Golden PATRIOT GR575 User manual

Patriot
Service Guide
This Service Guide contains:
Troubleshooting
Replacement Instructions
Illustrated Parts Breakdown
Model GR575

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Table of Contents
Nomenclature and Contact Information…………………………………………………………………..3
ABOUT THIS SERVICE GUIDE..............................................................................................................4
GR575 Components.................................................................................................................................4-7
S-Drive Wiring Diagram......……………………………………………………………………………...8
S-Drive tiller Interface Socket Details (Connector CN7)...........................................................................8
Patriot Wiring Diagram...............................................................................................................................9
SCENARIO 1: Turn the Key to the On Position and No Power...............................................................10
SCENARIO 2: Batteries will not Charge...........................................…...................................................11
BEEP CODES.....................................................................................................................................12-14
BEEP CODE #2 - Low Battery Voltage...................................................................................................12
BEEP CODE #3 - High Battery Voltage..................................................................................................12
BEEP CODE #5 - Solenoid Brake Trip...............................................................................................12-13
BEEP CODE #6 - Throttle Trip (out of neutral).......................................................................................13
BEEP CODE #7 - Throttle Trip / Speed Control Fault (voltage error).....................................................13
BEEP CODE #8 - Motor Disconnected....................................................................................................14
BEEP CODE #9 - Possible Controller Fault.............................................................................................14
COMPONENT REPLACEMENT INSTRUCTIONS.........................................................................15-23
Controller...................................................................................................................................................15
Drive Wheel...............................................................................................................................................16
Dash...........................................................................................................................................................16
Key Switch, High/Low Switch, and Motor Brushes.................................................................................17
Motor/Brake Assembly........................................................................................................................18-19
Transaxle..............................................................................................................................................18-19
Batteries.................……………………………………………………………………………………....20
Shrouds.................................................................................................................................................21-23
APPENDIX A – HOW TO USE A VOLTMETER……………………………………………………..24
APPENDIX B - HOW TO USE AN OHM METER……………………………………………………25
APPENDIX C - WIRING DIAGRAMS..............................................................................................26-28
ILLUSTRATED PARTS BREAKDOWN..........................................................................................29-48
DASHBOARD AND HAND BRAKE.....................................................................................................49
WIRING DIAGRAM................................................................................................................................50

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PATRIOT NOMENCLATURE
1 – Seat Assembly
2 – Dash
3 – Tiller
4 – Front Basket
5 – Headlights
6 – Front Bumper
7 – Front Wheel
8 – Circuit Breaker
9 – Rubber Floor Mat
10 – Side Rail
11 – Drive Wheel
12 – Rear Bumper
13 – Freewheel Lever
14 – Battery Cover
15 – Arm Assembly
16 – Hand Brake
17 – Tiller Adjustment Lever
Figure 1. Patriot (Model GR575)
Contact Information
Golden Technologies
401 Bridge Street
Old Forge, PA 18518
Toll-free: 800-624-6374
Fax: [phone]
Email: [email protected]
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ABOUT THIS SERVICE GUIDE
This service guide provides you with the information necessary to repair the Golden Technologies Patriot
scooter. There are two parts to the service guide: Troubleshooting and Component Replacement. The
Troubleshooting section will assist you in finding the source of the problem. The Component Replacement
section contains step-by-step replacement instructions for key components.
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 that the batteries are in good working order. When possible, keep sets of known good batteries of
various ratings in your shop at all times. The GR575 requires 75AH batteries. Problems that surface during
troubleshooting are often due to the fact that the batteries are not fully charged or cannot hold their charge.
• Make sure that the electrical connections are secure. Unplug the connectors and make sure all of the pins are
seated properly. Push the pins back into the connector housing if necessary.
If you get to a point during troubleshooting where you cannot continue, call tech
support at 800-624-6374.
GR575 COMPONENTS
The GR575 is a battery-operated scooter controlled by a P+G Drives S-Drive controller. The S-Drive controller
monitors the systems and displays BEEP codes when it detects a fault in the system. The GR575 was designed
to operate with between 18 – 24 volts (V) of direct current (DC).
The GR575 control system is made up of the following components:
• 12V/75AH Batteries (2)
• Battery Harness(es) (2)
• Main Circuit Breaker
• Off-Board Battery Charger
• Power Harness
• Motor Brake
• P+G S-Drive Controller
• Main Harness
• Dash
• Paddle (Throttle pot)
• Speed Pot
• Key Switch
• High/Low Switch
Parts and service must be authorized by 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].
Component: 12VDC/75AH Batteries (2)
Location: Connected in series inside the battery compartment.
Function: Supply 24VDC to the motor and/or accessories (12VDC x 2).
Connections: BAT+ and BAT- are located on each battery.
Failure Signs: Batteries drain quickly. Scooter runs slowly or not at all. Batteries will not charge, but charger is
working properly. Beep Codes #2 and #3.
Tests: Load test. Fully charge the batteries first. Make sure the charging system is working.
Expected Readings: 12 - 14VDC each when fully charged. 24VDC across the B+ and B- terminals of opposite
batteries. Serviceable: Replace battery.
Component: Battery Harness(es) (2)
Location: Connected to each of the batteries.
Function: Supply 24VDC from the batteries to the S-Drive controller. (12VDC each battery x 2).
Connections: BAT+ and BAT- are located on each battery.

