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Mini Crosser 125 Service Manual

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Mini Crosser T
Servicemanual
Type: 125, 127, 130 og 140
Version 1.4.4 Valid from 2000 - 2010
KS 23-02-2010
England

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Summary of Contents for Mini Crosser 125

  • Page 1 Mini Crosser T Servicemanual Type: 125, 127, 130 og 140 Version 1.4.4 Valid from 2000 - 2010 KS 23-02-2010 England...

  • Page 2: Table Of Contents

    Table of contents 1.0....Introduction ......................3 2.0....Safety service ......................4 3.0....List of tools ......................5 4.0....Maintenance ......................6 4.1....Once a day ....................... 6 4.2....Once a quarter ......................6 4.3....Safety inspection..................... 6 5.0....Service list, MC standard model ................7 5.1....

  • Page 3: Introduction

    Mini Crosser A/S. • For reasons of safety your Mini Crosser is designed for 10 years of use (but no more than 5,000 hours), providing that it passes a safety test every year (corresponding to 500 hours of use). Servicing must be carried out by an authorised workshop.

  • Page 4: Safety Service

    Safety service It is important to become familiar with the product before carrying out service on the scooter in order to avoid injury to technicians and users. Read the relevant sections in the user’s instructions and the service manual. Pay particular attention to the following: The main switch on the scooter MUST be turned off.

  • Page 5: List Of Tools

    List of tools The following tools are necessary to carry out service on the scooter: • A Seeger circlip • Allen wrenches • Box spanners, 7 – 17 mm • Spanners, 7 – 17 mm • Screwdrivers for Phillips and torx screws, 10, 15, 20, 25 slots •...

  • Page 6: Maintenance

    Check tyre pressure and wear on tyres. 4.3 Safety inspection For reasons of safety your Mini Crosser is designed for 10 years of use (but no more than 5,000 hours), providing that it passes a safety test every year (corresponding to 500 hours of use). Ser- vicing must be carried out by an authorised workshop.

  • Page 7: Service List, Mc Standard Model

    Service list, MC standard model Area Component Checks and remedies Suspension and Rear suspension. Check to see if the rear end of the scoo- wheels. ter is too low. The rear wheel should not scrape against the splash guard when the seat is loaded.
  • Page 8 Area Component Checks and remedies Suspension and 3W models: Front wheel. Check ball bearings for play and wear. wheels 4W: Suspension front. Check that the front wheels do not rub against the lower edge of the front shrouds. Check that the rubber damping devices, position 15 in the spare parts catalogue, are fi...
  • Page 9 Area Component Checks and remedies Steering unit/ Throttle and twist grip. It should not be possible to drive the scooter operating panel con- now. The battery indicator should ripple up and tinued. down. Twist the throttle slightly forwards when the scooter is switched on. When the throttle is released the scooter should come to a stand- still and there should be a click from the brake.
  • Page 10 (transaxle). 3.5 bar pressure in the tyres and 75 – 100 kg on the seat is: 125 – 10 km/h: 12 – 15 A 125 – 13 km/h: 14 – 16 A 130 – 15 km/h: 17 – 20 A Use a clip-on ammeter on one of the battery cables to measure this.
  • Page 11 This can be remedied by drilling a hole for a split pin between the tiller axle and the aluminium part. Contact Mini Crosser A/S. Cables. Check that the cables cannot be pinched or stretched when the handlebars are tur- ned and when the tiller is lowered.
  • Page 12 Area Component Checks and remedies Chassis, seat, Shrouds. Check to ensure that the plastic shrouds shrouds. are in good condition. Parts with sharp and projecting edges should be replaced. The same applies to shrouds with an operational function such as the splash guard and the battery shroud (water in the controls).

