P1-010 - Service Manual.pub
Contents
1. fig 12 223 Service Manual APPENDIX D IPC CONTROL PCB OPTIONAL 50K SPEED RANGE REDUCTION A POTENTIOMETER i ioe 1 IT PL PW PH 5 MAIN SPEED POTENTIOMETER INHIBIT SWI A WITCH Bu N SWITCH BRAKE BATTERY eS 3 40 3 80 MOTOR fig 13 fe UPPER CONTROL BOX WIRING DIAGRAM HORN 2 A je IB TROTTLE CONTROL E SPEED 1 lk 3 qe 8 1 SWITCH LED LIGHT HORN val fig 14 31 Shoprider Scoot APPENDIX D BATTERY VOLTAGE AUDIBLE WARNING UPPER CONTROL BOX COVER KEY 1 TO 10 SPPED SWITCH CONTROL BATTERY VOLTAGE PCB BATTERY VOLTAGE LIGHTS HORN BUTTON fig 15 Disconnection Instructions To disconnect low voltage horn GREEN TO RED PLUG LOWER COVER BLACK TO HORN UNIT 1 De solder the 1 mm black wire connecting the horn button to TP2 2 On the low voltage PCB at TP2 cover wire end with insulating tape and clip the other wires with cable tie 432 Service Manual DYNAMIC FAULT SHEET Flash Code No of flashes Fault Di2. Faulty motor SOLUTION Remove three screws holding brake to motor and check if the brake will move freely with your finger If voltage to brake is not 24V when power is turned on and when throttle is engaged re place main controller circuit board Replace motor if necessary 4 2 General Troubleshooting Tips amp Test Points The most common problem with the scooters is in the batteries Check the battery cables for secure terminal connection Measure motor voltage at the white 4 pin connector going to the motor The thicker wires are the motor wires This should measure 0 Volts when you first turn on scooter As you press throttle and increase speed this will increase to a maximum of 24 Volts Measure brake voltage at the white 2 pin connector going to the brake This should measure 0 Volts when the brake is engaged either with scooter powered on or off Once you engage the throttle the brake voltage should increase to 24 volts thus releasing the brake If less than 24 Volts is going to the brake the brake may only be partially releasing Intermittent problems are usually cause by faulty wiring Check all connections and run a continuity test on the wiring If after thoroughly troubleshooting the scooter you have any further questions please call the DMA Shoprider service department and we will be glad to assist you For warranty replacement have the Model Serial and purchase date of the sco
3. Polarity Protection When the key switch 15 turned on a pre charge control circuit detects incorrect polarity at the battery terminals and will not allow the controller to be switched on High Pedal Disable When the key switch is turned on the high pedal detect looks for applied throttle If this con dition is found the controller will remain in neutral until the throttle is returned to a low level This prevents the scooter from starting abruptly when switched on Under Voltage Detect When the batteries discharge to about two thirds of their capacity this circuit cuts back motor current to maintain battery voltage to the cut back level This prevents the batteries from de pleting completely thus helping to extend battery life Potentiometer Fault Detection If the throttle control potentiometer wire or wiper are broken this circuit will return the control ler to neutral preventing a loss of control 3 4 2 Circuit Board Replacement Curtis and IPC only 1 Disconnect the five colour coded connectors from the motor controller and remove the mounting screws 2 Remove the screws on the control box and open the casing 3 Remove the wires to the circuit breaker NOTE Breaker may be externally mounted in which case remove the wire leads on the cir cuit board 4 Remove the white two pronged connector from the electromagnetic brakes 5 Remove the two large black and red wires from the batteries 6 Remove the two
4. SERVICE MANUAL Shoprider Scoot CONTENTS CHAPTER 1 ASSEMBLY 1 1 Removal from shipping carton 3 1 2 Installing Batteries 3 1 3 Cable Connections 4 1 4 Test Procedure 4 1 5 If the Scooter will not Operate 4 CHAPTER 2 ROUTINE SERVICE 2 1 Transaxle 5 2 2 Steering 5 2 3 Seat 5 2 4 Articulation Points 5 CHAPTER 3 SCOOTER MAINTENANCE 3 1 Batteries 6 3 2 Battery Charger 6 3 3 Upper Control Box Assembly 7 3 4 Transistorised Motor Control Unit Main Control Box Assembly 9 3 5 Adjustments 10 3 6 Steering 11 3 7 Transaxle 12 3 8 Electro Magnetic Brake 13 3 9 Drive Motor 13 3 10 Tyres and Wheels 13 3 11 The Seat 14 3 12 Miscellaneous 15 CHAPTER 4 TROUBLESHOOTING 4 1 Trouble Shooting Guide 16 4 2 General Troubleshooting Tips and Test Points 22 APPENDIXES A Shoprider Light Package Installation 23 B TE 889 Battery Installation 25 C Miscellaneous Figures and Drawings 26 D Miscellaneous Controller Information 30 TOOLS REQUIRED FOR SCOOTER SERVICING 13 mm Socket with Ratchet 9 10 11 13 26 mm Spanner Soldering Iron 4 5 6 mm Allen Key Flat Head Screw Driver Pozidrive No 2 Head Screw Driver Service Manual CHAPTER 1 ASSEMBLY Shoprider Scooters will require partial assembly before delivery to customer These are gen eral instructions for assembl
5. 1 Remove the front chassis cover Shoprider Scoot 2 Raise the front wheels off the ground and place a block under the frame 3 Remove the centre bolt on the wheel hub holding the wheel to the axle spindle See fig 5 Appendix 4 Disconnect the connecting rod ball joint s from the wheel axle NOTE may be necessary to tap the joint out with a small hammer because of the compression fit 5 Remove the cotter pin and the wheel axle retaining nut 6 Pull the wheel axle straight up and remove the bearings 7 Lubricate or replace the front axle bearings if necessary 8 Install the new wheel axle 3 6 4 Converting Handle Bar to Delta Control with Reverse Throttle Con trol Not applicable on the model TE889DX DXS DXF or NB 1 Remove handle bar cover assembly See fig 7 Appendix C 2 Disconnect cable to upper control box 3 Remove upper control box assembly from the handlebars 4 Remove the two Allen screws attaching the handle bar to the steering tiller 5 Remove handlebars by pulling straight up while twisting left to right 6 Install the new delta type handle bar 7 Open casing on the upper control box 8 With a soldering gun de solder and reverse connections on the orange and yellow wires at the throttle control potentiometer or at the plug See 3 3 7 9 Close upper control console casing 10 At the thumb control lever install the two lever extensions with the nuts and