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Failure Signs: Scooter will not operate or stops operating abruptly. Batteries will not charge, but charger is
working properly. Beep Codes #2 and #3.
Tests: Check for corrosion and/or loose hardware. Check for 12VDC out of each battery harness. Check battery
harness(es) connections for continuity.
Expected Readings: 12 - 14VDC each when fully charged. 0 ohms resistance across each battery cable.
Serviceable: Replace harness(es) if necessary.
Component: Circuit Breaker
Location: Mounted on the front of the battery compartment.
Function: Protects battery circuit from current overload. When the current draw exceeds breaker rating, the
circuit breaker will open.
Connections: Two terminals on the circuit breaker connect the circuit breaker to the batteries.
Failure Signs: Opens repeatedly. May indicate a failed circuit breaker or short in the wiring. Also, may open if
the motors are overloaded (from excessive weight, excessive uphill driving, etc).
Test: Measure resistance across circuit breaker. Check for continuity across wires between circuit breaker and
batteries.
Expected reading: Less than 10 ohms.
Serviceable: Circuit breaker must be replaced with exact current rating. Replace wires as necessary.
Component: Battery Charger (Model: HP1202B, off-board charger only).
Location: Off-Board
Function: Recharges batteries. There is one LED on the charger. The LED is red when the charger is plugged
into an electrical outlet. If the LED does not go on, then check the electrical outlet. When the charger is on and
plugged into the charger port, an orange LED indicates that the batteries are charging. A green LED indicates
that the batteries are fully charged.
Connections: Charging Port and AC wall outlet.
Failure Signs: LED does not go on. Batteries will not charge.
Tests: Test for voltage. Test by measuring DC output of the charger.
Expected reading: 24.5VDC - 27VDC
Serviceable: Replace if necessary.
Component: Charging Harness
Location: Inside the rear tiller shroud.
Function: Provides external charger with connection to the batteries.
Connections: Charger port
Failure Signs: Batteries will not charge.
Tests: Test for voltage across the two outside pins of the charging port. Test harness for continuity.
Expected readings: Total battery voltage.
Serviceable: Replace as necessary.
Component: Power Harness
Location: Mounted inside the battery compartment.
Connections: Batteries, Circuit Breaker, and Controller
Function: Provides voltage to the controller.
Failure Signs: Scooter will not run.
Tests: Test for continuity.
Expected readings: Not open.
Serviceable: Replace as necessary.

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Component: Motor
Location: Rear section of scooter on transaxle.
Function: Drives the scooter.
Connections: Controller
Failure Signs: Scooter runs slowly or not at all.
Tests: Test for internal resistance in motor. Test motor wires for continuity. See Beep Code #8.
Expected readings: Internal resistance is less than 50 ohms but not shorted. (Note: Can be as low as 0.2 ohms).
Serviceable: Replace motor brake.
Component: Motor Brake
Location: End of motor.
Function: Parking brake for the motor.
Connections: Controller
Failure Signs: Scooter will not move or moves sluggishly. No audible click when the scooter stops.
Tests: Test for open. See Beep Code #5.
Expected readings: Less than 80 ohms but not shorted.
Serviceable: Replace motor brake.
Component: Controller
Location: Mounted inside the battery compartment.
Function: Monitors the system and beeps when something in the system is out of range. These faults are heard
as a fast series of Beeps, followed by a Beep Code (BEEP CODES 2, 3, and 5-9).
Connections: Batteries, Motor, Motor Brake, Charging Port, and Main Harness.
Failure Signs: Beep Code #9.
Tests: Test for voltage to motor when paddle is pressed.
Expected readings: Voltage varies.
Serviceable: Replace as necessary.
Component: Main Harness
Location: Front and rear sections of the scooter.
Function: Connects controller to the dashboard.
Connections: Dashboard, Hand Brake, Key Switch, Charging Port, High/Low Switch, and Controller.
Failure Signs: Scooter does not run or runs slowly.
Tests: Test for voltage at (batteries and key switch), resistance at (speed pot and throttle pot), and continuity.
Expected readings: 24VDC (batteries and key switch), resistance (speed and throttle pot) varies, and continuity
not open.
Serviceable: Replace as necessary.
Component: Paddle Assembly (throttle Pot)
Location: Underside of the dash.
Function: The throttle pot uses variable resistance to control speed and direction of travel by reversing polarity.
Connections: Dashboard
Failure Signs: Beep Codes #6 and #7
Tests: Test resistance with the paddle deflected either way.
Expected readings: Depends on direction of deflection.
Serviceable: Replace dash.

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Component: Speed Pot
Location: Dash
Function: The speed potentiometer (pot) uses variable resistance to control the top speed of the scooter.
Connections: Dashboard and Main Harness
Failure Signs: Speed will not vary when knob is turned.
Tests: See Beep Code #7
Expected readings: Depends on speed pot position.
Serviceable: Replace the dash.
Component: Dash
Location: Mounted on top of the tiller
Function: Provides connectivity between controller and key switch, battery meter, throttle pot, and speed pot.
Connections: Main Harness, Lighting Harness(es), and Throttle Pot.
Failure Signs: Damaged or loose connectors. Pins not seated properly in connectors.
Serviceable: Replace as necessary.
Component: High/Low Switch
Location: Mounted on the rear tiller
Function: Provides connectivity to the controller.
Connections: Main Harness
Failure Signs: Scooter speed does not increase/decrease when the switch is operated.
Serviceable: Replace as necessary.

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TYPICAL S-DRIVE WIRING DIAGRAM
S-DRIVE TILLER INTERFACE SOCKET DETAILS
PIN NUMBER DESCRIPTION WIRE COLOR
1 Throttle Wiper Yellow
2 Throttle High Reference Orange
3 Audible Alarm Purple
4 Slow/Fast Switch Yellow
5 On/Off Switch White
6 Inhibit 2 N/A
7 24V Red
8 Throttle Low Reference Blue
9 Speed Limiting Potentiometer Gray
10 Status Indicator Green
11 Spare N/A
12 Reverse Switch N/A
13 0V Black
14 Inhibit 3 N/A

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PATRIOT
WIRING DIAGRAM