  • Page 13: Heating

    5.1 Heating Controler Check the controller for signs of overheating. Melted plastics. Burned wirers. Burned con- nectors. Gently fell if some of the 4 connectors at the controller have come loose. Damaged or warned wirers. If some of the wirers or 4 connectors to the controller look damaged you can repair it as described in the section “Replace receptor”.
  • Page 14 Controler Cut away the bad connector or wirer piece. Remove 10 mm of insulation. Insert the wirers to the sleeve. Adjust the tool to the correct square millimetre wirer. 8 mm2 for two motor wirers in the sleeve and 6 mm2 for one battery wirer in the sleeve.
  • Page 15 Controler Crimp the sleeve. Crimp the heat shrinkage sleeves onto the wirer and the operation is fi nished. Connectors Check to see if any of these connectors have signs of overheating, burned or damaged wi- rers. Example of burned connectors and melted wirer.
  • Page 16 Test the mechanical brake and adjust if necessary. Check if the brushes are okay or need changing. Whether it is a Schmid or a Mini Crosser trans-axle, the brushes must be replaced when they are worn down to 10 mm.

  • Page 17: Fuses And Bulbs

    Fuses and bulbs The fuses are located beneath the rear shroud. 40 A 10 A 10 A 40 A 10 A Fuse 1: 1 x 40 A fuse Charging Product number SR-00066 (40 A) Fuse 2: 1 x 10 A fuse Control system Product number SR-00066 (10 A) Fuse 3:...

  • Page 18: Plugs And Fuses In The Operating Panel

    6.2 Plugs and fuses in the operating panel MiniCrosser A/S T-127-5-002 Issue 2.0 Some of the plugs on the PCB are for extra equipment. Some of them have been connected at the factory and they have been led to the areas of the scooter where they will be used. The table below shows the cases in which the operating panel should be opened.

  • Page 19: Batteries / Charging

    The charger will fl ash until it has fi nished charging. It will then be lit up continuously. If the Mini Crosser is stored over a lengthy period of time, it is suffi cient to charge it once a month. During storage the batteries must always be kept fully charged because they will be da- maged by long-term storage in discharged condition.

  • Page 20: Storage

    INHIBIT Storage The Mini Crosser scooter is designed for use in all kinds of weather. It should be stored and charged under cover, at a temperature above 0o Celsius. In addition, the charger must be kept dry. If necessary tyres can be protected by blocking up the scooter. We also recommend covering the scooter to protect it against dust, dirt, and sunlight.

  • Page 21: Trouble-Shooting

    Control fuse blown. Change fuse. Main fuse blown. Contact your supplier. Mini Crosser won’t move. Mini Crosser has been overloa- Wait approx. 1 min. (with the ded. scooter switched off) before driving on (see page 10, Driving the Mini Crosser T).
  • Page 22 The table below indicates the types of fault that the battery indicator can show in connection with an electronic defect in the Mini Crosser. A number of lamps will fl ash. Count these and consult the table to see which type of fault is involved. Where faults 2, 3, 8, and 10 are concerned users will typically not be able to do anything.

  • Page 23: Programming Unit

    10.1 Programming unit The Driving properties of the Mini Crosser can be changed with the help of a type SP1B program- ming unit, which can also be used for more in-depth trouble-shooting. Read more about this in the enclosed manual from Penny & Giles.

  • Page 24: Air Transport Certifi Cate

    12.0 Air transport certifi cate A copy of the air transport certifi cate can be obtained by contacting Mini Crosser A/S.
  • Page 25 CERTIFICATE NON-RESTRICTED TRANSPORT OF BATTERIES ® ® ® ® Concorde’s Chairman , Lifeline , Reliant and Sun~Xtender Sealed, Valve Regulated Lead Acid [VRLA] Absorbent Glass Mat [AGM] Batteries have been tested to the U.S. Department of Transportation [DOT] requirements affecting packaging and transportation of all batteries containing acid or alkali.

  • Page 26: Special Adaptations

    Products from Mini Crosser can be specially adapted for the individual user. Any special adapta- tions must be carried out in accordance with written instructions from a person qualifi ed in this respect: a therapist or Mini Crosser A/S. When special adaptations have been carried out they will be accompanied by: •...

