Medema Mini Crosser M1 User manual

Service Manual Mini Crosser M1
P9-0155-S ver. 2.0.2 - August 2011 GB
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Service Manual P9-0155-S 2 of 62 Version 2.0.2/2011
Medema Production A/S
Serial number: ___-______________-______-_______
Delivery date: ________________ Year 20______
This vehicle was supplied by: Date: /

Service Manual P9-0155-S 3 of 62 Version 2.0.2/2011
Medema Production A/S
Table of contents
Table of contents................................................................... 3
Introduction............................................................................ 4
Symbols.................................................................................. 5
Warning!................................................................................. 5
Safe servicing........................................................................ 6
Tool list................................................................................... 7
Storage................................................................................... 8
Cleaning ................................................................................. 8
Declaration of conformity..................................................... 9
Maintenance........................................................................... 10
Service summary for Mini Crosser M Model....................... 11
Troubleshooting .................................................................... 16
Programming unit.................................................................. 19
Programming via PC............................................................. 20
Information about the vehicle via PC .................................. 22
Fuses and bulbs.................................................................... 27
Summary of battery connections......................................... 27
Sockets and control panel.................................................... 28
Batteries................................................................................. 30
Battery disposal..................................................................... 30
Charging................................................................................. 31
Fitting an accelerator switch................................................ 33
Fitting a speedometer........................................................... 35
Fitting corner speed reduction, 3W..................................... 37
Fitting corner speed reduction, 4W..................................... 38
Parent potentiometer ............................................................ 39
Fitting an hour counter......................................................... 40
Fitting a parent key................................................................ 41
Fitting a foot pedal ................................................................ 42
Fitting a twist grip accelerator, right & left.......................... 44
Fitting accessories on the C-rail.......................................... 47
Replacing bulb in headlight.................................................. 48
Fitting a side-view mirror...................................................... 49
Electrical seat turning from right to left.............................. 50
Securing to vehicle floor with belts..................................... 51
Transporting by plane........................................................... 54
Towing.................................................................................... 54
Front wheel alignment, 4W................................................... 55
Technical data........................................................................ 56
Checklist for servicing M1: ................................................... 58

Service Manual P9-0155-S 4 of 62 Version 2.0.2/2011
Medema Production A/S
Introduction
This manual contains servicing instructions for the Mini Crosser
M1Model mobility scooter.
The Service Manual is a supplement to our Spare Parts
Catalogue and User Manual.
The Mini Crosser M1is designed for safe travel for at least
10 years, up to a max. of 5,000 hours, provided it is serviced
and safety-checked every year, corresponding to 500 hours of
operation. The service must be carried out either by Medema
Danmark A/S or 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, which could generate heat and cause a fire.
If help is required with troubleshooting, Medema Production is
always happy to provide telephone assistance. If the problem
seems to be an electrical fault that prevents the scooter from
working, please tell us the error code. This can be found on the
battery indicator on the control panel. Read more about this in
the section on Troubleshooting.
Please also have the scooter’s serial number handy when
contacting Medema Production A/S.
If you have any questions that are not answered directly by this
manual, you are always welcome to contact us at:
Medema Production A/S
Tel: [phone]
Email: [e-mail]
Internet: www.medema.com
NB: Errors and omissions excepted. Specifications subject to
change.
Medema Production A/S also reserves the right to update the
service manual in line with any modifications or improvements
to the product.

Service Manual P9-0155-S 5 of 62 Version 2.0.2/2011
Medema Production A/S
Symbols
Used in the manual to indicate sections describing situations
where extra care is required owing to the risk of personal injury.
Used to indicate sections on electromagnetic compatibility
(EMC).
Warning!
For safety reasons the vehicle must not be lent to persons who
are not completely familiar with it. The vehicle is designed for
one person only.
The Mini Crosser M Model has been designed for users
weighing max. 175 kg. Can be supplied in a HD version as
standard for a max person weight of 250 kg.

Service Manual P9-0155-S 6 of 62 Version 2.0.2/2011
Medema Production A/S
Safe servicing
• To avoid injuries to both the service engineer and the subsequent
user of the scooter, it is important to get to know the product
before servicing it.
• Be particularly aware of the following:
• The Mini Crosser MUST be turned off at the main switch. If
electrical components are being serviced, the positive terminal on
the battery MUST also be disconnected.
• If the voltage needs to be measured in the course of
troubleshooting, take great care not to short-circuit anything.
• Take great care not to short-circuit the battery terminals.
• Be careful not to lift heavy parts such as the seat, battery and
motor gear incorrectly or drop them.
• Make sure to raise one rear wheel off the ground so that the
scooter cannot drive off accidentally.
• Use professionally maintained tools.
• Where lock nuts are used, NEW ones MUST be fitted when the
scooter is reassembled.
• Take care to fit new cable strips in the same way as the old ones.
Make sure that no cables can be trapped by moving parts or stick
out in such a way as to catch on things.
• End every service by making sure that the product is roadworthy:
- Check that all the connectors are plugged in correctly.
- Check that all the mechanical parts are properly secured.
Turn the scooter on and check
-that the magnetic brake clicks when the accelerator is activated.
-When the accelerator is released, it must not be possible to push
the scooter.

