Golden Technologies Buzzaround Extreme GB118EX User manual

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Buzzaround Extreme
Service Guide
This Service Guide contains:
Troubleshooting
Replacement Instructions
Multi-meter Instructions
GB118EX GB148EX

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Table of Contents
Nomenclature and Contact Information.........................................................................................................4
ABOUT THE BUZZAROUND EXTREME SERVICE GUIDE..................................................................5
Buzzaround Extreme Components............................................................................................................5-10
Wiring Diagram.......................................................................................................................................11-12
SCENARIO 1: Turn the key to the on position and no power.....................................................................13
SCENARIO 2: Batteries will not charge......................................................................................................14
BEEP/FLASH CODES...........................................................................................................................15-20
BEEP/FLASH CODE #1 – Batteries Low (Scooter may drive slowly).......................................................15
BEEP/FLASH CODE #2 – Batteries Low (Scooter will not operate).........................................................15
BEEP/FLASH CODE #3 - High Battery Voltage........................................................................................15
BEEP/FLASH CODE #4 - Current Limit Timeout.................................................................................15-16
BEEP/FLASH CODE #5 - Brake Fault..................................................................................................16-17
BEEP/FLASH CODE #6 - Paddle Fault (out of neutral).............................................................................17
BEEP/FLASH CODE #7 - Paddle Fault/Speed Control Fault (voltage error)........................................18-19
BEEP/FLASH CODE #8 - Motor Voltage Fault (Open/Shorted)..........................................................19-20
BEEP/FLASH CODE #9 - Controller Fault.................................................................................................20
BUZZAROUND EXTREME REPLACEMENT INSTRUCTIONS......................................................21-27
Drive Wheel..................................................................................................................................................21
Drive Train....................................................................................................................................................21
Throttle Pot...................................................................................................................................................21
Battery...........................................................................................................................................................22
Circuit Breaker..............................................................................................................................................23
Battery Harness Fuse....................................................................................................................................23
Controller......................................................................................................................................................23
Main Harness................................................................................................................................................24
Control Panel................................................................................................................................................24
Motor/Brake..................................................................................................................................................25
Front Intermediate Harness.....................................................................................................................25-26
Rear Intermediate Connector........................................................................................................................26
Power Harness..............................................................................................................................................27
APPENDIX A - HOW TO USE A VOLTMETER......................................................................................28
APPENDIX B - HOW TO USE AN OHM METER...................................................................................29

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BUZZAROUND EXTREME NOMENCLATURE
Figure 1. Buzzaround Extreme (Model GB118EX)
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1 - Seat Assembly with arms
2 - Control Panel
3 - Battery packs
4 - Rear Section
5 - Freewheel Lever
6 - Drive Wheel
7 - Front Section
8 - Controller (located under floor panel)
9 - Removable Anti-Slip Floor Panels (Gray/Textured)
10 - Front Wheel
11 - Tiller
12 - Front Basket
13 - Seat Post
14 - Bolt, Arc Washer, and Nut
15 - Lockup Handle
16 - LED Headlight
17 - Tiller Adjustment Knob
18 - Tiller Lock Knob
19 - LED Taillight
20 - Drive Train (Transaxle, Motor, and Brake)
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Contact Information
Golden Technologies
401 Bridge Street
Old Forge, PA 18518
Toll-free: 800-624-6374
Mobility Tech: x501
Lift Chair: x502
VA Tech: x505
Fax: [phone]
Email: [email protected]
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This service guide provides you with the information necessary to troubleshoot the Golden Technologies
Buzzaround Extreme GB118EX/GB148EX. 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 measure voltage and continuity with a multimeter.
Before troubleshooting, check the following:
Make sure that the circuit breaker is reset.
Visually check terminals for corrosion. Check wires for missing insulation.
Make sure the battery terminals are securely tightened.
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 Buzzaround Extreme
uses two (2) 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.
Make sure that the electrical connections are secure. Unplug the connectors and make sure all the
pins in the connectors are seated securely. If necessary, push any unseated pins back into their con-
nector housings to securely seat them.
If you get to a point during troubleshooting where you cannot continue, call
Technical Support at 800-624-6374.
BUZZAROUND EXTREME COMPONENTS
The Buzzaround Extreme is a battery-operated scooter with a controller that monitors the system and beeps
when it detects a fault in the system. The Buzzaround Extreme was designed to operate within a range of
between 18 - 24 volts (V) of direct current (DC).
The Buzzaround Extreme control system is made up of the components listed below. Each
of these components is designated by its assigned number. Refer to the wiring diagram on page 11.