  • Page 27: Installing Accessories

    15.0 Installing accessories The following sections contain descriptions of how to install standard accessories on the Mini Crosser T. In cases of doubt you can contact Mini Crosser A/S. NB! Please read the precautions on page 4 »Safety service«. 15.1 Throttle regulation Installing two throttle regulators on the same vehicle.
  • Page 28 Figure 5: Install the two throttle regulators. Figure 6: Figure 7: Install the switch so that it points to Figure 8: Install the operating panel. Take care the correct side. not to pinch or stretch wires. Switch on the scooter and check that the magnetic brake clicks when the throttle is activated. When the throttle is released it should not be possible to push the scooter.

  • Page 29: Speedometer

    15.2 Speedometer Figure 1: The set comprises these Figure 2: Remove the left rear wheel. components: Figure 3: Install the magnet in the groove on Figure 4: Loosen the rear M10 bolt. Remove the fl ange. Push in. the front bolt. Figure 5: Use a self-locking nut when installing Figure 6: Install the sensor with a rubber the holder for the magnetic sensor.
  • Page 30 Figure 7: Distance between sensor and Figure 8: Connect the sensor to the socket on magnet. the aluminium plate. Figure 9: Attach the cable binder. Figure 10: Connect the speedometer to the plug beneath the rubber bellows.

  • Page 31: Lowering Curve

    15.3 Lowering curve Figure 1: The set comprises these parts. Figure 2: Remove the plastic handle from the »gas spring release«. Figure 3: Remove the rear plastic shroud by Figure 4: Install the sensor in the holder. removing the six plastic screws. Figure 5: Adjust the height of the sensor so Figure 6: Connect the sensor to socket no.

  • Page 32: Parent Potentiometer

    15.4 Parent potentiometer Figure 1: The potentiometer with plug and Figure 2: Remove the three-pin jumper. jumper. Figure 3: Install the potentiometer and push Figure 4: Install the potentiometer plug as the three-pin plug out of the shown. Remove the plastic cover aluminium plate.

  • Page 33: Hour Counter

    15.5 Hour counter Figure 1: Hour counter kit. To be installed as Figure 2: The four-pin plug is located above an intermediate cable to the the socket area on the PCB above connection to the solenoid brake. the motor. Figure 3: Remove the existing four-pin plug Figure 4: Attach the other plug from the hour from the PCB.
  • Page 34 Figure 7: Secure the cable with cable binders. Figure 8: • Switch on the scooter. • Check that the display lights up when the throttle is activated. • Check that the solenoid brake is activated when the throttle is activated, and that the scooter cannot be pushed when the throttle is released.

  • Page 35: Parent Key

    15.6 Parent key Figure 1: The set comprises these parts. Figure 2: Remove the rubber plug from the plastic cover. Figure 3: Remove the plastic handle. Figure 4: Remove the rear plastic shroud by removing the six plastic screws. Figure 5: Insert the key in socket no. 3. Figure 6: Replace the plastic shroud.

  • Page 36: Foot Pedal Throttle 3W And 4W

    15.7 Foot pedal throttle 3W and 4W Figure 1: Complete foot pedal throttle. Figure 2: Open the operating panel to install the forward/reverse switch. Figure 3: Cut out a hole for the reverse switch. Figure 4: Connect the forward/reverse switch to socket no.
  • Page 37 Figure 7: Remove the standard throttle regula- Figure 8: Connect the wires to the foot tor. Remove the rocker arm itself. If pedal throttle to the socket where you remove the potentiometer it the standard throttle regulation was is important to close the holes with installed.
  • Page 38 Figure 13: Remove the plastic handle. Figure 14: Remove the plastic shroud by remo- ving the six plastic screws. Figure 15: Insert the small crimps in the socket Figure 16: Connect the foot pedal throttle to so that the matching colours are socket number 4.

  • Page 39: Electric Seat Adjustment

    15.8 Electric seat adjustment Figure 1: Complete electric seat adjustment Figure 2: Remove the fi xed seat post. unit. Figure 3: Install the electric seat adjustment Figure 4: Connect the two-pin and fi ve-pin unit in the same holes. plugs to the wiring plate. See drawing.
  • Page 40 Figure 7: Install the box for the up/down Figure 8: Install the up/down switch in the switch beneath the armrest. box.

