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Golden Technologies Buzzaround Lite Service Manual

Other manuals for Buzzaround Lite: Service Manual

Summary of Buzzaround Lite

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    Buzzaround lite service guide this service guide contains: troubleshooting replacement instructions illustrated parts breakdown model gb106.

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    Buzzaround_sg_reva_040711 1.

  • Page 3: Table of Contents

    Buzzaround_sg_reva_040711 2 table of contents nomenclature and contact information...........……………………………………………………………………..3 about this service guide..............................................................................................................................4 gb106 components............

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    Buzzaround_sg_reva_040711 3 buzzaround lite nomenclature 1 – seat assembly with arms 2 – control panel 3 – battery pack 4 – rear section (drive train – motor/brake/transaxle located under rear shroud) 5 – drive wheel 6 – free wheel lever 7 – detent pin 8 – front section 9 – controller (located insid...

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    Buzzaround_sg_reva_040711 4 about this service guide this service guide provides you with the information necessary to repair golden technologies buzzaround lite. There are two parts to the service guide: troubleshooting and component replacement. The troubleshooting section will assist you in findi...

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    Buzzaround_sg_reva_040711 5 component: 12vdc/12ah batteries (2) location: connected in series inside the battery box. Function: supply 24vdc to the motor and/or accessories (12vdc x 2). Connections: bat+ and bat- are located on each battery. Bat1 – bat3 are located on the outside of battery box. Fai...

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    Buzzaround_sg_reva_040711 6 component: power harness (ph) location: rear section of scooter. Connections: ph1 – ph13 function: provides connectivity between batteries and controller, inhibit and controller, motor and controller, and motor brake and controller. Failure signs: scooter will not run or ...

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    Buzzaround_sg_reva_040711 7 component: main harness (mh) location: front section. Function: connects controller to control panel. Connections: mh1 and mh2 failure signs: scooter does not run or runs slowly. Tests: test for voltage at (batteries and key switch), resistance at (speed pot and throttle ...

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    Buzzaround_sg_reva_040711 8 rear wiring diagram bat3 ich6 ich4 bat1 bat2 ich3 ich2 cb3 bat+ bat- bat- bat+ batt ery 12v12ah batt ery 12v12ah red red black red green black in te rm ed ia t e charger harnes s ( ich) ch2 charger harnes s (ch) ch1 cb5 cb4 cb1 cb2 circuit breaker ich1 ph1 ph2 ph3 r g b r...

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    Buzzaround_sg_reva_040711 9 control panel wiring diagram 5k ohm throttle pot pinout (front view – tp1) to throttle pot connection (tp1) to main harness connection (mh2) td2 td1 purple black white blue yellow orange red nc pin 3 pin 2 pin 1 battery voltage meter power key switch (on/off) horn horn bu...

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    Buzzaround_sg_reva_040711 10

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    Buzzaround_sg_reva_040711 11.

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    Buzzaround_sg_reva_040711 12 scenario 1: no power you insert the key into the key switch, and the battery condition meter indicates no battery power. 1) check the circuit breaker (cb). • tripped? – reset it. If it resets, then operate the scooter. • not tripped? – go to the next step. • does not res...

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    Buzzaround_sg_reva_040711 13 charger tests note: the charger will not work properly if the battery voltage is to low. Boost charge the batteries to bring the voltage up to a level that the hp1202b off-board charger will see, then plug the charger into the charging port and charge for 8 hours. 1) mak...

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    Buzzaround_sg_reva_040711 14 beep code #2 – low battery voltage the battery needs charging or there is a bad connection to the battery. Check the connections to the battery. If the connections are good, try charging the battery. 1) charge the batteries. 2) if the batteries will not charge, then open...

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    Buzzaround_sg_reva_040711 15 11) unplug the brake harness (ph10) from the controller. Are the pins on ph10 seated correctly? • yes? – go to the next step. • no? – reseat the pins, reconnect the power harness to the controller, and try to run the scooter. 12) measure resistance across pin 1(orange wi...

