Mini Crosser 125 User manual

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

2
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..................Heating................................................................................................................... 13
6.0..................Fuses and bulbs .................................................................................................... 17
6.1..................Diagram of battery connections.......................................................................... 17
6.2..................Plugs and fuses in the operating panel............................................................... 18
7.0..................Batteries / charging .............................................................................................. 19
8.0..................Storage................................................................................................................... 20
9.0..................Cleaning ................................................................................................................. 20
10.0................ Trouble-shooting ................................................................................................... 21
10.1................Programming unit ................................................................................................. 23
11.0................International addresses........................................................................................ 23
12.0................Air transport certificate ........................................................................................ 24
13.0................Special adaptations .............................................................................................. 26
14.0................Declaration of conformity .................................................................................... 26
15.0................Installing accessories........................................................................................... 27
15.1................Throttle regulation................................................................................................. 27
15.2................Speedometer ......................................................................................................... 29
15.3................Lowering curve...................................................................................................... 31
15.4................Parent potentiometer............................................................................................ 32
15.5................Hour counter ......................................................................................................... 33
15.6................Parent key .............................................................................................................. 35
15.7................Foot pedal throttle 3W and 4W ............................................................................ 36
15.8................Electric seat adjustment ...................................................................................... 39
15.9................Twist grip throttle regulator – right and left ........................................................ 41
15.10..............Installing accessories in the C rail ...................................................................... 44
15.11..............Replacing bulb in headlight.................................................................................. 45
15.12..............Installing a side-view mirror................................................................................. 46
16...................Technical data ....................................................................................................... 47
17...................Belts for securing an MC in a car ........................................................................ 51
18...................Programming......................................................................................................... 53
18.1................125T 3 & 4W ........................................................................................................... 53
18.2................130T 3 & 4W ........................................................................................................... 54
18.3................140T 3 & 4W ........................................................................................................... 55
19...................Front wheel alignment 4W.................................................................................... 56
20...................Wiring diagram ...................................................................................................... 58
21...................PG Drivers Technology ......................................................................................... 60
Appendix A ... Check list ............................................................................................................. 108

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This service manual is a supplement to our spare parts catalogue and user’s instructions.
• Use the spare parts catalogue to find product numbers of parts that need to be replaced.
The drawings in the catalogue show in general how to replace the individual parts.
• The service manual contains pictures showing how to make changes to and/or install
electrical accessories step by step.
• The user’s instructions contain a general description of how to use the scooter. For the
sake of clarity the information on maintenance, batteries / charging, and trouble-shooting
from the user’s instructions is also included in this service manual.
• The user’s instructions contain instructions for general maintenance of the scooter.
• Service and repairs may only be carried out on the scooter by authorised persons trained
by 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.
• IMPORTANT! For safety reasons it is of the utmost importance that the servicing
and safety check intervals are complied with as this minimises the risk of brake
failure and short-circuits in the wiring with possible heat generation and fire to follow.
• Mini Crosser is always available to provide telephonic help in connection with questions
regarding trouble-shooting. Where faults connected with an apparent electrical defect are
concerned please inform us of the fault code. This is shown on the steering unit display.
Read more about this in the section “Trouble-shooting”.
• We would also ask you to inform us of the scooter’s serial number in connection with all
inquiries to Mini Crosser A/S.
• Mini Crosser reserves the right to update the service manual in connection with any
changes to or improvements in the product.
1.0 Introduction
Mini Crosser A/S
Telefon: [phone]
E-mail: [e-mail]
Internet: www.minicrosser.com

4
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:
1. The main switch on the scooter MUST be turned off. Remove the ignition key. When
carrying out service on electrical components the positive pole on the battery MUST also
be removed.
2. When measuring voltage in connection with trouble-shooting be very careful not to create
a short-circuit.
3. Be very careful not to short-circuit the battery poles.
4. Take care when lifting heavy components such as seats, batteries, and motor gears, and
do not drop these.
5. Always lift one rear wheel in order to ensure that the scooter cannot move under power in
connection with incorrect operation.
6. Always use professional, properly maintained tools.
7. If lock nuts are removed in connection with servicing, NEW nuts MUST be used when
reassembling the scooter.
8. When installing new cable strips make sure they are installed in the same way as they were
originally. Make sure that cables cannot be pinched by moving parts or project so that
clothing can catch on them.
9. Always finish off servicing by making sure that the product is in roadworthy condition.
• Check that all plugs are correctly installed and that all mechanical components have
been properly tightened.
• Start the scooter and check that the solenoid brake clicks when the throttle is
activated. When the throttle is released it should not be possible to push the
scooter.
2.0 Safety service