  • Page 41: Twist Grip Throttle Regulator - Right And Left

    15.9 Twist grip throttle regulator – right and left Figure 1: Twist grip throttle, right, and pro- Figure 2: Twist grip throttle, left, and gramming unit. programming unit. Figure 3: Remove plastic cover. Figure 4: Remove the rubber plug. Figure 5: Remove the handle. Figure 6: Remove the potentiometer.
  • Page 42 Figure 7: Install the electric plug and rubber Figure 8: Install the twist grip on the handle- plug in the hole. bars. Figure 9: Tighten the screws. Figure 10: Connect the twist grip to the three- pin plug which the standard poten- tiometer was connected to.
  • Page 43 Figure 12: Figure 13: Connect to socket 2 on the PCB. Insert the small crimps in the socket so that the matching colours are opposite each other. Figure 14: Install the switch and place the Figure 15: Program the junction box to »single- sticker as shown.

  • Page 44: Installing Accessories In The C Rail

    15.10 Installing accessories in the C rail Examples: • Walking stick holder • Zimmer frame holder • Oxygen bottle holder • Manual wheelchair holder Figure 1: Remove the rubber strip in the C Figure 2: Install the equipment. Remember profi le. Cut off the length that will not washers.

  • Page 45: Replacing Bulb In Headlight

    15.11 Replacing bulb in headlight Switch off the scooter. Remove the front shroud by removing the three screws as shown. The shroud can then be lifted off towards the front. Figure 1 Figure 2 Figure 3: Lift the bracket at the back of the Figure 4: The socket holder can now be pulled headlight upwards and remove it.

  • Page 46: Installing A Side-View Mirror

    15.12 Installing a side-view mirror Remove the rubber plug from the threaded bush on the handlebars. Twist off the centre piece as shown. Figure 1 Figure 2 Install the plug and press the rubber edge down along the edge of the round bush. Figure 3 Figure 4 Install the side-view mirror.

  • Page 47: Technical Data

    16 Technical data MC 130 T 3W MC 140 T 3W MC 130 T 4W MC 140 T 4W Transport height without seat 68 cm. 68 cm. 68 cm. 68 cm. (tiller down) Total weight 142 kg. 179,5 kg. 151,5 kg 188 kg.
  • Page 48 3.5 bar 3.5 bar Classifi cation (ISO) Class C Class C Class C Class C Mini Crosser Mini Crosser 130 T 3W & 4W 140 T 3W & 4W 56 Ah batteries v. Standard v. Standard Max. range with new batteries 40 km.

  • Page 51: Belts For Securing An Mc In A Car

    17 Belts for securing an MC in a car Beskrivelse: Selesæt til fastspænding af køretøj Description: Belts for securing a MC in car Issue: Date: Dwg. no. T-127-06-146 20-05-2003 T - 1 27 Mini Crosser SHEET 1 OF 1...
  • Page 52 SAE J2249 standards. These standards stipulate that an 85 kg wheelchair must be used for the tests, but in recognition of the fact that the Mini Crosser T series is considerably heavier, the tests were carried out to the same specifi cations as those for the lighter chair.

  • Page 53: Programming

    18 Programming 18.1 125T 3 & 4W Programmering af MC 125T + 4W med P&G Det er kun tilladt at reducer: Speed, Deceleration tid og Throttle Gain. Fast Slow Forward Acceleration Forward Deceleration Reverse acceleration Reverse Deceleration Forward Speed Reverse Speed Invert Throttle Polarity Power Down Time Current Limit...
  • Page 54 18.2 130T 3 & 4W Programmering af MC 130T + 4W med P&G Det er kun tilladt at reducer: Speed, Deceleration tid og Throttle Gain. Fast Slow Forward Acceleration Forward Deceleration Reverse acceleration Reverse Deceleration Forward Speed Reverse Speed Invert Throttle Polarity Power Down Time Current Limit 130A...