Service Manual P9-0155-S 7 of 62 Version 2.0.2/2011
Medema Production A/S
Tool list
The following tools are needed to service the scooter:
• Circlip pliers
• Allen keys
• Box spanners, 7-17 mm
• Open-ended spanners, 7-17 mm
• Phillips and torx screwdrivers, 10/15/20/25 slot
• Needle-nose pliers
• Side-cutting pliers
• Plastic hammer
• Set of punches
• Retractable knife
• Steel brush
• Water pump pliers
• Wire strippers
• Crimping tool
• Pliers for Molex 5556/5558 crimps
• Riveting pliers
• Small cable ties
• Multimeter
• Battery tester
• Tyre pressure gauge
• Tyre pump with Schrader valve
• Acid-free oil and grease
• Loctite 406 / 603
• Cable ties
• PC
• PC Programming package for S180

Service Manual P9-0155-S 8 of 62 Version 2.0.2/2011
Medema Production A/S
Storage
The Mini Crosser is designed for use in all types of weather.
The scooter should, however, be stored and charged under
cover at temperatures in excess of 0°C. The charger must also
be kept dry.
If the scooter is not going to be used for a long time, it is
advisable to protect the tyres by chocking the scooter up. It is
also a good idea to cover the scooter to protect it from dirt, dust
and sunlight.
Cleaning
The Mini Crosser should be cleaned with a damp cloth. A little
washing-up liquid can be used if necessary. The plastic covers
can be polished with an ordinary glass cleaner or car wax.
Note!
Using a high-pressure cleaner or hose may damage the Mini
Crosser’s electronics.

Service Manual P9-0155-S 9 of 62 Version 2.0.2/2011
Medema Production A/S
Declaration of conformity
Medema Production A/S hereby declares that:
Machine: Mini Crosser
Use: (Prescribed use in
User Manual)
Model No: M1
Complies with the Medical Device Directive 93/42/EEC
The product is made in accordance with the harmonized
standard EN 12184 - Electrically powered wheelchairs, scooters
and their chargers.
The product is risk analysed in accordance with the harmonized
standard DS/EN ISO 14971:2007-04-10 2. edition - Medical
devices - Application of risk management to medical devices.
Mini Crosser scooters can, for a fee, be taken to the nearest
dealer for disposal in accordance with current environmental
regulations.
Manufacturer: Medema Production A/S
Address: Enggårdvej 7, DK-7400 Herning
Tel./Fax [phone] [phone]
Date: 12.04.2010 Signature: _____________________

Service Manual P9-0155-S 10 of 62 Version 2.0.2/2011
Medema Production A/S
Maintenance
Daily:
• Test the lights and indicators before using the scooter in the dark
or poor visibility.
Every three months:
Test the brakes. With the disengagement lever up, it must not
be possible to push the Mini Crosser.
• Test the brake disengagement function.
With the brake disengagement lever down, the scooter must
not be able to go when the accelerator is activated. The battery
indicator should flash error 9.
When the disengagement lever is up and the scooter has been
switched off and on, the scooter should be able to go again. It
must not be possible to push it.
• Test the accelerator.
With the scooter turned off, activate the accelerator while turning
the scooter on. The scooter must not be able to go. The battery
indicator should go up and down.
With the scooter turned on, press the accelerator forward a touch.
When it is released, the scooter should stop completely and the
brake should click. It must not be possible to push the scooter.
Perform the same test again, but pressing the accelerator back.
• Lubricate the lever arm on the front brake hub with acid-free oil.
• Check the tyre pressure and tread.
Annual
Safety checks
The Mini Crosser M1is designed for safe travel for at least
10 years, up to a max. of 5,000 hours, provided it is serviced
and safety-checked every year, corresponding to 500 hours of
operation. The service must be carried out either by Medema
Danmark A/S or 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, which could generate heat and cause a fire.

