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Summary of Contents for Golden Companion
- Page 1 Companion Service Guide This Service Guide contains: Troubleshooting Replacement Instructions...
- Page 2 Contact Information Golden Technologies 401 Bridge Street Old Forge, PA 18518 Toll-free: 800-624-6374 Fax: 800-628-5165 Lift Chair/Bed Tech: x502 Mobility Tech: x501 VA Tech: x505 Email: parts@goldentech.com WWW.GOLDENTECH.COM info@goldentech.com PAGE - 2...
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Page 3: Table Of Contents
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 WON'T CHARGE ....................14 FLASH CODES ................................ 15 FLASH CODE #1 – Batteries Low (Scooter may drive slowly.) ....................15 FLASH CODE #2 –... -
Page 4: About The Companion Service Guide
• Make sure that the batteries are fully charged and are in good working order. When possible, keep sets of known good batteries of various ratings in your shop at all times. The Companion uses two (2) 35AH (U1) batteries. Problems that surface during troubleshooting are often due to the fact that the batteries are not fully charged or cannot hold their charge. - 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.
- 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).
- Page 7 Component: Front Intermediate Motor Harness (11) Location: On the right side of the front frame. See figure 7. FRONT INTERMEDIATE MOTOR HARNESS Function: Provides connectivity for Rear Intermediate Motor Harness (10) and the Controller (8). Connections: Connects to the Rear Intermediate Motor Harness (10a) and the Controller (8b, 8c, and 8d.) Failure Signs: Scooter will run slowly or not at all.
- Page 8 Component: Speed Pot (15) Location: Control Panel. See figure 10. Function: The speed potentiometer (pot) uses variable resistance to control the top speed of the scooter. Connections: Control Panel Harness Failure Signs: Flash Code #7 Tests: Call Tech Support Expected readings: Depends on speed pot position. KEY SWITCH SPEED POT Serviceable: Replace the Control Panel.
- 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.
- Page 10 *24V/5W bulbs Figure 13. Companion Wiring Diagram WWW.GOLDENTECH.COM info@goldentech.com PAGE - 10...
- Page 11 CONNECTOR 9a CONNECTOR 9a (Front View) CONNECTOR 9b (Front View) CONNECTOR 9b NOTE: Color shades may vary. Figure 14. Companion Wiring Schematic WWW.GOLDENTECH.COM info@goldentech.com PAGE - 11...
- Page 12 NOTE: Color shades may vary. Figure 15. Companion Wiring Schematic (Control Panel) WWW.GOLDENTECH.COM info@goldentech.com PAGE - 12...
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Page 13: Scenario 1: Turn The Key To The On Position And No Power
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. -
Page 14: Scenario 2: Batteries Won't Charge
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. -
Page 15: Flash Codes
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. -
Page 16: Flash Code #5 - Brake Fault
Make sure that the batteries are secure. Lower the tiller. 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. -
Page 17: Flash Code #6 - Paddle Fault (Out Of Neutral)
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 “+”... -
Page 18: Flash Code #8 - Motor Voltage Fault (Open)
11) Insert the multimeter probes into the main harness connector 9a at pin 1 and pin 8 (blue wire and yellow wire.) See figures 13 and 14. Note the resistance reading. Insert the multimeter probe into the main harness connector at pin 1 and pin 2 (yellow wire and orange wire.) Note the resistance reading. •... -
Page 19: Flash Code #9 - Controller Fault
14) Inspect the front and rear intermediate motor harness connectors. Are they discolored or corroded? • No? - Replace as necessary. • Yes? - Go to the next step. 15) Take a quarter and slide into the contacts marked “+” and “-” on the front intermediate motor harness connector. -
Page 20: Companion Replacement Instructions
COMPANION REPLACEMENT INSTRUCTIONS MOTOR/BRAKE ASSEMBLY Tools needed: 13mm socket, 5mm hex key, 6mm hex key, wire cutters. Place the freewheel lever in the engaged position. Remove the key from the key switch. Remove the seat. Remove the rear shroud. Remove the batteries. -
Page 21: Motor Brush Replacement
MOTOR BRUSH REPLACEMENT Tools needed: Slotted screwdriver Place the freewheel lever in the engaged position. Remove the key from the key switch. Remove the seat. Remove the rear shroud. Remove the motor brush cap. (See #1 on figure 21.) Remove the brush. Install the new brush. -
Page 22: Throttle Pot Replacement
THROTTLE POT REPLACEMENT Tools needed: Phillips screwdriver Place the freewheel lever in the engaged position. Remove the eight (8) screws that fasten the back tiller shroud to the tiller. Disconnect the throttle pot from the main harness. Remove the two (2) screws that fasten the throttle body to the tiller shroud (See #1 on figure 24.) Remove the two screws that fasten the throttle lever to the throttle control lever bracket (See #2 on figure... -
Page 23: Circuit Breaker Replacement
CIRCUIT BREAKER REPLACEMENT Tools needed: Slotted screwdriver, Phillips screwdriver, adjustable wrench Place the freewheel lever in the engaged position. Remove the key from the key switch. Remove the seat. Remove the rear shroud. Remove the batteries. Use a slotted screwdriver to pry off the circuit breaker cover. -
Page 24: Charger Harness Fuse Replacement
15. Reconnect the front and rear frames. 16. Reinstall the batteries. 17. Reinstall the rear shroud. 18. Reinstall the seat. CHARGER HARNESS FUSE REPLACEMENT Place the freewheel lever in the engaged position. Remove the eight(8) screws that fasten the back tiller shroud to the tiller. - 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.
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Page 26: Appendix A - How To Use A Voltmeter
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. -
Page 27: Appendix B - How To Use An Ohm Meter
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: Appendix C - Wiring Diagram
APPENDIX C - WIRING DIAGRAM 24V/5W bulbs WWW.GOLDENTECH.COM info@goldentech.com PAGE - 28... - Page 29 Golden Technologies 401 Bridge Street Old Forge, PA 18518 www.goldentech.com Yo u r L i f e I n M o t i o n GCX40SERVMAN_06/11/2013...