Golden Technologies GP162 Service Manual
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Golden Technologies GP162 Service Manual

Literider ptc
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See also: Owner's Manual
LiteRider PTC
Service Guide
Model GP162
This Service Guide contains:
Troubleshooting
Replacement Instructions
Illustrated Parts Breakdown

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Summary of Contents for Golden Technologies GP162

  • Page 1 LiteRider PTC Service Guide Model GP162 This Service Guide contains: Troubleshooting Replacement Instructions Illustrated Parts Breakdown...
  • Page 2 LiteRider PTC_GP162_SG_REVA_051614 www.goldentech.com info@goldentech.com...

  • Page 3: Table Of Contents

    LiteRider PTC_GP162_SG_REVA_051614 Table of Contents Nomenclature and Contact Information ....................3 ABOUT THE LITERIDER PTC SERVICE GUIDE ………………………………....... 4 LiteRider PTC Components .………………………………………………………………………..4-6 The VR2 Controls ..........................7-8 SCENARIO 1: Press the on/off button and the LED array does not light up ........9-10 SCENARIO 2: Batteries will not charge ....................

  • Page 4: Nomenclature And Contact Information

    12. Off Board Battery Charger 13. Rear Section 14. Drive Wheel 15. Rear Anti-Tip Wheel 16. Motor/Brake Assembly 17. Diagnostic Label 18. Battery Box Contact Information Golden Technologies 401 Bridge Street Old Forge, Pa. 18518 Toll-free: 800-624-6374 Fax: 800-628-5165 Email: parts@goldentech.com www.goldentech.com info@goldentech.com...

  • Page 5: About The Literider Ptc Service Guide

    This service guide provides you with the information necessary to troubleshoot the Golden Technologies LiteRider PTC (GP162) equipped with the PG VR2 controller. The troubleshooting scenarios in this manual consist of procedures that enable you to systematically trace and correct faults in the system.
  • Page 6 LiteRider PTC_GP162_SG_REVA_051614 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. Failure Signs: Power chair will not move or moves sluggishly. No audible click when the chair stops. Tests: Test for open circuit.
  • Page 7 LiteRider PTC_GP162_SG_REVA_051614 Component: PG VR2 Power Module Location: Front 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 Vr2 Controls

    LiteRider PTC_GP162_SG_REVA_051614 VR2 USER CONTROLS Battery Gauge On/Off Button Horn Button Maximum Speed / Profile Indicator Speed / Increase Profile Button Speed / Decrease Profile Button CONTROL PANEL (FRONT VIEW) VR2 CONTROLS On/Off Button and Battery Gauge The on/off button applies power to the control system electronics, which in turn supply power to the wheelchair’s motors.
  • Page 9 LiteRider PTC_GP162_SG_REVA_051614 To unlock the wheelchair: • Use the on/off button to switch the control system on. The maximum speed / profile indicator will be rippling up and down. • Deflect the joystick forwards until the control system beeps. • Deflect the joystick in reverse until the control system beeps. •...

  • Page 10: Scenario 1: Press The On/Off Button And The Led Array Does Not Light Up

    LiteRider PTC_GP162_SG_REVA_051614 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. If the batteries are not fully charged or connected properly, then voltage measurements may produce faulty readings.

  • Page 11: Scenario 2: Batteries Will Not Charge

    LiteRider PTC_GP162_SG_REVA_051614 11. Measure Resistance across the terminals on the circuit breaker. • Less than 10 ohms – Go to the next step. • Open – Replace the circuit breaker. 12. Check continuity across the circuit breaker wires. Remove the positive (red) terminal and the negative (black) terminal wires from the batteries and check continuity across each wire.

  • Page 12: Troubleshooting Guide For (Pg Vr2)

    LiteRider PTC_GP162_SG_REVA_051614 Troubleshooting Guide for the VR2 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 13: Control System Status Indication

    LiteRider PTC_GP162_SG_REVA_051614 Control System Status indication The battery gauge and maximum speed / profile indicator show the status of the control system. Battery Gauge is Steady This indicates that all is well. Battery Gauge Flashes Slowly The control system is functioning correctly, but you should charge the battery as soon as possible. Battery Gauge Steps Up The wheelchair batteries are being charged.

  • Page 14: Step 2: Checking "Flash Codes

    LiteRider PTC_GP162_SG_REVA_051614 Step 2: Diagnostic “Flash Codes” If a system trip occurs, you can find out what has happened by counting the number of bars on the battery gauge that are flashing. Below is a list of self-help actions. Go to the number in the list which matches the number of flashing bars to diagnose the problem.