5
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
• Pointed pliers
• Side-cutting pliers
• A plastic hammer
• A set of punches
• A retractable knife
• A steel brush
• An adjustable pipe wrench
• A wire and cable stripper
• Cable socket pliers
• Pliers for Molex 5556/5558 crimps
• Riveting tongs
• Small and large cable binders
• A multimeter
• A battery tester
• A tyre pressure gauge
• A tyre pump with automatic valve
• Acid-free oil and grease
• Locktite 406 / 603
• Repair kit, lacker black 9005 dim lustre 30 +/-5 (Item number SR-04804)
3.0 List of tools

6
The following can be carried out by the user and/or a helper.
4.1 Once a day
Check lights and indicators.
Test the indicators and also the lights before using the scooter at night or in conditions where
visibility is poor.
4.2 Once a quarter
1. Check the brakes.
It should not be possible to push the Mini Crosser when the brake release lever is pushed
back.
2. Check the brake release mechanism.
When the brake release lever is pushed forwards it should not be possible to drive the Mini
Crosser even when the throttle is activated. The battery indicator should flash and indicate
defect 9.
When the release lever is pushed backwards and the scooter has been switched off and
switched on again it should be possible to drive it. It should not be possible to push the
scooter now.
3. Check throttle regulation
Activate the throttle when the scooter is switched off. Then switch on the scooter. It should
not be possible to drive it now. The battery indicator should ripple up and down.
Twist the throttle slightly forwards when your scooter is switched on. When you release
the throttle your scooter should come to a standstill and there should be a click from the
brake. It should not be possible to push your scooter now. Carry out the same check while
turning the throttle slightly backwards.
4. Lubricate the rocker arm on the front brake hub using acid-free oil.
5. 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.
IMPORTANT! For safety reasons it is of the utmost importance that the servicing and safety
check intervals are complied with as this minimises the risk of brake failure and short-circuits in
the wiring with possible heat generation and fire to follow.
4.0 Maintenance

7
5.0 Service list, MC standard model
Area Component Checks and remedies
Rear suspension. Check to see if the rear end of the scoo-
ter is too low. The rear wheel should not
scrape against the splash guard when
the seat is loaded. Replace the blue sus-
pension blocks behind the battery. See
the spare parts catalogue.
Check to see if the rear suspension
and the transaxle are securely installed.
Tighten or install nuts and bolts.
Check that cables cannot be-
come caught in moving parts.
Install cable binders.
Check the wheels. Check to ensure they are properly tighte-
ned and that the rims are in good condi-
tion.
Check tyre pressure and wear
on tyres.
Recommended tyre pressure: 3.5 bar
(50 PSI). Minimum tread height for good
road holding is approximately 1 mm.
See spare parts catalogue for disassem-
bly.
NB! The rear wheels and front wheels on
4W models MUST always be removed
by loosening the five screws. NEVER
loosen the flange itself by removing the
screw in the centre. See spare parts
catalogue. NB! Always deflate the inner
tube before disassembling wheels.
Check that the handbrake
works.
Lubricate the rocker arm on the front
brake hub using acid-free oil. Adjust
cable length with the help of the adjust-
ment nipple. In cases of defective com-
ponents – see spare parts catalogue.
3W models: Front forks. Sus-
pension and straightness.
Check that the front forks are resilient.
Have they become crooked? Are there
oil leaks? If there are defects that must
be remedied replace the entire front
forks. See spare parts catalogue.
Suspension and
wheels.