Service Manual P9-0155-S 11 of 62 Version 2.0.2/2011
Medema Production A/S
Service summary for Mini Crosser M Model
Area Component Check and remedy
Suspension and
wheels Rear suspension Check whether the rear of the scooter is drooping. The rear wheel
must not rub on the mudguard with
a load on the seat. Replace the
shock absorbers/springs behind
the batteries. See the Spare Parts
Catalogue.
Check the shock absorbers for oil
leaks.
Check that the swivel axle/transaxle
is securely mounted. Retighten or fit
bolts/nuts.
Check that no cables
can be trapped by
moving parts.
Fit cable ties.
Check the wheels Check the fastenings and the
condition of the rims.
Check the tyre
pressure and tread. Recommended tyre pressure: 2.8 bar (50 psi)
The minimum tread depth for good
grip is approx. 1 mm.
See the Spare Parts Catalogue for
disassembly. NB! The rear and front
wheels on the 4W MUST always be
removed using the five bolts. NEVER
undo the actual flange using the bold
in the centre. See the Spare Parts
Catalogue. NB! ALWAYS let the air
out of the inner tube before taking a
wheel apart!
Check that the
handbrake is working. Lubricate the lever arm on the brake hub with acid-free oil. Adjust the
cable length using the adjusting
nipple. If parts are defective: See the
Spare Parts Catalogue.
3W: Front fork.
Suspension and
straightness.
Check that the front fork can bounce.
Is it crooked?
Is there an oil leak?
If there is a defect that needs to be
repaired, replace the entire front fork.
See the Spare Parts Catalogue.
3W: Front wheel. Check the ball bearings for play and
wear.
4W: Front suspension. Check that the front wheels do not hit
the underside of the front mudguards.
Check that the rubber dampers are
secure. They should just touch the
axle beam. See the Spare Parts
Catalogue.
Check that the T-suspension block is
working and does not droop.

Service Manual P9-0155-S 12 of 62 Version 2.0.2/2011
Medema Production A/S
Area Component Check and remedy
Suspension and
wheels (contd) Front wheel suspension. Check that the guide rods and balls are in good condition and properly
tightened.
Check the ball bearings in the front
wheels and guide spindles for play/
wear.
Front wheel tracking. See the sketch
for correct tracking if uneven tyre
wear shows that adjustment is
necessary.
Steering/Control
panel Lights, indicators, hazard warning and
horn
Check functioning and the condition
of the switches.
If an indicator is not working: Check
the connectors and the fuse in the
control panel.
Or change the bulb.
Seals Check that the rubber switch covers
are intact and in good condition.
Check that all the holes have plugs.
Fit new ones if necessary.
Check that the sign on the control
panel is straight.
Accelerator and
handlebars Check that the accelerator is mounted securely on the
potentiometer shaft.
Function test: Turn the scooter on
while the accelerator is activated.
The scooter must not be able to go.
The battery indicator should go up
and down.
With the scooter turned on, press the
accelerator forward a touch. When it
is released, the scooter should stop
completely and the brake should
click. It must not be possible to push
the scooter. Perform the same test
again, but pressing the accelerator
back.
Max. speed
potentiometer Check that all the lamps come on when the batteries are fully charged.
If there is no indication at all, try
another controller, as the signal
comes from there. If not, the card will
have to be replaced. If a single lamp
is not working, a diode is defective.
Check that ”True Charge calibration”
is set to 99m ohm. This ensures the
best indication of power consumption
in hilly terrain.

Service Manual P9-0155-S 13 of 62 Version 2.0.2/2011
Medema Production A/S
Area Component Check and remedy
Motor / gear /
brake
(Transaxle)
Wear Check: That the motor runs smoothly
and evenly. If not, the carbon brushes
in the motor usually need to be
replaced. The minimum length of the
brushes is 1-1.5 cm. See the Spare
Parts Catalogue for replacement.
Check: The gear wheel in the
transaxle for wear. Lift one rear
wheel and measure the play around
the periphery of the tyre. On a new
machine the play is 16-18 mm. If
the play is much bigger, replace the
whole unit. See the Spare Parts
Catalogue for replacement.
Check: The rear wheel bearings in
the gear for wear. Lift the rear of the
scooter. Get hold of one wheel at
a time. Lift it up and down to see if
there is any play in the bearings in
the transaxle. If there is, the whole
unit should be replaced.
Power consumption Power consumption on a level road
with a tyre pressure of 2.8 bar and
75-100 kg on the seat:
10 km/h = 12 - 15 A
15 km/h = 17 - 20 A
Measure on one of the battery cables
using a clip-on ammeter.
Brakes and
disengagement
Check function
When the disengagement lever is up:
It must not be possible to push the
scooter.
It must be possible to drive normally
when the scooter is turned on.
When the disengagement lever is
down:
It must be possible to push the
scooter.
The scooter must not be able to
go. Error 9 should appear when the
accelerator is activated.
The brake must be able to hold the
scooter on a 15° (26%) slope with 75
- 100 kg on the seat.
If not, it must be adjusted or
replaced, depending on how much
wear there is.