  • Page 15: Flash Code 3: Left Motor Wiring Trip

    LiteRider PTC_GP162_SG_REVA_051614 Flash Code 3: Left Motor Wiring Trip A. Check the resistance of the left 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 16: Flash Code 6: Charger Connected

    LiteRider PTC_GP162_SG_REVA_051614 B. Check the resistance of the M1 motor connector on the controller.  Disconnect the battery from the controller.  Set your meter to the 200k ohm scale.  Touch the leads together to make sure the meter is accurate. You should have 0 ohms at this point. If not, your meter needs to be calibrated.

  • Page 17: Flash Code 10: High Battery Voltage

    LiteRider PTC_GP162_SG_REVA_051614  Place the red and black meter leads on the two top pins of the left and right motor connectors as shown in figure 7.  Meter reading should be between 40 and 80 ohms.  Any reading outside this range, replace that park brake. C.

  • Page 18: Battery Charging Guidelines

    LiteRider PTC_GP162_SG_REVA_051614 IMPORTANT New batteries MUST be fully charged prior to the initial use of the power chair. Charge new batteries for 12 hours even if the battery gauge already shows a full charge. This is to condition the new batteries for maximum performance. •...
  • Page 19 LiteRider PTC_GP162_SG_REVA_051614 Battery Charging Alternatively, you may charge the battery pack directly. 1. Remove the battery pack from the power chair. 2. Locate the charger port on the right side of the battery pack and swing the cover out of the way. 3.

  • Page 20: Electrical Connections

    LiteRider PTC_GP162_SG_REVA_051614 VR2 POWER MODULE CONNECTIONS VR2 50 BATTERY MOTOR 1 MOTOR 2 Brake +ve Brake -ve Brake +ve Brake -ve Motor +ve Motor -ve Motor +ve Motor -ve Right Motor Brake Circuit Brake Left Motor Breaker INHIBIT 2 ON-BOARD CHARGER ACTUATORS Note: The inhibit-2, on-board charger, and actuator connections are not being used on this power chair.

  • Page 21: Wiring Diagram

    LiteRider PTC_GP162_SG_REVA_051614 WIRING DIAGRAM www.goldentech.com info@goldentech.com...

  • Page 22: Replacement Instructions

    LiteRider PTC_GP162_SG_REVA_051614 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 17mm nut holding the drive wheel onto the axle. Note: Make sure to retain the nut and washer. 5.

  • Page 23: Motor/Brake Assembly

    LiteRider PTC_GP162_SG_REVA_051614 MOTOR/BRAKE ASSEMBLY 1. Turn off power. 2. Place the power chair in drive mode. 3. Disconnect the bus cable coming from the joystick. 4. Remove the seat. 5. Remove the battery box. 6. Disconnect the motor harness (either left or right) from the power module. 7.

  • Page 24: Power Module

    LiteRider PTC_GP162_SG_REVA_051614 POWER MODULE 1. Turn off power. 2. Place the power chair in drive mode. 3. Disconnect the bus cable coming from the joystick. 4. Remove the seat. 5. Remove the battery box. 6. Remove the basket by removing the (4) Phillips head screws securing it to the frame. 7.
  • Page 25 LiteRider PTC_GP162_SG_REVA_051614 8. Remove the two batteries. 9. Place the two new batteries into one half of the battery box. 10. Reconnect each battery harness to each battery terminal and tighten the hardware. 11. Place the second half of the battery box on top of the first half, reinstall the (8) Phillips head screws and tighten to secure.

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

    LiteRider PTC_GP162_SG_REVA_051614 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

    LiteRider PTC_GP162_SG_REVA_051614 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