8
Area Component Checks and remedies
Suspension and
wheels
3W models: Front wheel. Check ball bearings for play and wear.
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 firmly attached. They
must be installed so that they just touch
the axle beam. See the spare parts cata-
logue.
4W models: Check that the
Rosta suspension block has
not been displaced after a
collision so that the front axle
beam scrapes against the
bottom frame.
Loosen the four installation bolts/nuts
and push the block back into position.
See spare parts catalogue.
4W models: Front wheel sus-
pension.
Check that the guide rods and guide
balls are in good condition and properly
tightened.
Check the ball bearings in the front
wheels and in the guide spindles for
play/wear.
Front wheel alignment. See sketch
below for correct alignment if uneven
tyre wear makes this necessary.
Lights, indicators, hazard
lights, and horn.
Check functions and check that the con-
tacts are in good condition.
If the indicators and/or lights are defec-
tive: replace bulbs if necessary.
If this does not help check the plug
connections, and he fuse in the steering
unit. See chapter 6, page 13.
Sealing. Check that the rubber covers on con-
tacts are intact and in good condition.
Check to ensure there are no ho-
les that lack plugs and install these if
necessary.Check that the sign on the
operating panel is straight.
Throttle and twist grip. Check that the throttle twist grip is firmly
secured to the potentiometer axle. Func-
tion test: switch on the scooter at the
same time as the throttle is activated.
Steering unit/
operating panel.

9
Area Component Checks and remedies
Steering unit/
operating panel con-
tinued.
Throttle and twist grip. It should not be possible to drive the scooter
now. The battery indicator should ripple up and
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.
It should not be possible to push the scooter
now. Carry out the same check while turning
the throttle slightly backwards.
Maximum speed poten-
tiometer.
Check that the potentiometer is firmly in posi-
tion on the axle.
Check that the scooter drives fast and slow in
the hare and tortoise positions respectively.
Battery indicator. Check that all lights can be switched on when
the battery is fully charged. If there is no dis-
play at all try another control as this will be
where the signal comes from. If this does not
help the PCB must be replaced. If one light
fails to go on this indicates a defective diode.
Check that the parameter “True Charge ca-
libration” is set at 99 ohm. The best test of
this can be obtained while driving in hilly sur-
roundings.
Wear. Check:
That the motor runs smoothly and uniformly.
If it does not, this will typically indicate that
the carbon brushes in the motor should be
replaced. The minimum length of the brushes
should be 1 cm. See spare parts catalogue for
instructions.
The gear wheel in the transaxle for wear. Lift
one of the rear wheels and measure the play
around the periphery of the tyre. Wheel play
on a new machine should be between 16 – 18
mm. Replace the entire unit if there is greater
play than this. See spare parts catalogue for
instructions.
Wear in the rear wheel bearings in the gear. Lift
the rear end of the scooter. Lift one wheel up
and down at a time to see if there is play in the
transaxle bearings. If there is, the entire unit
should be replaced.
Motor, gear, brake
(transaxle).

10
Area Component Checks and remedies
Motor, gear, brake
(transaxle).
Power consumption. Power consumption on a level road with
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.
Brake and brake release.
Check function and check that
it prevents the scooter from
moving.
It should not be possible to push the
scooter when the brake release lever is
pushed back.
When the brake release lever is pushed
forwards it should be possible to push
the scooter, but it should not be possible
to drive it. The battery indicator should
indicate defect 9 when the throttle is
turned.
If the release lever is pushed backwards
it should be possible to drive the scooter
again. NB: the scooter must be switched
off and on again first.
The brake should be capable of holding
the scooter on a 15º slope = 26% with
75 – 100 kg on the seat. If it cannot the
brake may be defective and must be
replaced.
Braking distance.
Check that the scooter can
brake as follows when the
throttle is released at full
speed on a firm, non-slip sur-
face (asphalt).
Speed of scooter / maximum braking
distances:
10 km/h – 2.0 m (11)
13 km/h – 2.8 m (10)
15 km/h – 3.5 m (11)
The figures in parentheses indicate the
normal braking parameter when the
scooter leaves the factory. This can be
changed with the help of a programming
unit (forward deceleration). Read more
about this later. Please note that braking
distances should not be longer than
indicated in order to comply with official
requirements.
Play/wear. Check the following:
• The cardan joint
• The pins in the tiller axle / front forks
• Make sure that the lower aluminium
part of the handlebars is firmly secured
to the tiller axle (*)
Tiller.
Continued