Service Manual P9-0155-S 14 of 62 Version 2.0.2/2011
Medema Production A/S
Area Component Check and remedy
Braking distance 10 km/h - 2.0 m (9)
15 km/h - 3.5 m (9)
The figures in brackets indicate the
normal braking parameter when the
scooter leaves the factory. It can be
changed with the programming unit
(forward deceleration). See below
for more information. Please note
that the braking distance must not
be longer than specified in order to
comply with official requirements.
Steering column Play/wear Check the following:
- Universal joint
- Pins in steering shaft/front fork
- That the aluminium bottom section
of the steering column is firmly
secured to the steering shaft. (*)
Wear/rust on the bearings in the
steering column. Top support bearing.
The bearings in the head tube are
protected by seal rings. If the front
fork is a bit stiff, the seal rings can be
lubricated with a little grease.
(*) On models with an 8 mm bolt
going into the steering shaft from
the aluminium bottom section of
the steering column. The bolt can
work loose if the steering column is
twisted/knocked hard. This can be
remedied by drilling a hole for a split
pin between the steering shaft and
the aluminium section. Contact Mini
Crosser A/S.
Cables Check that the cables cannot
become trapped or be subjected
to strain when the handlebars are
turned or the steering column is
folded down.
Gas spring Check:
That the gas spring locks the steering
column securely.
Check that there is no play in the
release lever and the bolts/bushes
securing the gas spring.
Key switch / charging
socket Check that the key switch does not wobble.
Clean with a damp cloth or
compressed air if dirty. If the contacts
are corroded, clean them with
contact spray or replace the charging
sockets.
Chassis / seat /
covers Footplate Check the plastic rivets securing the mat. Fit new ones if necessary.
Seat post Check that it is properly secured and
in good condition.

Service Manual P9-0155-S 15 of 62 Version 2.0.2/2011
Medema Production A/S
Area Component Check and remedy
Chassis / seat /
covers (contd) Seat Check that: The release lever locks the seat
properly.
The seat is firmly secured on the seat
frame/plate.
The seat tube is in good condition. If
necessary, lubricate the tube with a
little acid-free grease.
The armrests are in good condition.
Covers Check that the plastic covers are in
good conditions. Parts with sharp or
projecting edges should be replaced.
The same applies to covers with an
operational function, e.g. the splash
guard and battery cover. (water in the
controller)
Cleaning: See the section on
Cleaning.
Other mechanical
components Check that the other components work properly.
Electrical
components Control card Check that it is dry and in a good condition.
Check that all the connectors are
firmly in place.
Cables/plugs Check that the cables are firmly in
place and not sticking out in such a
way as to catch on something or get
trapped.
Check that the plugs are firmly in
place.
Battery straps Check that they are properly secured.
Batteries/charger
(see also the
section on
Batteries)
Batteries Check that there are no cracks in the
batteries, that batteries look good
and that the battery connections are
firmly in place.
Battery capacity Check this with a battery tester. If
it indicates that new batteries need
to be fitted, take care to pair them
with an accuracy of 0.1 V. Apply a
little acid-free vaseline to the battery
terminals before connecting them.
Battery charger Check that the indicator lamp on
the battery charger changes to
CHARGING when the scooter is
connected.
If necessary, measure the charging
voltage during charging. It should be
approx. 28.8 V.
Leave the scooter to charge
overnight. Disconnect the charger
and measure the battery voltage
after about 15 minutes. It should be
approx. 27.6 V for fresh batteries.
Check that the scooter cannot
go while the battery charger is
connected.