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    Buzzaround_sg_reva_040711 16 16) connect the negative lead (black) from the multimeter to bat-. Use the bat- terminal that is connected to ich2. Measure voltage. • approximately 25vdc? – go to the next step. • out of range? – replace the main harness. 17) disconnect the main harness (mh1) from the c...

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    Buzzaround_sg_reva_040711 17 component replacement instructions controller replacement to replace the controller: 1) place the freewheel lever in the engaged position. 2) remove the key from the key switch. 2) remove the seat. 3) remove the battery box. 4) turn the scooter over onto its side. 5) rem...

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    Buzzaround_sg_reva_040711 18 drive wheel replacement to replace the drive wheel: 1) place the freewheel lever in the engaged position. 2) remove the key from the key switch. 3) place a support under the scooter frame to raise the drive wheel. 4) remove the hubcap. 5) remove the nut and washer that f...

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    Buzzaround_sg_reva_040711 19 control panel replacement to replace the control panel: 1) place the freewheel lever in the engaged position. 2) remove the key from the key switch. 3) use a slotted screwdriver to remove the control panel cover. See figure 5. 4) use a phillips screwdriver to remove the ...

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    Buzzaround_sg_reva_040711 20 drivetrain (motor/brake and transaxle) to replace the transaxle: 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 rear section from the front section. 6) remove th...

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    Buzzaround_sg_reva_040711 21 batteries to replace the batteries: 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 twelve screws holding the top and bottom halves of the battery pack together. Se...

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    Buzzaround_sg_reva_040711 22 battery replacement – continued 13) reconnect the charger harness and the intermediate charger harness. 14) place the top half of the battery pack, onto the bottom half. 15) tighten the twelve screws to secure two halves. 16) reinstall the battery pack. 17) reinstall the...

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    Buzzaround_sg_reva_040711 23 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 dc...

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    Buzzaround_sg_reva_040711 24 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 pr...

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    Buzzaround_sg_reva_040711 25 appendix c - wiring diagrams control panel main harness 1 5 8 4 white pur ple black nc blue yellow or ange red buzzer 24vdc 25k ohm speed pot 3 pin connector (male) td2 to throttle pot connector (tp1) to main harness connector (mh2) connector td1 horn button pin 3 pin 2 ...

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    Buzzaround_sg_reva_040711 26 intermediate charger harness charger harness power harness connector (ich6) to controller +24v connector (ich3) to controller inhibit connector (ich4) to controller – 0v to battery (-) terminal (ich2) to battery (+) terminal (ich5) to charger harness connector (ch2) inhi...

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    Buzzaround_sg_reva_040711 27 circuit breaker and harness intermediate motor harness to battery terminals cb6 cb3 to motor connector plate to motor connector (mt1) connector (imh1) 4 pin connector (female) imh3 imh5 imh4 imh2.

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    Buzzaround_sg_reva_040711 28 appendix d - troubleshooting flow charts scenario 1: no power you insert the key into the key switch, and the battery condition meter indicates no battery power. Not tripped? T ripped? 18vdc-25vdc? 0vdc? 12-17vdc? 18-25vdc or battery voltage? 0vdc? 0vdc? 18-25vdc or batt...

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    Buzzaround_sg_reva_040711 29 scenario 2: power to control panel, but scooter will not run. You insert the key into the key switch. The status led indicates power (but no beep code) and the battery condition meter indicates a full charge. You push the paddle and the scooter does not move. Less than 1...

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    Buzzaround_sg_reva_040711 30 beep code #2 – low battery voltage the battery needs charging or there is a bad connection to the battery. Won’t charge? 0vdc? 16-24vdc or battery voltage open? Less than 1 ohm? Beep code #3 - high battery voltage an excessive voltage has been applied to the s-drive. Thi...