6. Electro magnetic Brake The Electro magnetic brake is located on the end of the motor and may be housed inside an aluminium cover The magnetic brake is an independent unit that joins with the motor at the drive shaft When the brake receives current from the motor control unit an electromagnetic coll releases the normally engaged disk brake Should the scooter lose its normal braking effi ciency 1t may be necessary to replace the magnetic brake 3 8 1 Replacing the Electro magnetic Brake 1 Remove the three screws holding the aluminium brake cover if applicable 2 Disconnect the cable to the brake 3 Remove the three screws attaching the brake to its connecting plate 4 The newer brakes may have a different style drive axle looks like a hex nut so the old drive axle will need to be removed Use a small nail to drive the roll pin through the hole in the drive axle and drive shaft 5 Install the new style drive axle and use a 2 mm Allen head drive to tighten 6 Install the new magnetic brake and fasten with the three screws 3 9 Drive Motor Shoprider Scooters use direct drive from the 24 Volt direct current motors The drive motors use maintenance free sealed bearings on the main shaft Should a loss of power be traced to the motor the cause is most probably insufficient contact at the carbon brushes The procedure for replacing the brushes is listed below 3 9 1 Drive Motor Removal 1 Disconnect the drive motor and magnet
7. all for use with sealed lead acid batteries The sizes of batteries are 17 30 38 48 and 70 The following specification refers to the blue or grey chargers The black smaller charger is the Shoprider battery charger that operates on a constant reading of the voltage Service Manual 3 2 1 General Specification Input 220 240 Volts 50 Hz Output The charger provides a constant current limited output until the battery on charge voltage reaches 29 Volts This voltage is then maintained constant and current gradu ally reduces as the battery becomes charged This constant voltage phase lasts for 8 hours Af ter this period has expired the battery is fully charged and a green LED on the front panel of the battery charger illuminates Maintenance After the time period described above has expired and the fully green LED has illuminated the constant voltage level falls from 29 Volts to 27 1 Volts At this level the bat tery 18 held in a fully charged condition Slow Start There is a short delay approx 2 sec after the battery is connected before charging commences This ensures that a secure battery connection has been made Overall Timer An over timer is included which starts to operate at the beginning of charge This timer is set to run for approximately 16 hours When the battery voltage reaches the con stant voltage level of 29 Volts this timer is aborted and is no longer effective If the on charge
8. travel POSSIBLE CAUSE Faulty throttle control potentiometer Loose cable connection to motor Loose battery terminal connection Worn carbon brushes or springs in motor SOLUTION Test throttle control potentiometer or try with a different upper control box assembly See 3 3 Check cable connections to motor and batteries Test with new motor installed CONDITION Horn sounds weakly when throttle applied POSSIBLE CAUSE Low battery voltage Fault at upper control box circuit board 2 Shoprider Scoot Moisture in the upper control box SOLUTION Test the batteries 3 1 1 and check battery connections Test with new upper control box assembly If this resolves problem change circuit board See 3 3 CONDITION Scooter suddenly stops while in motion and brakes engage instantly POSSIBLE CAUSE Lost contact at key switch Fuse blown at main control box assembly Lost connection in wire harness Circuit breaker tripped on control box Relay not working or lost connection to relay SOLUTION Check all wire harness connections Check fuses and circuit breakers Try replacing with new control console Check connections on relay Replace relay if necessary CONDITION Circuit breaker trips frequently POSSIBLE CAUSE Overload caused by excessive demand on motors Heavy load on a steep incline Brakes seized or no disengaging causing motor to stra
9. connection cable for shorted or open lines Check upper control box assembly for any visible faults loose wire etc See 3 5 4 Replace with another upper control box assembly if necessary Replace PCB in speed control box CONDITION Reduced braking power slow to engage slipping on incline POSSIBLE CAUSE Brakes worn out Weak spring brake Deceleration trim pot on control box circuit board improperly adjusted Throttle control pot not centred SOLUTION Brake should engage 3 5 seconds after releasing throttle Check wire connection to magnetic brake Replace electromagnetic brake if necessary Adjust dec trim pot on ctrl box circuit board only IPC amp Curtis 1203 See 3 4 Listen for brake clicking on then off when key switched on See 3 3 CONDITION Brake won t disengage or engage randomly POSSIBLE CAUSE 19 Shoprider Scoot Faulty electromagnetic brake Wires to brake disconnected Fault in wiring or in control box SOLUTION Test for voltage at wire harness to the brake by connecting a voltmeter and applying throttle If no voltage present problem is with control box Test spring brake Scooter should not be able to roll with power off Listen for brake engaging when key turned on See 3 3 Brake should stay engaged until throttle is pushed then disengage or click off CONDITION Motor runs but scooter does not move POSSIBLE CAUSE Free wheeling lever at T