  • Page 55: & 4W

    18.3 140T 3 & 4W Programmering af MC 140T + 4W med P&G Det er kun tilladt at reducer: Speed, Deceleration tid og Throttle Gain. Fast Slow Forward Acceleration Forward Deceleration Reverse acceleration Reverse Deceleration Forward Speed Reverse Speed Invert Throttle Polarity Power Down Time Current Limit 130A...

  • Page 56: Front Wheel Alignment 4W

    19 Front wheel alignment 4W Front wheel alignment (toe-in) 4W...

  • Page 58: Wiring Diagram

    20 Wiring diagram...
  • Page 59 In case of doubt, ask. Mini Crosser A/S...

  • Page 60: Pg Drivers Technology

    21 PG Drivers Technology PG DRIVES TECHNOL PG DRIVES TECHNOL PG DRIVES TECHNOL PG DRIVES TECHNOL PG DRIVES TECHNOLOG OGY Y Y Y Y SP1B PROGRAMMER FOR SOLO AND EGIS CONTROLLERS PROGRAMMING AND DIAGNOSTICS SK73750/7...
  • Page 61 SP1B DRIVES TECHNOLOGY © PG Drives Technology 2002 All rights reserved. This manual is furnished under copyright and may only be used in accordance with the terms laid out by PG Drives Technology. The information in this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by PG Drives Technology.
  • Page 62 21.1 Indholdsfortegnelse til PG SP1B DRIVES TECHNOLOGY TABLE OF CONTENTS About this manual ..........................ICONS ................................Chapter 1 - Programming Introduction ..........................The SP1 Programmer ......................The SP1a Programmer - Basic Version ............ The SP1b Programmer - Engineering Version .......... Using The SP1b ........................
  • Page 63 SP1B DRIVES TECHNOLOGY 5.13 Low Battery Flash ? ................. 5.14 Soft-Stop ....................5.15 Throttle D’band ? ..................5.16 Output Voltage ? ..................5.17 TruCharge Cable ? ................5.18 TruCharge Cal. ? ..................5.19 Max. Charge Amps ? ................5.20 Min. Charge Amps ? ................5.21 Erase System Log? .................
  • Page 64 SP1B DRIVES TECHNOLOGY Trip Tables ..........................Trip Types and Their Possible Causes ............... Trip Type 1 - Low Battery Voltage ............Trip Type 2 - Motor Disconnected ............Trip Type 3 - Motor Wiring Trip ..............Trip Type 4 - Parking Brake Off ..............Trip Type 5 - Not Used ................

  • Page 65: About This Manual

    SP1B DRIVES TECHNOLOGY About this manual This manual is split into 3 chapters which are in turn split into separate sections. Each chapter deals with a specific issue. Chapter 1 - P Chapter 1 - P rogramming rogramming Chapter 1 - P Chapter 1 - P Chapter 1 - Programming rogramming...

  • Page 66: Chapter 1 - Programming

    21.2 Programmering SP1B - P DRIVES TECHNOLOGY ROGRAMMING CHAPTER 1 PROGRAMMING SK73750/7...
  • Page 67 SP1B DRIVES TECHNOLOGY SK73750/7...

  • Page 68: Introduction

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING Introduction The main advantage of using programmable controllers is that they can be easily tailored to the specific needs and capabilities of a particular vehicle while taking into account safe performance characteristics. The programmable controller achieves this great flexibility by referring to a set of internal parameters which govern factors such as the vehicle’s speed, acceleration and braking.