11
Area Component Checks and remedies
Tiller. Wear and/or rust on the tiller. The upper-
most supporting bearing. The bearings in
the headtube are protected by seal rings.
If the front forks are stiff they can be lubri-
cated with a small amount of grease.
(*) On models with an 8 cm screw from the
lower aluminium part of the handlebars
into the tiller axle: the screw may become
loose if the handlebars are turned violently
or knocked hard. 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.
Gas spring. Check that the gas spring locks the tiller
securely.
Check to ensure there is no play in the
throttle and in the screws / bushes that
secure the gas spring.
Ignition key / charging plug. Check that the ignition key is not loose
when turned.
Clean with a well wrung-out cloth or com-
pressed air if it is dirty. If the contacts are
corroded, clean with a contact spray or
replace the charging plug.
Footplate. Check the plastic rivets that secure the
mat. If necessary replace with new rivets.
Seat post. Check that this is properly tightened and in
good condition.
Seat. Check that:
The release handle locks the seat properly.
The seat is firmly installed on the seat
frame / seat plate.
The seat tube is in good condition. If ne-
cessary grease the tube with a little acid-
free grease.
The armrest is in good condition.
Chassis, seat,
shrouds.

12
Area Component Checks and remedies
Chassis, seat,
shrouds.
Shrouds. Check to ensure that the plastic 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). Clea-
ning, see below.
Other mechanical compo-
nents.
Check that the other components are in
good condition and function properly.
Controls in PCB. Check to ensure this is dry and in good
condition.
Check to ensure that all plug connections
are properly installed.
Cables, plugs. Check to ensure that the cables are properly
installed and do not protrude so that they
can catch on anything or can be pinched.
Check that plug connections are properly
locked.
Battery straps. Check that they are firmly secured.
Batteries. Check to ensure that the battery cases are
not cracked, that they are in good condition,
and that the battery connections are pro-
perly installed.
Battery capacity. Check with a battery tester. If this indicates
that new batteries should be installed make
sure to pair these with a precision of 0.1 V.
Apply a little acid-free Vaseline to the bat-
tery poles before connecting them.
Battery charger. Check that the pilot lamp on the battery
charger switches to CHARGING when it is
connected to the scooter.
If necessary check charging voltage during
charging. This should be approximately
28.8 V.
Charge the batteries overnight. Remove the
charger and measure battery voltage after
approximately 15 minutes. This should be
about 27.6 V for new batteries.
Check to ensure that the scooter is una-
ble to drive while connected to the battery
charger.
Electrical compo-
nents.
Batteries, charger.
(see section 6).

13
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”.
Example of damaged controller.
You can see the plastic on the controller is
deformed from overheating coming from the
motor cables.
You can see the connector on the left hand
side have come loose from the controller.
Replace receptor:
For this operation you need to have the repair
kit: T-127-05-033
And the tool: TN 70 SE

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.

15
Controler
Crimp the sleeve.
Crimp the heat shrinkage sleeves onto the
wirer and the operation is finished.
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. (Picture from an E-model).

16
Controler
Batteries
Check to see if there are any signs of burned
or damaged wirers going to the batteries and
to the fuse boxes just before the batteries.
Check the wirer going to the motor is not da-
maged, signs of overheated or warned spots.
Perform a brake test. Stopping distance must be less than 2 meters at 10 km/h and less than 3,5
meters at 15 km/h.
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.
Full length
10 mm