10. large black and red wires from the motor control Note which wire con nects to each terminal to ensure you maintain same motor direction 7 Finally remove the five pin connector from the tiller control 8 Install new circuit board in the reverse order taking care to attach battery and motor wires in correct polarity NOTE Depending on the circuit card you have the above connections may be slightly dif ferent Be sure you label the wires as you disconnect them so that you will be able to reinstall all wires in the correct place Penny and Giles control boxes can be adjusted using the SP1B Programmer there is no need to go into the control box suitable for DT125 amp Solo 3 5 Adjustments Curtis amp IPC only 3 5 1 Throttle Acceleration and Deceleration The time it takes to go from 0 to 100 throttle in forward or reverse can be adjusted from 0 5 to 3 5 seconds by independently adjusting the ACC acceleration and DEC deceleration trim pots located on the Curtis 1203 and the IPC circuit boards See Appendix D The rela tive position of the trim pot to time constraints is illustrated on the chart The acceleration and deceleration can also be adjusted on the DS100 by using a Dynamic Programmer The accel eration and deceleration cannot be adjusted on the Curtis 1208 circuit board Because it may be necessary to make a number of adjustments to fine tune this function just remove the con troller cover and expose the
11. trim pots if possible Disconnect batteries first Use a plastic screwdriver to turn the trim pots if available WARNING Voltage may still be present at circuit board Use caution not to short any 10 Service Manual posed wires 3 5 2 Top Speed Setting Model TE 777 Only Vehicle top speed can be optionally set with the use of a resistor or trim pot located at the power output speed control potentiometer This resistor will reduce the top speed of the scooter in both forward and reverse To increase the speed of the TE 777 simply remove the resistor and re solder the wire directly to the potentiometer See Appendix D 3 5 3 Reverse Speed Scaling The reverse speed trim pot is located next to the ACC and DEC trim pots on the Curtis 1203 and IPC circuit boards The reverse speed factory setting is 60 approx This pot has an ad justable range between 40 and 100 As with the throttle ACC and DEC trim pots the re verse speed can be adjusted using the same method as above To adjust the reverse speed on the DS 100 the Dynamic programmer is needed The reverse speed cannot be adjusted on the 1208 circuit board 3 6 Steering Locking Steering Tiller The steering tiller is located at the point where the handle bar joins the steering shaft There are three types of steering tillers used on the Shoprider Scooters Both types allow the user to lock the handle bar at varied angles to the rider Although the thre
12. AUSE Uneven tyre pressure in front wheels Excessive tyre wear on one wheel Front wheels out of alignment Worn ball joints or excessive play in linkage Wheel bearing worn out or contaminated SOLUTION Lift front end and secure handle bar Grasp wheel and rock back and forth watching for loose joints See 3 6 CONDITION Excessive play in steering squealing from tyres when moving on floors POSSIBLE CAUSE Front wheel out of alignment Worn ball joints or excessive play in linkage SOLUTION Wheels pointed in different direction cause squealing Raise front end and secure steering han dle bar Rock wheels back and forth Watch for loose or worn steering linkage Use a strait edge on tires to see if they are out of alignment CONDITION Batteries not charging or not holding charge POSSIBLE CAUSE Battery voltage too low Faulty charging cable Charger not working Charging circuitry in main control box assembly not working SOLUTION Ohm test the charging cable replace if necessary Test scooter with a different charger if new charger works replace charger Check wiring in main control box assembly replace in line relay if necessary If batteries charger and all wiring are good replace controller PCB Note the model number of the PCB for example 1208 2330 CONDITION 21 Shoprider Scoot Motor overheating POSSIBLE CAUSE Brake sticking No voltage to brake Brake not releasing
13. G LIGHT B R B Y R B R G 6 B POWER CONNECTOR 2 2 22 fig 1 24 Service Manual APPENDIX B TE 889 BATTERY INSTALLATION 2 SS Bus SES UY fig 2 25 Shoprider Scoot APPENDIX C TRANSAXLE ASSEMBLY Service Manual APPENDIX C FRONT STEERING ASSEMBLY TE 888 889 bo E SEAT ASSEMBLY PRE 1994 TYPE 50 27 Shoprider Scoot APPENDIX C TILLER ASSEMBLY gt l co 9 lt 14 l ER fig 8 28 Service Manual APPENDIX UPPER SPEED CONTROL BOX fig 9 CONTROL 8 CHARGING WIRING fig 10 29 Shoprider Scoot APPENDIX D CURTIS CONTROL PCB 1203A 5 1 24 SPARE OUTLET HORN 4 BUTTON ACC a h il m li E gt 1 a a T ke CHARGE fig 11 CURTIS CONTROL 1208 3 4 LED LIGHT HORN O 25 5K HORN BUTTON 5
14. SE Circuit breaker on main control box is tripped Fuse blown check fuse in main control box assembly Incorrect polarity at battery terminals Dead batteries Charging cable is still connected to charging receptacle One of the cable connections at the main control box is loose Control connection cable disconnected Broken key switch Throttle stuck fully open Throttle control potentiometer broken Speed potentiometer broken See 3 3 After turning on key three seconds not waited Carbon brushes stuck in their housings or springs failed SOLUTION Check above possible causes first If these check OK the problem is likely to be in the con trol connection cable or upper control box Verify that the upper control box is getting 24V Blue wire on red connector Ifthe upper control box is not getting 24V replace control connection cable Ifthe upper control box is getting 24V check key switch operation and verify wiring in the up per control box Trace voltage from key switch on to find where the problem occurs Replace upper control box if necessary CONDITION Scooter has reduced power limited speed and range POSSIBLE CAUSE or both batteries need replacement Insufficient charging time batteries are not fully charged Fault with charger batteries not receiving a proper charge Cable connectors not making proper contact Corrosion or b