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    Buzzaround_sg_reva_040711 31 beep code #5 – solenoid brake trip the parking brake has a bad connection. Outside that range? Less than 80 ohms but not shorted? Yes? No? Yes? No? Outside that range? Less than 80 ohm but not shorted? Less than 80 ohms but not shorted? Out of range? No? Yes? Less than 8...

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    Buzzaround_sg_reva_040711 32 beep code #6 – throttle trip (out of neutral) a throttle trip is indicated. Make sure the throttle is in the neutral position before switching on the scooter. Yes? No? Yes? No? Beep code #7 – throttle trip/speed control fault (voltage error). A throttle trip is indicated...

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    Buzzaround_sg_reva_040711 33 out of range? Approximately 2.7k ohms? Approximately 2.7k ohms? Out of range? No? Yes? Approximately 25vdc? Out of range? Yes? No? Approximately out of range? 2.7k ohms? Approximately 2.7k ohms? Out of range? Measure resistance across pin 1 (blue wire) and pin 2 (yellow ...

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    Buzzaround_sg_reva_040711 34 beep code #8 - motor disconnected the motor has a bad connection. 50 ohms but not shorted? Out of range? Out of range? 50 ohms but not shorted? No? Yes? 50 ohms but not shorted? Open? Beep code #9 – possible controller trip a control system trip is indicated. 1) make sur...

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    Buzzaround_sg_reva_040711 35 illustrated parts breakdown vehicle assembly (sb05e001) item part no. Description qty 01 sb05e101 front body assembly 1 02 3002325030 scooter limit set stickers 250lbs 1 03 sb3a106a metal storage basket 1 04 sb3p532a body on the right label stickers 1 05 sb3p531a label t...

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    Buzzaround_sg_reva_040711 36 front body assembly (sb05e101) item part no. Description qty 01 sb05e201 tiller, complete assembly not including colored plastic for buzz gb106 january 2010 1 02 sb3p132a knob label 1 03 sb3a501a t the knob 1 04 sb3e503a pedal pad set 1 05 sb3p501a head tube sheath paint...

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    Buzzaround_sg_reva_040711 37 rear body assembly (b05e102) item part no. Description qty 01 3110605051 cross pan head screws m5 * 16l (white zinc plated) 4 02 sb3p511a after the bumper 1 03 sb3e502a rear shell combination 1 04 3111704011 cross trough with meson drilling screw st4.2 * 13l (white zinc ...

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    Buzzaround_sg_reva_040711 38 front frame assembly (sb05e103) item part no. Description qty 01 sa2p002a handle joint seat 1 02 sb2p505a rubber sheath 1 03 3000406072 flat washer Ø6.2 * Ø13 * 1.5 (black) 2 04 3003106019 spring washer Ø6 (black) 2 05 3100206012 cap-shaped nut m6 (black) 2 06 3090400010...

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    Buzzaround_sg_reva_040711 39 23 sb2p209a stud m8 * 88l 1 24 3003108019 spring washer Ø8 (black) 2 25 3100208012 cap-shaped nut m8 2 26 3111704011 cross trough with meson drilling screw st4.2 * 13l (white zinc plated) 4 27 3002330030 barcode sticker 30 * 13 1 28 sb3p113a bottom panel 1 29 3100304011 ...

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    Buzzaround_sg_reva_040711 40 dashboard and tiller assembly (sb05e202) item part no. Description qty 01 se06a621 key, set of 2 for companion gc221/321/421/240/340/440, buzz gb106 january 2010 and literider gl110 1 02 se05p508blue cover, dashboard blue for buzz gb106 january 2010 and literider gl110 1...

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    Buzzaround_sg_reva_040711 41 front wheel assembly (sb05e203) item part no. Description qty 01 3090106080 bearing 608-2z 2 02 sb2p208a bearing sleeve electric black 1 03 sb05a201 8 "front wheels 1 seat assembly (sb05e401) item part no. Description qty 01 wc6e401a arm, assembly left for literider gl11...