  • Page 69: The Sp1 Programmer

    SP1B DRIVES TECHNOLOGY The SP1 Programmer The SP1 is a handheld programmer for use with PGDT Solo and Egis controllers. Primarily intended for the specialized design and test requirements of electric vehicle manufacturers and engineers, the SP1 takes full advantage of the programmability of the controller, offering functions not available with less sophisticated controller designs.
  • Page 70 SP1B - P DRIVES TECHNOLOGY ROGRAMMING SP1B KEYPAD LAYOUT Enter PG DRIVES TECHNOLOGY Help Button: Pressing this button displays information regarding the function you have selected. In menus, HELP tells you what each option does. In options, it tells you what to do next. Up / Yes Button: This button steps up through the menu lists, increases the value of settings and selects functions...
  • Page 71 SP1B DRIVES TECHNOLOGY Function Range Res. SP1a SP1b Forward Acceleration 0.1 to 10s, Fast / Slow 100ms Forward Deceleration 0.1 to 10s, Fast / Slow 100ms Reverse Acceleration 0.1 to 10s, Fast / Slow 100ms Reverse Deceleration 0.1 to 10s, Fast / Slow 100ms Forward Speed 0 to 100%, Fast / Slow...
  • Page 72 SP1B - P DRIVES TECHNOLOGY ROGRAMMING Functions indicated by (1) are only available with revisions of controller’s identified by a letter on the barcode label fixed to the underside of controller as shown below. SOLO Type: D49594/X 17010001 PG DRIVES A3 60 TECHNOLOGY MADE IN ENGLAND...

  • Page 73: Using The Sp1B

    SP1B DRIVES TECHNOLOGY Using The SP1b Please read this guide carefully before using the SP1b Programmer. Programming should only be conducted by competent personnel with in-depth knowledge of PGDT electronic controllers. Incorrect programming could result in an unsafe set-up of a vehicle for a user. PGDT accept no liability for losses of any kind if the programming of the controller is altered from factory pre-set values.

  • Page 74: Root Menu

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING Root Menu The ROOT menu, contains all the parameters which set the normal drive characteristics of the vehicle. Each parameter is explained in the following paragraphs. Forward Accel’n ? Adjusts the value for forward acceleration of the vehicle, in increments of 1. There are two settings: Fast This value is used when the vehicle’s slow/fast switch is set to...

  • Page 75: Reverse Decel'n

    SP1B DRIVES TECHNOLOGY Reverse Decel’n ? Adjusts the value for reverse deceleration (or braking) of the vehicle, in increments of 1. There are two settings: Fast This value is used when the vehicle’s slow/fast switch is set to fast. Slow This value is used when the vehicle’s slow/fast switch is set to slow.

  • Page 76: Pwrdn Timer

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING On a single-ended type system, No means that if the reverse switch input is connected to 0V then direction will be reverse, Yes is opposite to this. PwrDn Timer ? A length of time can be set, such that if the controller accepts no valid input for that period of time, it will power down safely.

  • Page 77: Engineer Menu

    SP1B DRIVES TECHNOLOGY Engineer Menu ? Selection of this enters the ENGINEER menu and allows you to adjust the technical performance parameters or functions of the controller. The ENGINEER menu is included in the SP1b. Each parameter or function is described below. Current Limit ? This sets the current limit of the controller.

  • Page 78: Brake Time

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING Brake Time ? This sets the period of time between the controller detecting zero motor speed and the application of the solenoid brake. This value should be set long enough to ensure the vehicle doesn’t jerk or skid on a level surface, but short enough to minimize roll-back or roll-forward on slopes.

  • Page 79: Bridge Hold

    SP1B DRIVES TECHNOLOGY Note: this function is not present on Solo controllers. Bridge Hold ? This function allows a length of time to be set such that voltage is held on the bridge after the vehicle has come to rest. It is usually set to 200 ms and should not normally require adjustment.

  • Page 80: Low Battery Flash

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING 5.13 Low Battery Flash ? This allows you to inhibit the slow flash of the TruCharge display when a low battery condition is detected. If this inhibit is set to yes, the TruCharge display will not flash on low battery.

  • Page 81: Trucharge Cal

    SP1B DRIVES TECHNOLOGY batteries. The value corresponds to the total resistance in both the positive and negative paths. You can set this between 10mΩ and 250mΩ in steps of 5mΩ. 5.18 TruCharge Cal. ? This allows further fine calibration of the TruCharge battery gauge. This is normally set at the factory and should not need adjustment.

