...
  • Page 53 Compass Sport_SG_REVA_041211...
  • Page 54 Compass Sport_SG_REVA_041211 Golden Technologies 401 Bridge Street Old Forge, PA 18518 www.goldentech.com COMPASS SPORT SG_REVA_041211...

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