15. ad connection at battery terminals SOLUTION Perform a battery test See 3 1 Check all wire connections from batteries to control box Check battery charger output Check battery charger for short circuit or reverse polarity 16 Service Manual Check battery charger AC Circuit Breaker and fuse CONDITION Scooter has no power or reduced power in forward or reverse POSSIBLE CAUSE Cable connection may be loose Throttle control lever has slipped on potentiometer shaft and is not achieving full rotation Throttle or speed potentiometer is broken See Chapter 3 Throttle control lever is not centred on potentiometer shaft Acceleration trim pot on control box circuit board is adjusted to low Motor not receiving proper voltage or motor not working SOLUTION Re seat cable connections tighten nuts on battery terminals Test throttle and speed potentiometers See Chapter 3 Examine Throttle control lever for looseness on potentiometer shaft Verify that brake completely disengages when Throttle control lever is pressed Verify motor voltage from the main control box assembly Should range from OV to 24V as you engage Throttle control to full throttle If motor voltage is OK check motor to ensure it is drawing around 4 Amp unloaded If motor is drawing too much current replace motor CONDITION Erratic throttle control scooter hesitates in forward or reverse dead spots in throttle control
16. be equal 4 Turn the shaft on the potentiometer until the resistance from left to centre equals the resis tance from right to centre 5 Re install thumb lever and tighten Allen screws 3 3 4 Throttle Control 5kQ Potentiometer Replacement 1 Remove and disconnect upper control box assembly from the handle bar 2 Remove the thumb lever from the Throttle control potentiometer by loosening the two small Allen screws at the post See fig 9 Appendix C 3 Next remove the four screws that join the plastic casing 4 With a soldering iron disconnect the three wires to the potentiometer noting the positions of the colour coded wires 5 Remove the nuts and spring that are holding the potentiometer in place and then remove the potentiometer 6 Install the new potentiometer by reversing the above steps Do not forget to solder the wires to their appropriate terminals 3 3 5 Speed Control 25kQ Potentiometer Replacement 1 Remove and disconnect upper control box assembly from the handlebars 2 Remove the knob from speed potentiometer using small flat head screwdriver to loosen the holding screw 3 Open control box casing See fig 9 Appendix C 4 With soldering gun disconnect the two wires to the potentiometer noting the position of the colour coded wires 5 Remove the nut holding the potentiometer and remove the potentiometer 6 Install new potentiometer tightening the nut Solder the wires onto the correct te
17. bolts pro vided NOTE t may be necessary to replace the thumb lever Some thumb levers do not have holes pre drilled for the extensions 11 Finally re install the upper control console and handle bar cover and change the labels to denote forward and reverse NOTE Delta controls can not be fitted to NB or DX scooter models 3 7 Transaxle The motor electromagnetic brake and Transaxle are housed in one unit attached to the rear frame section The Transaxle much like a car s differential is a sealed unit requiring little or no maintenance These three components make up the drive train and can be serviced inde pendently 3 7 1 Removing the Transaxle 1 Raise the rear wheels off the ground and place a block under the frame 2 Locate the U clamp over the left axle See fig 4 Appendix C 3 Remove the two lock nuts under the frame 4 Remove the U clamp and bracket 5 Where the right axle joins the frame remove the two nuts under the frame along with the rubber spacer and bracket If the Transaxle does require lubricant simply remove the four bolts holding the motor and in sert the lubricant This refers to the Transaxle that has the motor with the worm gear from the motor The sealed Transaxle can be recognised by the motor being fixed by a coupling also ld Service Manual the motor has carbon brush holder ports that are proud The fitting on the top of the Transaxle is a breather only 3 8
18. e 4 Place the knobs into the threaded holes on the seat base and tighten to secure arms in place 5 Re engage the transmission by bringing the red lever at the Transaxle back to the lock po sition 6 Replace the rear plastic shroud cover 7 Position seats spindle over top of attachment post and then gently drop the seat into place 8 Press down on the seat locking lever This will secure the seat into place and prevent it from rotating NOTE The seat lever can be installed on the left or right side by removing the seat lever bolt and rotating the lever 90 degrees 3 11 4 Reversing Seat Locking Lever 94 1 Remove the seat from the scooter and place upside down on a clean surface 2 Remove the self locking nut holding the locking lever in place See fig 10 3 Remove the Allen type bolt retaining the seat clamping collar and install the lock lever in the reverse direction 3 12 Miscellaneous 3 12 1 Replacing the Chrome Bumper 1 Remove the two bolts located at the front of the frame under the plastic shroud 2 Place the bumper between the frame and the guard plate with the holes aligned 3 Replace the bolts and adjust the position of the bumper Now tighten the bolts into place NOTE On the newer models the bumper is pre installed 15 Shoprider Scoot CHAPTER 4 TROUBLE SHOOTING 4 1 Troubleshooting Guide CONDITION No power scooter will not move with key switched on POSSIBLE CAU
19. e steering tillers differ slightly in appearance they are both installed and removed in the same manner 3 6 1 Replacing Locking Steering Tiller 1 Remove the handle bar cover assembly See fig 7 Appendix C 2 Remove the two Allen type screws securing the handle bar to the tiller See fig 8 Appen dix C 3 Disconnect the cable to the upper control box 4 Remove the handlebars by pulling straight up while twisting left to right Skip step 5 unless you are replacing top half of tiller only 5 Remove the large bolt or knob holding both halves of the steering tiller together 6 Remove the front chassis cover 7 Remove the two Allen type screws securing the tiller to the steering shaft 8 Install the new steering tiller using the same procedure in reverse 3 6 2 Replacing the Steering Shaft 1 Remove handle bar cover ass y and charging plug receptacle fig 6 App 2 Disconnect the cable to the upper control box 3 Remove the large bolt or knob holding the two halves of the steering tiller together 4 Remove the front chassis cover 5 Remove the two Allen type screws securing the tiller to the steering shaft See fig 5 Ap pendix 6 Remove the two bolts connecting the steering shaft U plate to the steering linkage 7 Remove the bearing cap nut 8 Pull the steering shaft down through the frame 9 Retain all the bearings and housings for re assembly 3 6 3 Replacing Front Wheel Axle or Bearings