• Circuit Breaker (1)
• 12V Batteries (2 and 3)
• Battery Harnesses (4)
• Power Harness (5)
• Dynamics R-Series Controller (6)
• Main Harness (7)
• Front Intermediate Harness (8)
• Rear Intermediate Connector (9)
• Motor/Brake Assembly (10)
• Brake (11)
• Control Panel - includes Speed Pot (12), Key Switch (13), Horn Button, and Battery Meter
• Throttle Pot (14)
• Charger Harness (15)
• Off-Board Battery Charger – (Not shown)
Parts and service must be authorized by the Golden Technologies Service
Department. Unauthorized parts or service may void the warranty. For more information, contact the
Golden Technologies Service Department at 800-624-6374 or [email protected].

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Component: Circuit Breaker - #1
Location: Mounted on the right-side battery pack. See figure 2.
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 positive (+) terminal on one battery and the negative (-) terminal
on the other. (Note: Both circuit breaker wires are orange in color.)
Failure Signs: Opens repeatedly. May indicate failed circuit breaker or short in the wiring. May also open if the
motors are overloaded (from excessive weight, excessive uphill driving, etc).
Test: Measure the resistance across the circuit breaker and the wires that connect the circuit breaker to the batteries.
Expected reading: Less than 10 ohms.
Serviceable: 40 amp circuit breaker must be replaced with exact current rating.
Figure 2. Battery packs (Qty. 2) Figure 3. Inside Battery packs
Component: 2-12VDC Batteries - #2 and #3
Location: Inside the Battery packs. See figure 3.
Function: Supply 24VDC to the motor and/or accessories (12VDC x 2).
Connections: Connected in series. The positive (+) terminal of one battery is connected to the negative (-) of the
other (red wires) through the circuit breaker (1). The most positive and negative terminals are connected to the (red and
black wires) to the controller through the power harness (5). Refer to the wiring diagram on page 11.
Failure Signs: Batteries drain quickly. Scooter runs slowly or not at all. Batteries will not charge, but charger is
working properly. Beep Code #1 or #2.
Tests: Fully charge the batteries first and load test. Make sure the contacts are not corroded. See figure 4 below and
figure 16 on page 14.
Expected Readings: 12 - 14VDC each when fully charged.
Serviceable: Replace batteries as necessary.
Component: Battery Harness - #4
Location: Inside the Battery packs. See figure 3.
Function: Connects the batteries to the Power Harness (5).
Provides short circuit protection through a 100-amp inline fuse,
located on the left-side battery harness only.
Connections: Connected to the power harness, batteries, and
battery fuse. Refer to the wiring diagram on page 11.
Failure Signs: Corroded wires may cause the batteries not to
work properly. Make sure connector pins are seated properly.
Batteries will not charge if the inline fuse is blown. Figure 4. Scooter Battery Connection
Tests: Test the harness for continuity. Test the fuse for continuity.
Expected Readings: Less than 10 ohms.
Serviceable: Replace the harness as necessary. Replace inline fuse with exact type and rating. See figure 3.
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Figure 5. Controller
Component: Power Harness - #5
Location: Mounted to the front frame – located under the battery packs. See #5, figure 4 on page 6.
Function: Connects the Battery packs to the controller.
Connections: Connects the battery packs to the controller (Bat -) and (Bat +) connections.
Refer to the wiring diagram on page 11.
Failure Signs: Scooter will not power up. The controller is not receiving the correct battery voltage.
Tests: Test harnesses for continuity. Check connectors. Make sure the contacts are not corroded and are seated
properly. Slide a quarter into each of the four contacts to test the spring tension. Each one should retain the quarter, not
allowing it to fall out.
Expected Readings: Continuity (less than 10 ohms).
Serviceable: Replace as necessary.
Component: Controller - #6
Location: Mounted to the front frame - under the floor shroud. See #1 on figure 5.
Function: Controls and monitors the system. Uses a series of beeps/flashes when something in the system is out of
range.
Connections: Connected to the main harness, charger & inhibit, brake, motor (M-M+), battery (B-B+). See figure 5.
Refer to the wiring diagram on page 11.
Failure Signs: Beep Code #9. No power to the control panel or the motor.
Tests: Test for voltage coming into and out of the controller.
Expected readings: Battery voltage.
Serviceable: Replace as necessary.
Component: Main Harness - #7
Location: Inside the tiller and under the frame. See #2 on figure 5.
Function: Provides connectivity for the tiller components and the controller.
Connections: Connected to the controller, and control panel. Refer to the wiring diagram on page 11.
Failure Signs: Scooter will not run.
Tests: Test for voltage and continuity. Check connectors. Make sure the pins are not corroded and are seated properly.
Expected readings: Battery voltage. Continuity (less than 10 ohms).
Serviceable: Replace as necessary.
Main
Harness
Charger & inhibit
Brake
M- M+
Bat- Bat+
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Component: Front Intermediate Harness - #8
Location: Mounted on the front frame. See figure 6.
Function: Provides connectivity between the motor/brake
and the controller.
Connections: Connected to the rear intermediate connector (9)
and the controller (6). Refer to the wiring diagram on page 11.
Failure Signs: Scooter will run slowly or not at all.
Tests: Test for voltage and continuity. Check connectors.