  • Page 82: Tips On Programming

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING Tips on Programming PGDT controllers have a large number of programmable parameters which can be used to optimize the driving performance of almost any vehicle. Many of these factors are dependent on one another, which means that if you change one factor to achieve a certain performance characteristic then other factors may also need to be adjusted.
  • Page 83 SP1B DRIVES TECHNOLOGY If you have any questions about the programming sequence, then please contact PGDT SK73750/7...

  • Page 84: Factory Programmed Options

    SP1B - P DRIVES TECHNOLOGY ROGRAMMING Factory Programmed Options Miscellaneous settings There are several settings that can be factory programmed for specific applications. Please refer to the relevant controller Data Sheet or contact PGDT for details. 7.1.1 Check Lo Ref This option allows the lo reference of a single ended throttle to be tied to 0 Volts.

  • Page 85: Safety Fences

    SP1B DRIVES TECHNOLOGY display the TruCharge trip code. This is done by pulsing the lamp on for a number of times equivalent to the number of TruCharge bars that would be flashing for a given trip. The information in Chapter 2 section 3.1.1, still applies, so for example, if an Egis with this option enabled had a throttle trip, the status lamp would flash 7 times, pause briefly, flash 7 times, pause briefly and so on.

  • Page 86: Chapter 2 - Diagnostics

    22.2 Diagnostics SP1B - D DRIVES TECHNOLOGY IAGNOSTICS CHAPTER 2 DIAGNOSTICS SK73750/7...
  • Page 87 SP1B DRIVES TECHNOLOGY SK73750/7...

  • Page 88: Introduction

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Introduction The primary objective of this chapter is to assist service personnel in finding the likely area of a detected fault within the whole scooter electrical system. It is important to realize that even though the controller is signaling a fault, it may not be the controller itself that is defective.

  • Page 89: Detecting A Trip Has Occurred

    SP1B DRIVES TECHNOLOGY Detecting a Trip has Occurred Depending on how the controller is programmed and the setup of the scooter a trip will be identified in one of two ways. • Via the TruCharge Indicator. • Via the LED or single Lamp indicator. The TruCharge indicator operates in the following manner.

  • Page 90: Trip Diagnosis

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Trip Diagnosis Depending on the type of status indicator fitted to the vehicle - single bulb (or LED) or TruCharge battery and diagnostics indicator - there are two methods of trip diagnosis. Trip Diagnosis with a TruCharge Display Type Status Indicator This section is only applicable if the vehicle is fitted with a PGDT TruCharge battery and diagnostics indicator.

  • Page 91: Trip Diagnosis With A Single Bulb (Or Led) Type Status Indicator

    SP1B DRIVES TECHNOLOGY Trip Diagnosis with a single bulb (or LED) type status indicator 3.2.1 Solo Controllers & Egis prior to 2002 If the vehicle is not fitted with a TruCharge type status indicator you will need a PGDT SP1 Programmer to determine the trip type. You must connect the SP1 to the controller whilst the status indicator is flashing rapidly, a trip message will then be displayed on the SP1’s screen.

  • Page 92: Trip Tables

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Trip Tables Trip Trip Description Code Type 0002 Possible Controller Trip 0003 Possible Controller Trip 0100 Possible Controller Trip Possible Controller Trip 0203 0204 Possible Controller Trip 0810 Throttle Trip 0814 Throttle Trip 0815 Throttle Trip 0816 Throttle Trip...
  • Page 93 SP1B DRIVES TECHNOLOGY Trip Trip Description Code Type 3602 Possible Controller Trip Possible Controller Trip 3603 3604 Possible Controller Trip 3605 Possible Controller Trip 3607 Possible Controller Trip 3608 Possible Controller Trip 3609 Possible Controller Trip 360A Possible Controller Trip 360B Possible Controller Trip 360C...

  • Page 94: Trip Types And Their Possible Causes

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Trip Types and Their Possible Causes Once the trip type has been established, refer to the relevant section below for further information. Trip Type 1 - Low Battery Voltage This occurs when the controller detects that the battery voltage has fallen below 16V. Check the condition of the batteries.