20. he slots Be careful to not scratch the paint On the long Tiller Cover Assembly the Phillips screw in front must be removed before the two pieces can be worked apart 2 Disconnect the red connector on the cable 3 Remove the four Phillips screws that hold the box to the mounting plate 4 On the new tiller 4 screws at the side of the tiller cover can be released to remove head set Shoprider Scoot 3 3 2 Testing Throttle Control and Speed Potentiometers 1 Remove and discomnect the upper control box assembly from the scooter handlebars 2 Open the upper control box casing 3 With ohmmeter check for dead spots in the throttle control potentiometer by connecting one lead to the centre terminal and the other lead to the right or left terminal 4 Slowly turn the potentiometer The ohmmeter should show a smooth resistance curve up the scale From approximately 2 5kQ at no throttle to at full throttle 5 Perform the same test for the opposite terminal If applicable 6 If there are any abrupt drops in resistance when performing this test the potentiometer should be replaced 3 3 3 Throttle Control Potentiometer Calibration 1 Remove and disconnect upper control box assembly from the handle bar 2 Remove the thumb lever from the throttle control potentiometer 3 With an ohmmeter measure the resistance from the centre to the left lead and from the cen tre to the right lead These two resistance values should
21. ic brake cables fig 3 Appendix C 2 Remove the aluminium brake cover if applicable 3 Remove the Electro magnetic brake and connecting plate 4 Remove the four Allen type bolts attaching the drive motor to the Transaxle 3 10 Tyres and Wheels Shoprider Scooters use 8 10 and 12 inch pneumatic tyres and tubes mounted on two piece split rims The entire wheel and hub can be removed for access to the wheel bearings or the tyre and rim can be removed for changing a flat tyre 3 10 1 Replacing the Inner Tube or Tyre 1 Raise the wheels off the ground and place a block under the frame 2 Remove the hubcap by grasping and pulling straight out if applicable 3 Remove the wheel from the axle by removing the 13 mm centre bolt 4 Deflate the inner tube 5 Remove the four bolts attaching the rim to the hub 6 Separate the rim from the tyre 7 You can now replace the inner tube or tyre 3 10 2 Checking the Wheel Bearings 1 Raise the wheels off the ground and place a block under the frame 2 Remove the hubcap if necessary 213 Shoprider Scoot 3 Remove the centre bolt holding the wheel rim to the hub See fig 4 App C 4 Pull the entire wheel and the hub off the axle 5 The wheel bearings can be tapped out of the hub with a small hammer against a screw driver 6 Examine bearings for build up of dirt or foreign matter 7 Clean or replace bearings as required WARNING Never remove any bolt
22. in and overheat Low tyre pressure or seized wheel bearings SOLUTION Find out what type of terrain and load scooter is subject to You may require more powerful model Check that the batteries capacity matches demand from motors See 3 1 Make certain brakes disengage when scooter moves Check that motor is not drawing too much current should be approx four amps unloaded Ifno fault found elsewhere replace circuit breaker See 3 4 CONDITION Control box hum brakes disengage click when key switched on up Scooter moves slowly without touching throttle control POSSIBLE CAUSE Throttle has not returned to neutral position May be stuck partially open 18 Service Manual Return spring worn or broken Potentiometer not centred at neutral Throttle control getting stuck on plastic tiller cover SOLUTION With an ohmmeter test throttle control potentiometer for neutral Examine return spring for excessive play Check for any obstructions in throttle control lever path Straighten upper control box if necessary CONDITION Flashing red yellow and or green LED lights POSSIBLE CAUSE Battery cable connectors not making proper contact Fault in control connection cable Fault in upper control box assembly Lost connection at relay for charging interlock in control box SOLUTION Tighten battery cable connections with wrench or pliers to ensure proper contact Check control
23. minals red to positive black to negative 2 Switch to the on position no link up to any mains power is required 3 Press the button on this will show 1 0 4 Press High the last reading will be shown 5 Press to set the amperage of the battery using the plus or minus symbols 6 When reaching the correct amperage for the battery 7 Press the start button and the test will begin 3 1 2 Common Battery Problems Sulphated cells Older batteries can have mineral build up on the internal plates causing it to have reduced power limiting the scooters range Shorted cell Although a rare occurrence this condition will cause battery to reject a charge The battery must be replaced Insufficient charge Depending on the size of batteries used and how discharged they were it can take up to 17 hours to obtain a full charge NOTE Refer to manufacturer recommendations Typically batteries have a life expectancy of 1 year depending on their usage It is recom mended that batteries be replaced in pairs when they get near the end of their life span For longer battery life it is recommended that the batteries are charged before they become completely depleted It is better to charge batteries daily after each use IMPORTANT Do not allow batteries to remain discharged for an extended period 3 2 Battery Charger There are five sizes of 24 Volt battery chargers supplied 2 A 4 A 4 Shoprider 5 A and 7 A J M Clark
