medemagroup Mini Crosser M2 User manual

Service Manual Mini Crosser M2
P9-0157-S ver. 1.0.3 - October 2018 GB
medemagroup

Service manual P9-0157-S 2 of 68 Version 1.0.3/2018
Medema Production A/S

Service manual P9-0157-S 3 of 68 Version 1.0.3/2018
Medema Production A/S
Contents
Contents................................................................................. 3
Introduction............................................................................ 4
Symbols.................................................................................. 5
Warning! ................................................................................. 5
Safe servicing ........................................................................ 6
Tool list ................................................................................... 7
Storage ................................................................................... 8
Cleaning ................................................................................. 8
Declaration of conformity..................................................... 9
Maintenance........................................................................... 10
User menu.............................................................................. 12
Service summary for Mini Crosser M Model....................... 15
Control panel ......................................................................... 21
Programming the technician menu ..................................... 22
Display charge curve ............................................................ 29
Troubleshooting .................................................................... 32
The vehicle’s driving characteristics................................... 35
Batteries ................................................................................. 36
Battery disposal..................................................................... 36
Charging................................................................................. 37
Fuel for heater........................................................................ 39
Heater ..................................................................................... 39
Windscreen wiper / washer .................................................. 40
Replacing the wiper blade .................................................... 41
Replacing the bulb - headlight ............................................. 41
Fitting an accelerator switch................................................ 43
Fitting corner speed reduction, 4W ..................................... 45
Fitting a foot pedal ................................................................ 46
Fitting a twist grip accelerator, right & left.......................... 48
Elevated footrest ................................................................... 50
Anti-theft alarm, tilt alarm and temperature sensor. .......... 50
Securing to vehicle oor with belts..................................... 51
Transporting by plane ........................................................... 53
Towing .................................................................................... 53
Front wheel alignment, 4W................................................... 55
Troubleshooting .................................................................... 56
Programming ......................................................................... 59
Technical data........................................................................ 59
Appendix A: ........................................................................... 64

Service manual P9-0157-S 4 of 68 Version 1.0.3/2018
Medema Production A/S
Introduction
This manual contains servicing instructions for the Mini Crosser
M2 Model mobility scooter.
The Service Manual is a supplement to our Spare Parts
Catalogue and User Manual.
The Mini Crosser M2 is 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 re.
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 Danmark A/S
Tel: [phone]
Email: [e-mail]
Internet: www.minicrosser.dk
NB: Errors and omissions excepted. Specications subject to
change.
Medema Production A/S also reserves the right to update the
service manual in line with any modications or improvements
to the product.

Service manual P9-0157-S 5 of 68 Version 1.0.3/2018
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 P9-0157-S 6 of 68 Version 1.0.3/2018
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 tted when the
scooter is reassembled.
Take care to t 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 P9-0157-S 7 of 68 Version 1.0.3/2018
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 P9-0157-S 8 of 68 Version 1.0.3/2018
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.
While drying, the Mini Crosser must be placed on a at surface.
It must be kept indoors; preferably in a heated room. The
temperature must not exceed 50°.

Service manual P9-0157-S 9 of 68 Version 1.0.3/2018
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: M2
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 P9-0157-S 10 of 68 Version 1.0.3/2018
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 ash 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 show running lights from the center and out.
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.

Service manual P9-0157-S 11 of 68 Version 1.0.3/2018
Medema Production A/S
Annual
Safety checks
The Mini Crosser M2 is 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 re.

Service manual P9-0157-S 12 of 68 Version 1.0.3/2018
Medema Production A/S
User menu
Term Description
Menu / information Press the button and a menu at the top of the display
switches between ”Date”, ”Time”, ”Complete km”,
”Complete running time”, ”Battery Voltage” Service
”and” inclination ”.”Slope” is optional, and appears
only if it is engaged.
Button Menu / information are also used to modify the
user parameters.
Access these parameters by holding the menu button
for approx. 3 sec.
Key switch To start the vehicle:
Turn the key to position (1). The rst half second after
the Mini Crosser is on, the control is making a safety
check of the electrical system. If the accelerator is
affected during this time, the Mini Crosser will not be
able to run, before the key again has been turned at 0
and back to 1 again.
Speed selector The turtle indicates lowest speed range. 0-6 km / h.
The hare indicates the highest speed range. Up to 15
km / h. Increase/decrease with + / - button.
The icons turtle/hare can be turned on/off from the
User menu.
Battery indicator The left side of the display shows battery level indicator.
Indicates that after approx. ½ seconds, the battery
state of charge. Provides a more accurate indication
after approx. 1 minute drive. When both red, yellow and
green box lights are the batteries fully charged. Can be
divided into 10 or 3 boxes. When the view is down the
bottom of the yellow batteries should be recharged as
soon as possible. If there is only light in the red boxes
or  ashing the batteries must be charged immediately.
Trip meter TRIP button resets the trip meter. Can be used while
driving.
Hand brake Works on the left rear wheel and should only be used
as extra brake / emergency brake and parking brake.
It can be blocked in the locked position. Also available
as a foot brake.