Service Manual P9-0155-S 16 of 62 Version 2.0.2/2011
Medema Production A/S
Troubleshooting
The following is a list of various problems that we are frequently
asked about. Possible causes and solutions are given.
Problem Possible causes Solution
The Mini Crosser will not
go.
The battery indicator is
not lit.
The key has not been
turned to start.
The batteries are
completely flat.
The control fuse has
blown.
The main fuse has burnt
out.
Turn the key and wait 5
secs. before activating the
accelerator.
Charge the batteries.
Change the fuse.
Contact supplier.
The Mini Crosser will not
go.
There is a light in the
battery indicator. The Mini Crosser has been overloaded.
The handbrake is on.
There is a fault in the
electronics.
The batteries are flat.
The charging plug has not
been removed.
Wait approx. 1 min. before
trying again. The vehicle
must be turned off (See
page 10, Driving the Mini
Crosser)
Release the handbrake.
Contact supplier.
Contact supplier.
Remove the charging
plug.
Driving speed is too low. The speed selector is on
slow.
The electronics are
overloaded.
There is too little air in the
tyres.
Change to a faster speed.
Stop and wait a few
minutes before starting.
Pump the tyres up to the
right pressure.
The driving distance per
charge is too short. There is a problem with the batteries.
Low temperature.
There is a problem with
the charger.
There is too little air in the
tyres.
The charging method is
wrong.
Charge the batteries and
check that the green
lamps on the charger light
up before driving off.
Contact supplier.
Pump the tyres up to the
right pressure.
Read the operating
instructions.
The charging lamp on
the charger does not light
up when the charger is
connected to the mains
and Mini Crosser.
(Read the operating
instructions for the
charger)
No power to the switch.
Fault in cable.
Fault in charger.
Turn the switch on.
Contact supplier.
Contact supplier.

Service Manual P9-0155-S 17 of 62 Version 2.0.2/2011
Medema Production A/S
Problem Possible causes Solution
The ready lamp on the
charger does not light up
even though the charger
has been on for 10-12
hours.
(Read the operating
instructions for the
charger)
There has been a power
cut.
The charger is doing a
top-up charge.
There is a problem with
the batteries.
There is a fault in the
charging plug for the Mini
Crosser
Reconnect the charger
and repeat the charging
process.
Check again after half an
hour.
Contact supplier.
Push the charging plug all
the way in and repeat the
charging process.
The ready lamp on the
charger lights up even
when partly discharged
batteries are connected.
(Read the operating
instructions for the
charger)
The fuse in the charger
has blown.
The switch in the charging
plug is malfunctioning.
Contact supplier.
Contact supplier.
The charging lamp
indicates a fault:
Read the operating
instructions for the
charger.
The charging plug has not
been inserted or there is a
mains fault.
The battery voltage is too
low for charging to start.
Push the charger plug in
or contact the supplier.
Contact supplier.

Service Manual P9-0155-S 18 of 62 Version 2.0.2/2011
Medema Production A/S
If the vehicle has an electronic fault, the battery indicator will
show what sort of fault it is. It is a good idea to be able to say
how many diodes/lamps light up when contacting the supplier.
Number of
lamps Electronic fault
1 lamp The batteries must be charged or there is a poor battery
connection. Check all connections between the controller and
batteries. If these are in order, try charging the battery.
2 lamps There is a poor connection to the motor. Check the connection
between the motor and the controller.
3 lamps There is a short circuit from the motor to a battery connection.
4 lamps Not in use
5 lamps Not in use
6 lamps The S180 is prevented from driving. Inhibit 2 is active. This
may be due to the battery charger being connected, the plug
to the thermal switches being disconnected, a fault in the
thermal switch or the scooter is overheating.
7 lamps Apotentiometer error has occurred. Ensure gas regulation is
in neutral when the Mini Crosser is switched on.
8 lamps Acontroller fault has occurred. Check that all connections are
sound.
9 lamps There is a poor connection in the magnetic brake. Check the
magnetic brake and the motor connections. Check that the
control connections are sound.
The scooter is disengaged or the disengager terminal is
affected.
10 lamps There is excess voltage in the controls This is usually due to
a poor battery connection. Check the battery connections. It
may also be due to excessive regeneration with fully charged
batteries.
Running lights Charger is connected. Remove charger.

Service Manual P9-0155-S 19 of 62 Version 2.0.2/2011
Medema Production A/S
Programming unit
The Mini Crosser’s running characteristics can be partially
altered using a type SP1B programming unit via PC and the PC
programming package for S180.
NB! SP1B cannot be used to change the speed, which can only
be done using the PC program.
Please note that the speed, deceleration, throttle gain and
motor compensation settings must not be increased. They
have a major influence on user safety and the durability of the
product.
If you have not received instruction in how to use the
programming unit, we strongly advise against trying to make
changes. The standard driving parameters for the various
scooter models can be found on the next page.
The latest standard parameters can be found on our website at
www.minicrosser.dk

Service Manual P9-0155-S 20 of 62 Version 2.0.2/2011
Medema Production A/S
Programming via PC
There are two different versions of the PC program, an OEM
version and a dealer version. The OEM version gives complete
access to all settings parameters. The dealer version gives
limited access.
Before programming can
commence, the five-pin plug
connecting the S-180 to
the thermal switches in the
transaxle must be removed.
6 lights will flash in the scooter
battery indicator.