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    Buzzaround_sg_reva_040711 42 05 wc9p453a square tube plug 32 * 32 * 2.5 (black) 1 06 3111308010 star bolt m8 * 20l 1 07 3000406032 flat washer Ø8.4 * Ø24 * 2 (white zinc plated) 4 08 3003108011 spring washer Ø8 (white zinc plated) 4 09 3110408081 hex bolts m8 * 25 (white zinc plated) 4 10 se1e403b b...

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    Buzzaround_sg_reva_040711 43 left arm assembly (wc6e401a) item part no. Description qty 01 wc6a405a pad, arm for literider gl110, buzz gb106 and buzz xl gb116 1 02 3110308072 large flat head socket screw m8 * 30l (black zinc-plated) 1 03 3110106032 large flat head socket screw m6 * 12l (black zinc-p...

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    Buzzaround_sg_reva_040711 44 seat swivel assembly (se1e403b) item part no. Description qty 01 se1a401b seat bottom group electric black 1 02 3000608012 rolling pin spring Ф 8 * 63.5 (black zinc-plated) 1 03 3030108010 lever sleeve 1 04 se1a404b seat lock handle set electric black 1 05 se1p413b limit...

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    Buzzaround_sg_reva_040711 45 battery box cover combinations (sb3e501a) item part no. Description qty 01 sb3p506a right decorative cover 1 02 3000411010 protector pad t = 0.5 1 03 3100511010 protector waterproof nut lb-d-11s 1 04 sb3p513a charging socket cover 1 05 3111005012 cross countersunk head s...

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    Buzzaround_sg_reva_040711 46 rear shell combinations (sb3e502a) item part no. Description qty 01 sb3p504a right wheel arc cover paint 1 02 3002343010 unlock stickers 48 * 8 1 03 3002318010 reading labels 18 * 18 1 04 sb3p503a rear shell texture on 1 05 sb3p523a back cover oval label 1 06 sb3p505a re...

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    Buzzaround_sg_reva_040711 47 front body section (sb3e504a) item part no. Description qty 01 sb3p526a foot screw black 4 02 3002300140 serial number sticker 64 * 34 1 03 sb3p502a front body texture on (black) 1 04 3002380020 battery warning labels 1 80 * 31 1 05 sb3p602a electrode insert nickel 3 06 ...

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    Buzzaround_sg_reva_040711 48 battery box assembly (sb3e601a) item part no. Description qty 01 sb3e501a combination of the battery box cover 1 02 3052512010 battery 12v12ah 2 03 3000325020 velcro hair surface 25 * 90 4 04 3000325010 velcro gill surface 25 * 90 4 05 3110904021 cross pan head tapping s...

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    Buzzaround_sg_reva_040711 49 electrode block ii (sb3e602a) item part no. Description qty 01 sb3p601a electrode folder nickel 4 02 sb3p519a electrode clamper (2) black 1 lower dashboard assembly (se05e601) item part no. Description qty 01 3110103031 large flat head cross tapping screw st3.5 * 16 (whi...

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    Buzzaround_sg_reva_040711 50 front cover assembly (se05e602) item part no. Description qty 01 se06p511 vice-speed control knob 1 02 se05p509 t to the black abs panels 1 03 sb3p608a gauge fixed film pcabs 1 04 3110103011 large flat head cross tapping screw st2.9 * 8 white zinc plated 2 05 se05a601 co...

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    Buzzaround_sg_reva_040711 51 tocos5kvr assembly (se05e603) item part no. Description qty 01 3111504022 hexagon socket set screws m4 * 6l (black zinc-plated) 2 02 se1p232a 5kvr holder se1p232a reform 1 03 se05a602 tocos5kvr line group 1 04 se05p511 paddle, plastic only (no potentiometer) for buzz gb1...

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    Buzzaround_sg_reva_040711 52.

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    Buzzaround_sg_reva_040711 53 buzzaroundlite_sg_reva _ 040711 golden technologies 401 bridge street old forge, pa 18518 www.Goldentech.Com.