    LiteRider PTC_GP162_SG_REVA_051614 ILLUSTRATED PARTS BREADOWN LITERIDER PTC Model GP162 www.goldentech.com info@goldentech.com...
  • Page 29 LiteRider PTC_GP162_SG_REVA_051614 Vehicle I (WF07E100) ITEM PART NO. DESCRIPTION QTY. WE01E101 Vehicle Right-side of the sticker WE01P509 Front cover labels SE06P123 WE01P508 Left-side stickers www.goldentech.com info@goldentech.com...
  • Page 30 LiteRider PTC_GP162_SG_REVA_051614 Vehicle II (WF07E101) ITEM PART NO. DESCRIPTION QTY. Seat Assembly WE01E401 Battery Box Assembly SE05E604 Label, Fault Diagnostic PP WE01511 Main Body Assembly I WF07E102 Charger 24V-3A 3050303010 Label, Max Load 275LBS WE01P510 SE05P516 Label, Warning WF07E104 Rear Body Assembly www.goldentech.com info@goldentech.com...
  • Page 31 LiteRider PTC_GP162_SG_REVA_051614 Front Frame Assembly I (WF07E102) ITEM PART NO. DESCRIPTION QTY. Screw, Cross Recessed Pan Head M4 * 12L 310604012 Washer, Flat Ø4.3 * Ø8 * 0.5 3000404042 Basket, Plastic PP WE01P501 Front Caster Arm Assembly WE01E201 Battery Adapter Cable Assembly WE01E601 Screw, Phillips Countersunk Head M5 * 16L 3111005052...
  • Page 32 LiteRider PTC_GP162_SG_REVA_051614 ITEM PART NO. DESCRIPTION QTY. Handle, Frame Lock WF07A103 Spring, Small Torsion 65Mn WF07P118 Lock 45 WF07P115 Screw, Hexagon socket head M5 * 25L 3110305032 Washer, Nylon A66 WF07P116 Screw, Hexagon socket head M5 * 25L 3111706152 WE01P503 Logo, Left-side Decorative Plate Plug NR SA2P139A...
  • Page 33 LiteRider PTC_GP162_SG_REVA_051614 Front Frame Assembly II (WF07E103) ITEM PART NO. DESCRIPTION QTY. Screw, Cross recessed Pan Head M4 * 35L 3110604122 Washer, Flat Ø4 * Ø9 * 0.8 3000404012 Controller VR2-50A 3051600070 Screw, Cross Recessed Pan Head M5 * 16L 3110605052 Controller Adapter Cable 3052300170...
  • Page 34 LiteRider PTC_GP162_SG_REVA_051614 ITEM PART NO. DESCRIPTION QTY. Foot Plate Assembly WE01E104 Bolt, Hexagon Round Head M6 * 40L 3110206022 Frame, Main Front Half WF07A101 Nut, Nylon M4 3100304012 Nut, Hexagonal M6 3100106012 Standoff SE05A107 Front Frame Electrode SF07A601 3111004062 Screw, Phillips Countersunk Head M4 * 14L Footplate Assembly (WE01E104) ITEM PART NO.
  • Page 35 LiteRider PTC_GP162_SG_REVA_051614 Rear Assembly (WF07E104) ITEM PART NO. DESCRIPTION QTY. Drivetrain, Right-side Assembly WF07E106 Frame, Rear Assembly WF07A102 Washer, Flat Ø8.4 * Ø16 * 1.6 3000408012 Washer, Spring 3003108012 Screw, Hexagon Socket Head M8 * 30L 3110308039 Screw, Hexagon Socket Head M8 * 45L 3110308049 Wheel, Anti-Tip Ø75 * 25 3070503010...
  • Page 36 LiteRider PTC_GP162_SG_REVA_051614 Left Wheel Assembly (WF07E105) ITEM PART NO. DESCRIPTION QTY. Cap, Wheel ABS SE06P517 Washer, Rear Tire Cover Fixed WE03P204 SE06E506 Wheel, 9-inch Cover Wheel, Drive 9 inch WE01E202 Motor/Brake Assembly, Left-side RA04E102 Handle, Brake PP WE03P510 Nut, Nylon M4 3100304012 Lever, Brake Q235B WF07P117...
  • Page 37 LiteRider PTC_GP162_SG_REVA_051614 Right Wheel Assembly (WF07E106) ITEM PART NO. DESCRIPTION QTY. Cap, Wheel ABS SE06P517 Washer, Rear Tire Cover Fixed WE03P204 SE06E506 Wheel, 9-inch Cover Wheel, Drive 9 inch WE01E202 Motor/Brake Assembly, Right-side RA04E101 Handle, Brake PP WE03P510 Nut, Nylon M4 3100304012 Lever, Brake Q235B WF07P117...
  • Page 38 LiteRider PTC_GP162_SG_REVA_051614 Caster Arm Assembly (WE01E201) ITEM PART NO. DESCRIPTION QTY. WE03P512 Cap, Caster Arm 3100312011 Nut, Nylon M12 White Zinc 3000413041 Washer, Flat φ13 * φ20 * 2 White Zinc 3090160020 Bearing, 6002-2Z WE03P149 Spacer WE01A201 Caster Dual arm Metal Only WE03E202 Caster Fork with Wheel and Mud Flap Right WE03E203...