Make sure the pins are not corroded and are seated properly.
Expected readings: Continuity (less than 10 ohms).
Serviceable: Replace as necessary.
Component: Rear Intermediate Connector - #9
Location: Mounted on the rear frame. See figure 7.
Function: Provides connectivity between the motor/brake Figure 6. Front Intermediate Harness
and the controller.
Connections: Connected to the front intermediate
harness (8) and the motor/brake assembly (10).
Refer to the wiring diagram on page 11.
Failure Signs: Scooter will run slowly or not at all.
Tests: Test for voltage and continuity. Check connectors.
Make sure the contacts are not corroded.
Expected readings: Continuity (less than 10 ohms).
Serviceable: Replace as necessary.
Component: Motor/Brake Assembly - #10
Location: Mounted on the transaxle. See #1 on figure 8.
Function: Drives the scooter.
Connections: Connected to the rear intermediate connector (9)
and the brake (11). Refer to the wiring diagram on page 11.
Failure Signs: Scooter runs slowly or not at all. Figure 7. Rear Intermediate Connector
Tests: Test for internal resistance in motor. Test motor
wires for continuity. See Beep Codes #5 and #8.
Expected readings: Internal motor resistance is
0.8 ohms – 1.5 ohms. Brake resistance is 45 ohms – 52 ohms.
Serviceable: Replace the motor/brake assembly.
Component: Brake - #11
Location: Mounted on the end of the motor. See #2 on figure 8.
Function: Keeps the motor from moving when the power is off.
Connections: Connected to the rear intermediate connector (9).
Refer to the wiring diagram on page 11.
Failure Signs: Scooter runs slowly or not at all.
Tests: Test for internal resistance. See Beep Code #5 on page 16
and Beep Code #8 on page 19.
Expected readings: Brake resistance is 45 ohms – 52 ohms.
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Component: Speed Pot (Potentiometer) - #12
Location: Mounted on the control panel. See #1 on figure 9.
Function: The speed pot uses variable resistance to control the
speed of the scooter.
Connections: Connected to the main harness through the control panel
harness.
Failure Signs: Beep Code #7
Tests: Call Tech Support
Expected readings: Depends on speed pot position.
Serviceable: Yes. Replace the speed pot.
Component: Key Switch - #13
Location: Mounted on the control panel. See #2 on figure 9.
Function: Completes the circuit to provide power to the motor.
Connections: Connected to the main harness through the
control panel harness.
Failure Signs: No power when the key is in the “ON” position.
Tests: Continuity when the key is in the “ON” position. Make
sure the connector pins are seated properly.
Expected readings: Less than 10 ohms.
Serviceable: Yes. Replace the key switch.
Component: Throttle Pot (Potentiometer) - #14 Figure 9. Control Panel (Back)
Location: Below the control panel. See #1 on figure 10.
Function: The throttle pot uses variable resistance
to control speed and direction of travel by varying voltage.
Connections: Connected to the main harness (7) and 1amp in-line fuse.
Refer to the wiring diagram on page 11.
Failure Signs: Beep Codes #6 and #7.
Tests: Test resistance across pins 1, 2, and 3 on the throttle pot.
Expected readings: Depends on direction of deflection.
Serviceable: Replace as necessary.
Component: Charger Harness - #15
Location: Left-side of tiller below the control panel. See #15 on figure 11
on page 11.
Function: Connects the charger to the batteries.
Connections: Connected to the controller (6), and the charger not shown.
Refer to the wiring diagram on page 11.
Failure Signs: Batteries will not charge.
Tests: Test for voltage and continuity. Check connectors.
Make sure the pins are not corroded and are seated properly.
Expected readings: Continuity (less than 10 ohms).
Serviceable: Replace the harness as necessary.
Figure 10. Throttle Pot
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Component: Off-Board Charger (Not shown)
Location: Stored inside a pouch on the seatback.
Function: Recharges batteries.
Connections: Connects to the charger port on the tiller. Refer to
the wiring diagram on page 11.
Failure Signs: Charger power LED does not go on. Batteries
will not charge.
Tests: With the charger connected to the charger port, measure
voltage across the most negative (black wire) and most positive
(red wire) battery terminals. While observing the voltage reading,
plug the charger into the wall outlet and make sure the voltage
reading increases.
Expected readings: Battery voltage first, approximately 27 volts
when fully charged. Then voltage should increase to approximately
29.5 volts with the charger connected and plugged into the wall outlet.
Also, refer to the charger test on page 13. Test charger harness and
fuse for continuity.
Serviceable: Replace if necessary.
Only use the charge that was supplied with the scooter. The charger was specifically
designed and tested for the product it came with.
Some Off-Board Battery Chargers may have a switch that enables them to be used with either
110 VAC or 230 VAC. This switch is typically located on the end of the charger. Some may also have a removable
glass fuse. *Fuses must be replaced with exact type and rating.*