Bruno Typhoon Scooter Manual

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Bruno Typhoon Scooter ManualI was helping a friend out this week with a project that will hopefully make life a little easier for the next person. His fiance died last fall after losing a battle with bladder cancer, and they had gotten a mobility scooter from a friend to help her get around in the last months of her battle. Unfortunately, it had been stored outside in a barn and wasn't working when they got it. After some money spent at the 'official' mobility repair shop and getting an answer that the batteries were dead and the motor seized and was 'unrepairable', it sat in the back of a car for 6 months never used. As my friend was starting to clean out and move on after his loss, I offered to take a look at it for him...

Bruno Typhoon Scooter Owners Manual

The unit was a BRUNO Typhoon C3 made in 2004, and apparently BRUNO no longer makes the scooters, just the lifts that move them in and out of cars, no repair manual available, and nothing to start from. First things first, follow the power.
Bruno
Under the rear faring
I removed the rear fairing and found the shop had 'recycled' the batteries (wondering why it was so light). So I hooked up a 24VDC/11A power supply for testing. Turning the key switch for the scooter did nothing... I removed the battery tray and disconnected the lead running into the 70A drive control. Popping open the drive control, all looked good in there, with little more than some dust and dirt in the connection openings. The battery harness was set up for connection to two 12VDC 18AH 1/2-U1 batteries, and wired so that there is a resettable circuit breaker between the cells. Battery power runs down the drive control, and is paralleled at the 6-position connector there to supply power back to 18AWG wires for the steering column controls through an 8A fuse, which was good.
As I dug into the driver controls, I noticed that I could get a very faint and momentary beep out of the horn. As I removed the control board I checked the key switch, which was fine. One trace didn't look very good. and it was the power coming off the key switch. I took the board downstairs and sure enough, didn't have continuity.
Corroded power trace (under 5X microscope)

Bruno Typhoon Scooter Manual Free

Manual
Trace repair with pink wire. Key switch connector is yellow.

I took the board back out, installed everything, and now the unit powered up, battery meter read out, and horn worked. The drive wouldn't do anything more than click.
I removed the axle/transmission/motor unit with the four bolts, and removed the motor (two M6x60 bolts, one of which was missing from the 'official' repair shop). I removed the the safety clutch with three screws and found that indeed, the motor shaft was stuck. A pair of channel locks and relatively little force broke it free. I removed both brushes, the lower was a little stuck, but seemed to be in good shape, as was the commutator. Once reassembled without the clutch, I juiced it with 24V and it spun. A quick trip to local hardware store (the HOMETOWN one, not big box, have to say I love that place for one-off small nuts and bolts!!!) got me new motor mount bolts for $2.86. Put it all back together, and it runs!!! A stop over to BatteryOne got me two new batteries for $84.70 with tax (not $300 like the mobility store was going to charge my friend!).
Darn thing works like a champ now. Hopefully the next person can get some use out of it and make enjoying life a little easier.

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