24. mper front frame or red lifting handle the other person should lift from rear frame or handle on Transaxle 1 2 Installing batteries 1 Place charged batteries on to the trays located on the base of the scooter Note the position of batteries as indicated by the Pos and Neg marks on the trays 2 Bolt the battery plugs to their terminal posts on the batteries Tighten nuts with wrench or pliers to ensure a good connection IMPORTANT Connect to the appropriate terminals on the battery as indicated by Pos and Neg markings on wire harness and batteries 1 Attach the battery carrying straps and fastening strap IMPORTANT Jf batteries are installed incorrectly damage can occur to the batteries rear chassis cover and rear wheels Shoprider Scoot 1 3 Cable Connections 1 Connect the two battery plugs to their polarised mates on the control box See fig 10 Appendix C 2 Connect the main console control cable from the front section to its mate on the control box 3 Connect the charging receptacle cable from the front section to its mate on the control box 4 Connect the motor brake cable to its mate on the control box 1 4 Test Procedure 1 Insert the key into the ignition and turn to the on position 2 The green LED light should be illuminated This indicates that there is a good charge on the batteries 3 Test the horn button 4 Set the speed adjustment dial to the minimum se
25. nt No 1 010 03
26. o the black wire on the wiring harness Connect the other black headlight wire to the red wire on the wiring harness The green and yellow wires are not used tie them back with cable ties Tail Lights Drill two holes for each taillight on the top of the rear chassis cover One hole is for the mounting screw the other is to run the black wire through Mount taillights and run black wires through holes Before tightening mounting screws fully connect the red ground terminal lug to each screw on the underside of the cover Connect the male black and red wires of the taillights to the female black and red wires of the rear interconnect Use cable ties to tie back loose cabling if necessary Installation Complete Turn on the scooter and test the system SPECS PARTS LIST 24 volt DC systems 1 Wiring harness Replacement bulbs 24 volt DC 1 Rear interconnect While installing do not let the black 1 Front headlight with mounting bracket bolts and red wires touch May cause fuse and nuts to blow 2 Rear taillights with mounting screws 1 Red ground wire 1 Switch 22 Shoprider Scoot APPENDIX A WIRING DIAGRAM SINGLE LIGHT TWO REAR LIGHTS INDICATORS 2 FRONT 2 BACK INDICATOR LIGHT RBBR AUDIBLE WARNING DEVICE INCLUDED AWS GEGER FLASHER UNIT R HAZARD SWITCH GREEN LINK WIRES FITTO B INDICATOR SWITCH ON EACH TERMINAL INDICATOR a E Ge G Y 2 W Y o Y Y B B
27. ol Box Assembly and battery charger and directing out put to the motors brakes and batteries All internal connections are made with plug in type connectors making for easy circuit board installation and removal The Main Control Box Assembly is located in the rear section mounted close to the Transaxle The control box can be removed as a whole unit by removing the two screws on the mounting plate There are five colour coded quick connectors linking the control box with its various components The Shoprider and Sunrunner Scooters from 1997 on use Penny amp Giles Solo main control lers Previous controls are the Curtis PMC 1203A the Curtis PMC 1208A the Dynamic DS100 the IPC and Penny and Giles DT125 The current model is the latest state of the art Penny amp Giles Solo 60 Amp and 70 Amp The model number sticker located inside the control box on the relays can identify the control unit Identifying which controller your scooter has will help in troubleshooting However this is not possible with the Dynamic DS100 and Penny amp Giles controllers These controllers have to be returned for repair or replacement 3 4 1 Some Important Motor Controller Features Thermal Protection Both the motor and controller are protected by a circuit which detects an over temperature con dition The circuit reduces controller output drive current until the controller cools back down It then returns to normal current output Shoprider Scoot
28. oter ready as well as the consumer name The scooter model and serial numbers are located on the frame of the scooter On four wheel scooters you will find the silver label in the front axle area between the front tyres On three wheel scooters the label is located on the rear frame between the anti tip wheels Older TE 777 has the label on the frame in the battery area 20 Service Manual APPENDIX A SHOPRIDER LIGHT PACKAGE INSTALLATION Wiring 55 Lay out wiring harness four pin white connector faces back Install rear interconnect to wiring harness at four pin white connector Power Cable and Switch Remove tiller cover and connect light package power lead connector one red and two black wires attached into connector to power connector off of red upper control box connection green and blue wire The yellow green and red wires with terminal lugs are not used and should be taped back with electrical tape Run wiring harness down the tiller of the scooter and underneath the scooter along the same path as the control connection cable and charging cable Front Headlight Attach mounting bracket to the headlight using the hardware provided Mount headlight at the base of the tiller Remove the Allen head bolts from tiller and re install with mounting bracket on 3 wheel scooters this is where the red lifting handle is lo cated Connect one of the black headlight wires t