Service manual P9-0157-S 13 of 68 Version 1.0.3/2018
Medema Production A/S
Term Description
Accelerator
Forw. / Backw.
Front arm activates slowly and the Mini Crosser will
start running forward. The more press, the faster it will
run. When the lever is released, the arm  ips itself
back
to the starting position and Mini Crosser stops.
Upon activation of the posterior arm, the Mini Crosser
run backward. The Magnetic brake on the rear wheels
will strike at standstill, corresponding to the parking
brake on a car. With speed regulation, speed can also
be regulated downhill. The engine will then act as a
brake.
Light switch Turns on the front and rear lights. The key switch must
however be turned to position 1 (drive).
Hazard warning lights Turns on all lamps at once. Also works when the key
is removed, or turned to 0 (stop position).
Indicator lights switch Arrow left: lamp left side. Arrow Right: lamp right side.
Activate the same button again to turn off ashing
lights.
Horn Electric horn which can be programmed in volume in
the User Menu. Activated by pressing the horn button.
Charging socket Turn off the Mini Crosser (key in position 0) during
charging. Note that it is not possible to run while the
batteries recharge. See also the section ”Batteries
and Charging.”

Service manual P9-0157-S 14 of 68 Version 1.0.3/2018
Medema Production A/S
Term Description
Extras
Anti-theft alarm (Extra) With this parameter set to ON, the anti-theft
alarm is turned on every time you turn off the Mini
Crosser. An activated alarm is turned off by turning the
key to 1 (drive).
If you have no opportunity to get to the Mini Crosser
with the key, the alarm will stop after approx. 20
seconds. Shake the scooter again, the alarm will be
activated again.
Tilt Tilt-symbols.
Tilt Alarm sideways By exceeding the preset value, the symbol ashes and
the horn hoots, if the parameter is enabled.
Tilt Alarm forw./backw. By exceeding the preset value, the symbol illuminate
and the horn hoots, if the parameter is enabled.
Overheating step 1 Step 1: The symbol ashes and the speed is reduced to
half power. Wait for 3-5 min and start again.
Overheating step 2 Step 2: The symbol will illuminate and Mini Crosser
stops. Wait 3-5 minutes and start again.

Service manual P9-0157-S 15 of 68 Version 1.0.3/2018
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 t
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 ve bolts. NEVER
undo the actual ange 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 P9-0157-S 16 of 68 Version 1.0.3/2018
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 show.running
lights from the center and out.
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
(Battery indicator)
Check that all the lamps come on
when the batteries are fully charged.
If there is no indication at all, check
the batteries. If they are okay, the
card or the S-180 will have to be
replaced.
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 10 mm. See the Spare
Parts Catalogue for replacement.
Motor / gear /
brake
(Transaxle)
(contd)
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.

Service manual P9-0157-S 17 of 68 Version 1.0.3/2018
Medema Production A/S
Area Component Check and remedy
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.
Power consumption when the scooter is
turned off and the key turned to 0 = 50 mA
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.
Braking distance 10 km/h - 2.0 m
15 km/h - 3.5 m
Please note that the braking distance
must not be longer than specied
in order to comply with ofcial
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 rmly
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.

Service manual P9-0157-S 18 of 68 Version 1.0.3/2018
Medema Production A/S
Area Component Check and remedy
Steering column
(contd)
(*) 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
Medema Production 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.
Chassis / seat /
covers (contd)
Seat Check that:
The release lever locks the seat
properly.
The seat is rmly 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.

Service manual P9-0157-S 19 of 68 Version 1.0.3/2018
Medema Production A/S
Area Component Check and remedy
Electrical
components
Control card Check that it is dry and in a good
condition.
Check that all the connectors are
rmly in place.
Cables/plugs Check that the cables are rmly in
place and not sticking out in such a
way as to catch on something or get
trapped.
Check that the plugs are rmly 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
rmly in place.
Battery capacity
Check this with a battery tester.
Mount new batteries if needed. 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.
See the carbon specication overleaf.

10 mm
Service manual P9-0157-S 20 of 68 Version 1.0.3/2018
Medema Production A/S
Check if the carbon is okay or needs replacing.
Whether it is a Schmid or Mini Crosser transaxle, the carbon
must be replaced when it has been worn down to 10mm.
Full length