  • Page 95: Solo Controllers

    SP1B DRIVES TECHNOLOGY connected. Check that the battery charger is disconnected. 5.6.1 Solo Controllers If the charger is disconnected, then the voltage at the Solo’s inhibit input, P2-6, should be checked. Depending on whether the controller is programmed to active low or active high inhibit (see chapter 1, section 5.7), then on a correctly functioning system the voltage at P2-6 should be as below.

  • Page 96: Trip Type 8 - Possible Controller Trip

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Trip Code 0817: Short Circuit between Throttle Wiper and Throttle Low Reference (Egis Pins 7 & 5) Check the operation of the throttle potentiometer or voltage input mechanism, in particular ensure it is returning to the rest position. The following voltage measurements can be made for either a potentiometer input throttle or voltage input throttle.
  • Page 97 SP1B DRIVES TECHNOLOGY this are overcharging of the battery or bad connections between the controller and the batteries. Check the batteries and the connections to them. If the trip is still present after the batteries and connections have been checked, then the controller may be defective.

  • Page 98: Other Trip Symptoms

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Other Trip Symptoms This section covers trips which are not displayed on the status indicator by the controller. This maybe because: either the controller cannot switch on; the trip is not considered critical enough to “trip” the controller; or the controller cannot detect the trip. None of these types of trips would present a hazard to the vehicle user.

  • Page 99: Motor Or Brake Becomes Very Warm

    SP1B DRIVES TECHNOLOGY controller is programmed to non-inverting or inverting throttle polarity (refer to Chapter 1 section 5.12), then on a correctly functioning system the voltage at reverse input should be as below. If the voltages are incorrect then check the wiring and connectors to the freewheel switch.

  • Page 100: Servicing Of Defective Units

    SP1B - D DRIVES TECHNOLOGY IAGNOSTICS Servicing of Defective Units There are no serviceable parts within the controller. Consequently, any defective units must be returned to PGDT or a PGDT approved service organization for repair. Opening or making any unauthorized adjustments or modifications to the controller or its components will invalidate any warranty and may result in hazards to the vehicle user, and is strictly forbidden.
  • Page 101 SP1B DRIVES TECHNOLOGY SK73750/7...

  • Page 102: Chapter 3 - Warning Summary

    SP1B - W DRIVES TECHNOLOGY ARNING UMMARY CHAPTER 3 WARNING SUMMARY SK73750/7...
  • Page 103 SP1B DRIVES TECHNOLOGY SK73750/7...

  • Page 104: Introduction

    SP1B - W DRIVES TECHNOLOGY ARNING UMMARY Introduction This section summarizes all of the very important warnings that appear throughout the text of this manual. Do not operate the SP1 Progammer without reading, understanding and observing the following warnings. Failure to observe these warnings could result in UNSAFE CONDITIONS for the user of a vehicle or affect the reliability of the programmer and controllers.

  • Page 105: Using The Sp1B

    SP1B DRIVES TECHNOLOGY Using the SP1b Programming should only be conducted by competent personnel with in-depth knowledge of PGDT electronic controllers. Incorrect programming could result in an unsafe set-up of a vehicle for a user. PGDT accept no liability for losses of any kind if the programming of the controller is altered from factory pre-set values.

  • Page 106: Tips On Pogramming

    SP1B - W DRIVES TECHNOLOGY ARNING UMMARY Tips on Pogramming If this method is used rather than using motor manufacturer’s figures, then to allow for the effects of temperature, the compensation level should be confirmed by performing the test again when the motor and controller have fully cooled. Chapter 1 section 6.
  • Page 107 SP1B DRIVES TECHNOLOGY SK73750/7...

  • Page 108: Appendix A ... Check List

    Appendix A Check list Supplier: Mini Crosser A/S TLF: 70101755 FAX: 97188835 GENERAL CHECK LIST FOR PERIODIC INDEX NO VALID FROM: INIT. MAINTENANCE OF: 2.4.2 MINI CROSSER S - T - TJ- E 01.02.10 APPLIANCE NO INDIVID. NO MODEL SERIAL NO EXE.

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