29. ransaxle is not engaged Free wheel lever is slipping on shaft SOLUTION If there is difficulty engaging lever roll the scooter ahead a bit and try again Sometimes gears are just slightly out of mesh with each other CONDITION Excessive noise from Transaxle area POSSIBLE CAUSE Gear lubricant not reaching parts of Transaxle Wheel axle bearings contaminated or worn out Imperfect mounting surfaces between Transaxle and motor faceplate SOLUTION Pull motor and check grease level in the Transaxle It should be approximately 1 2 cup of oil or grease The lubricant should be covering half of the lowest gear cog so enabling the rest of the gears to receive lubrication Gear lubricant can gravitate and pool in low areas missing some parts See Chapter 2 Remove motor and rotate 180 then re install Inspect wheel axle bearings Make sure that all nuts and clamps are secure Make certain that the motor gasket is in place CONDITION Scooter stops but lights and horn work POSSIBLE CAUSE Charging relay in motor control box is not secure Problem with the motor control printed circuit PC board SOLUTION Open motor ctrl box and remove the electricians tape from the relay Make sure all the con 20 Service Manual nections are intact Re insulate and secure the relay so that it cannot move Replace PC board See 3 4 CONDITION Scooter pulls to one side POSSIBLE C
30. rminals of the potentiometer and re install the control knob Service Manual 3 3 6 Upper Control Box Assembly Circuit Board Replacement 1 Remove and disconnect the upper control box assembly 2 Open the control box casing See fig 9 Appendix C 3 Disconnect the LED leads from the pins on the circuit board 4 With a soldering iron de solder red wire from key switch 5 De solder black wire from horn button NOTE Some boards have two Black wires to horn 6 Install the new circuit board and replace the LED leads Re solder the black and red wires NOTE Bar level indicator is replaced complete with PCB Release retaining clip under bar level indicator inside head set to remove 3 3 7 Reversing the Throttle Lever Control 1 Remove upper control box assembly and open casing See fig 9 Appendix C 2 With a soldering iron de solder the orange and yellow wires at the Throttle control poten tiometer Reverse these wires and re solder them to the potentiometer 3 Close upper control box casing The description refers to the type A version The operation on testing and repairing is the same as that of the Type B NOTE The throttle can also be reversed through Penny amp Giles control box with program mer 3 4 Transistorised Motor Control Unit Main Control Box Assembly The Motor Control Unit Main Control Box Assembly is the central processor for the scooter recelving input from the Upper Contr
31. s before deflating tire 3 10 3 Tyre Pressure Correct tyre pressure is necessary to have the scooter move with minimum resistance while maintaining a comfortable ride Tyre inflation pressures are recommended by the manufac turer for the different sized wheels and should be checked regularly An under inflated tyre can cause a sloppy ride with reduced range and uneven wear Similarly an over inflated tyre can also cause uneven wear and an uncomfortable ride The chart below shows the manufacturers recommended tyre pressure for different sized wheels Tyre pressure may be reduced by 3 p s i to give a smoother ride over small bumps Wheel Size Tyre Pressure Min Max 8 inch 25 5 1 22 25 10 inch 25 5 1 22 25 12 inch 25 5 1 20 25 14 inch 20 p s 1 15 20 3 11 The Seat The Shoprider and Sunrunner Scooters use two types of removable swivel seats One type of seat the fish on seat a folding backrest with an optional sliding bracket for forward and back ward adjustment The other type of seat used is the high back deluxe seat with headrest This seat allows the user to recline slightly however it does not work with the slider brackets Both seats can rotate 360 using a lever to lock the seat in any position Any maintenance on the seats will likely be to the locking lever assembly or the slider bracket described below Seat stem fittings from 1997 have square seat stem for the chassis 3 11 1 Replacing the Seat Sliding Bracke
32. splayed by Programmer DS 100 Condition Comment Battery needs re charging Battery voltage too low Battery voltage too high Driving still possible Drive inhibited Drive inhibited The battery voltage has dropped below 23 3 Volts in neutral Recharge the batteries soon The battery voltage at the Controller has dropped to 16 5 Volts Check the battery condition and connections The battery voltage at the Controller is greater than 32 Volts Check the battery condition and connections Suspect a charger malfunctions Current limit time out Brake feedback error Speed pot not in neutral Speed pot error Drive inhibited Drive inhibited Drive inhibited Drive possible if neutral se lected Drive inhibited The Controller has detected a shorted motor Check the loom for shorts or check out the motor Contact your Service Agent Check that the park brake release switch is off Check the park brake and wiring for open or short circuits Contact your Service Agent Return the speed lever to neutral Readjust the speed lever neutral if necessary Con sult your Service Agent Check speed pot wiring for open or short circuits Speed pot may not be correctly set up Contact your Service Agent Motor volts error Other internal er rors Drive inhibited Drive inhibited Contact your Service Agent Contact your Service Agent 233 Docume
33. t 1 Remove the seat from the scooter and place upside down on a clean surface 2 Remove the four bolts holding the locking swivel base to the sliding bracket See fig 10 3 Remove the four Allen type bolts attaching the sliding bracket to the seat 4 Install new sliding bracket 14 Service Manual 3 11 2 Replacing the Seat Locking Lever and Collar Adj Seat Height 1 Remove the seat from the scooter and place upside down on a clean surface 2 Remove the self locking nut holding the locking lever in place See fig 10 3 Remove the Allen type bolt retaining the seat clamping collar 4 The 1995 or newer models except TE 999 have 5 height adjustment so the locking lever and collar can be moved to a different position thus raising or lowering the height of the seat NOTE Jf the lever sticks spray some lubricant WD 40 on the post If this does not work remove some of the paint away from the collar Use a rubber mallet to tap the collar off the post WARNING Changing seat height affects the stability of scooter 3 11 3 Seat and Locking Swivel Base Pre 96 1 Place the seat upside down on a clean surface 2 Position the swivel base over the four bolts on the bottom of seat sliding bracket Bolt the swivel base onto the seat sliding bracket with the arm holders positioned toward the back rest See fig 10 3 Insert the arms into their appropriate holders on the left and right sides of seat bas