  • Page 39 LiteRider PTC_GP162_SG_REVA_051614 Drive Wheel (WE01E202) ITEM PART NO. DESCRIPTION QTY. 31001W3011 Nut, Hex 5 / 16 "-24 UFN White Zinc 3003108011 Washer, Spring Φ8 White Zinc 3000408011 Washer, Flat Φ8.4 * Φ16 * 16 White Zinc SE06P215 9" Wheel SE06P225 9”...
  • Page 40 LiteRider PTC_GP162_SG_REVA_051614 Seat Assembly (WE01E401) ITEM PART NO. DESCRIPTION QTY. WC6E403A Joystick with Straight Arm 3111308010 Knob WC6E402A Right Arm Assembly WE01E402 Seat Swivel Assembly 3000408031 Washer, Flat Φ8.4 * Φ24 * 2 White Zinc 3110408081 Bolt, Hex M8 * 25L White Zinc WC6E401A Left Arm Assembly WS62E100...
  • Page 41 LiteRider PTC_GP162_SG_REVA_051614 Seat Swivel Assembly (WE01E402) ITEM PART NO. DESCRIPTION QTY. WE01A402 Seat Swivel Plate Metal Only 3000608012 Pin, Spring Φ8 * 63.5 Black Zinc SE1P530A Seat Swivel Handle Cover Paddle Style SE1A404C Seat Swivel Handle SE1P413B Spacer SE1P424A Spring, Double Torsion Φ2 Black Zinc WC9P453A Plug WC9P529A...
  • Page 42 LiteRider PTC_GP162_SG_REVA_051614 Seat Tube Assembly (WE01E403) ITEM PART NO. DESCRIPTION QTY. WE01A402 Seat Swivel Plate Metal Only 3000608012 Pin, Spring Φ8 * 63.5 Black Zinc SE1P530A Seat Swivel Handle Cover Paddle Style www.goldentech.com info@goldentech.com...
  • Page 43 LiteRider PTC_GP162_SG_REVA_051614 Right Caster Assembly (WE03E202) ITEM PART NO. DESCRIPTION QTY. WE03P509 Mud Flap WE03A202 Caster Fork Only 3110308122 Screw, Hex Socket M8 * 82 Black Zinc WC9E112A Caster Wheel WC9P202A Spacer, Ø12 * φ8.5 * 4 White Zinc 3100308012 Nut, Nylon M8 Black Zinc www.goldentech.com info@goldentech.com...
  • Page 44 LiteRider PTC_GP162_SG_REVA_051614 Left Casters Assembly (WE03E203) ITEM PART NO. DESCRIPTION QTY. WE03P509 Mud Flap WE03A202 Caster Fork Only 3110308122 Screw, Hex Socket M8 * 82 Black Zinc WC9E112A Wheel, Caster WC9P202A Spacer, Ø12 * φ8.5 * 4 White Zinc 3100308012 Nut, Nylon M8 Black Zinc www.goldentech.com info@goldentech.com...
  • Page 45 LiteRider PTC_GP162_SG_REVA_051614 Left Arm Assembly (WC6E401A) ITEM PART NO. DESCRIPTION QTY. WC6A405A Arm Pad 3110308072 Screw, Cap M8 * 30L Black Zinc 3111706052 Screw, φ8/M6 * 33L Black Zinc 3100108012 Nut, Hex M8 Black Zinc 3110106032 Screw, Cap M6 * 12L Black Zinc WC6A401A Left Arm Tube www.goldentech.com...
  • Page 46 LiteRider PTC_GP162_SG_REVA_051614 Right Arm Assembly (WC6E402A) ITEM PART NO. DESCRIPTION QTY. WC6A405A Arm Pad 3110308072 Screw, Cap M8 * 30L Black Zinc 3100108012 Nut, Hex M8 Black Zinc 3111706052 Screw, φ8/M6 * 33L Black Zinc WC6A402A Right Arm Tube 3110106032 Screw, Cap M6 * 12L Black Zinc 3003106012 Washer, Spring φ6 Black Zinc...
  • Page 47 LiteRider PTC_GP162_SG_REVA_051614 Controller Assembly (WE6E403A) ITEM PART NO. DESCRIPTION QTY. 3051600060 Joystick WC6A403A Joystick Straight Arm 3003105012 Washer, Spring φ5 Black Zinc 3110105012 Screw, Cap M5 * 16L Black Zinc 17. 9" Wheel Cover Group (SE06E506) ITEM PART NO. DESCRIPTION QTY.
  • Page 48 LiteRider PTC_GP162_SG_REVA_051614 Battery Box Assembly (SE05E604) ITEM PART NO. DESCRIPTION QTY. SE05P503 Battery Box Cover 3052512100 Battery, 12V18AH 3110604062 Screw, Phillips Pan M4 * 40L Black Zinc 3003104012 Washer, Spring Ø 4 Black Zinc 3000404012 Washer, Flat Ø 4 * Ø9 * 0.8 Black Zinc SE05E609 Battery Harness 3111003012...
  • Page 49 LiteRider PTC_GP162_SG_REVA_051614 www.goldentech.com info@goldentech.com...
  • Page 50 Golden Technologies 401 Bridge Street Old Forge, PA 18518 www.goldentech.com LITERIDER PTC_GP162_SERVMAN_REVA_051614...

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