17
6.0 Fuses and bulbs
The fuses are located beneath the rear shroud.
1 2 3 4 5
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: 1 x 10 A fuse Seat adjustment Product number SR-00066 (10 A)
Fuse 4: 1 x 40 A fuse Extra
Fuse 5: 1 x 10 A fuse Extra (Discontinued, mid-2004).
Main fuses, 100 A, type of fuse DIN 2581 – 100 A Product number SR-00977
6.1 Diagram of battery connections
Fuses and extra sockets on PCB
Fuses on the PCB in the operating panel. Use a pair of tweezers to replace these.
F1: Lamp 2A: Little fuse: 154 002 RA900
F2: Lamp, rear 2A: The same
F3: Right indicator 2A: The same Discontinued, beginning
F4: Left indicator 2A: The same of 2004
F5: Braking lamp 2A: The same
F6: Horn 5 A: Little fuse 154 005 RA 900

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6.2 Plugs and fuses in the operating panel
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.
The connection for seat adjustment is not relevant to seat adjustment on the S model type. The
up/down contact on the T model is also located beneath the armrest.
Electric bulbs
Headlights (description of method) BA 15s 24 V/21 W MC product number SR-00066
Indicators, braking lamps: BA 15s 24 V/01 W MC product number SR-00033
Rear lamps: BA 15s 24 V/5 W MC product number SR-04244
F6
J12
J11
J10
J9
J6
J7
J8
J3
J2
J
J5
J13
J17
J16
J18
J19
J15
MiniCrosser A/S
T-127-5-002
Issue 2.0

19
7.0 Batteries / charging
The Mini Crosser should be charged whenever it is not in use. The type of charger supplied by
the manufacturer is automatic – it disconnects once the batteries have been fully charged. The
charger only consumes current while the batteries are being charged. The charger can therefore
be left connected until the Mini Crosser is used again.
The charger will flash until it has finished charging. It will then be lit up continuously.
If the Mini Crosser is stored over a lengthy period of time, it is sufficient 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.
On the next page you can see how to connect the charger to the scooter. Also refer to the manu-
facturer’s instructions for the charger in question, which explain how the charger shows that the
scooter is fully charged.
The Mini Crosser scooter uses closed, maintenance-free GEL batteries (Exide 12 V/56 Ah or
Trojan 12 V/71 Ah). They do not normally give off any gas, and must not be filled with water. Only
GEL-type batteries may be used for Mini Crosser T models.
Please note that the capacity of the batteries declines over time and at low temperatures. In prac-
tice, this means that a vehicle with old batteries will have a lower range than when its batteries
were new.
Battery capacity at -10˚C is about half the corresponding capacity at +20˚C.
The battery manufacturer recommends that batteries should be charged at a temperature from
+10˚C to +30˚C to achieve the charging time stated under “Technical Data”. Charging time is
about 60% longer at a temperature of 5º Celsius by comparison with charging at 20˚ Celsius. This
is because from a purely chemical point of view it is more difficult for batteries to absorb current
at low temperatures. To prevent batteries from running down completely, we recommend char-
ging them in a heated room. If this is not possible every day, it is a good idea to charge your Mini
Crosser in a heated room once a week.
New batteries do not achieve their full capacity until they have been run down and re-charged
about 20 times.
Used batteries should be given to your supplier or the local environmental waste disposal facility.
Be careful how you handle leaky batteries – they contain corrosive acids bound in a gel substan-
ce.
It is important to install the batteries correctly. Battery poles and snap locks are marked +/-. They
should be installed as shown in the sketch below. Make sure that the snap locks are closed pro-
perly. For the same reason the poles must not be burred.

20
Please note that the Mini Crosser may be equipped with several different types of charger (con-
tact the supplier for information on the various types of charger).
Never place the charger on the seat during charging.
Never use chargers that have not been supplied by the manufacturer without contacting your
supplier first.
Never use a charger that has not been designed for charging dry, maintenance-free batteries.
The maximum charge current is 12 A.
The figure below shows the polarity of the charge socket.
8.0 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.
9.0 Cleaning
The Mini Crosser can be cleaned with a damp cloth wrung out in a little water containing deter-
gent. The plastic shrouds can be polished with an ordinary window cleaning substance or wax for
car windows.
Using a high pressure cleaner or a hose to clean the Mini Crosser can damage its electronic com-
ponents.
Charge plug NEUTRIK NC6MX seen from the pin side.
12
3
0 V
24 V
INHIBIT