34. tiller lever 2 Remove front plastic shroud 3 Unscrew lock nut and collar at steering shaft 4 Lubricate with a light oil 5 Inspect ball joints and steering linkages for stiffness 2 3 Seat 1 Remove seat from scooter and place upside down 2 Apply grease along slider at base of seat 3 Add a thin coating of grease to seat post on scooter frame 2 4 Articulation Points There are two points where the frame allows for lateral movement The rear articulation point is located where the drive section joins the frame The front articulation point is located where the steering section joins the frame Spray some light oil or similar lubricant into these areas Shoprider Scoot CHAPTER 3 SCOOTER MAINTENANCE 3 1 Batteries When the batteries resist a charge have limited life or discharge prematurely this is usually an indication that the charger is faulty or the batteries may need replacement Although a battery may show a voltage near twelve volts this does not necessarily ensure the batteries ability to hold a charge Special battery testers are available to detect any faults in sealed lead acid batteries 3 1 1 Battery Testing The batteries supplied with all the scooters are all sealed lead acid either the Gel type or re combination type To ensure the true test of the batteries are carried out it is necessary to use the special Battery tester available the procedure is as follows 1 Connect the clips to the ter
35. tting Press the forward and then the re verse on the thumb control lever On models fitted with Penny and Giles control main controllers there is a three second delay before the switch will operate 5 Test forward and reverse at variable speed settings The scooter should accelerate and de celerate smoothly 1 5 If the scooter will not operate 1 Check that all the wire harness connections at control box are attached to their mates 2 Check for correct polarity connections at the battery terminals 3 Make sure the terminal bolts at the batteries have been tightened 4 Make certain the batteries are fully charged 5 Check that the battery charger plug is not connected This will cut the power to the scooter 6 Check that the red lever at transmission is engaged In the lock position NOTE If there is no fault found at these points refer to trouble shooting guide located in Chapter 4 of this manual Service Manual CHAPTER 2 ROUTINE SERVICE LUBRICATION Shoprider Scooters should be lubricated in the following areas as indicated below 2 1 Transaxle The Transaxle is a sealed unit and should not need lubrication unless it is leaking or has devel oped a squeak or noise If this is the case look to page 22 in the Troubleshooting guide sec tion of this manual We recommend the use of semifluid gear gel or an equivalent grease de pending on what the Transaxle contains 2 2 Steering 1 Remove handle bar at
36. voltage fails to reach 29 Volts due to battery failure the charge is terminated after the pre set period as a safety precaution 3 2 2 General Operating Instructions The battery to be charged must have a terminal voltage of 12 Volts minimum If batteries are discharged below this level the charger will not operate Please follow the operating instruc tions given on the battery charger WARNING Do not expose to rain or spray Do not obstruct ventilator slots or over heat ing will result No smoking or naked flames in battery vicinity Under no circumstances should this charger be used to attempt to recharge non rechargeable batteries To change the power cord the charger must be returned to the manufacturer 3 3 Upper Control Box Assembly Type A Complete control box dark Grey in colour Type B The tiller cover includes all the operating components Type A The upper control box assembly is located on the top of the steering handle This control box can be replaced as whole unit See 3 1 1 below There are a number of serviceable compo nents inside the control box as noted See fig 9 Appendix C 3 3 1 Removing Upper Control Box Assembly 1 Remove the tiller cover The two pieces of the tiller cover assembly are held together by plastic tabs See fig 7 Ap pendix C To remove the cover carefully insert a flat head screwdriver at the seam on the lower left side and push on the inner piece to work the tabs out of t
37. y Components may vary slightly between models NOTE Upon receipt of the scooter please open the carton and inspect the scooter BE FORE SIGNING THE RECEIVING DOCUMENT Ifunable to do so please sign for the scooter UNCHECKED Please note any damage on the receiving document You are respon sible for inspecting the scooter immediately for shipping damage 1 1 Removal from shipping carton 1 Carefully remove the packaging from the carton Scooter should be right side up 2 Remove all loose pack parts and set aside for later use 3 Using a knife cut down the carton at the front of the scooter Do not cut down carton if scooter has been damaged Advise DMA immediately so that there can be a claim made on the carriers Go to step 6 for removal without breaking down carton 4 Release scooter by moving free wheel lever at the rear of the scooter 5 Wheel scooter out of the container CAUTION Do not pull on plastic shroud 6 Bring handle bar to the up right position and lock into place with red tiller lever 7 Remove the seat by first pulling up the seat lever and then pulling straight up on the seat You may need to turn the seat from side to side as you are pulling straight up 8 Remove the rear plastic shroud by pulling gently straight up 9 To lift scooter directly out of box without breaking down box first follow steps 6 8 With two people carefully remove scooter from box One person should lift at front bu
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