medemagroup Mini Crosser X1 HD User manual

Service Manual Mini Crosser X1 HD
GB
medemagroup
1533-2003-S ver. 1.0.2 - February 2020

Service manual 1533-2003-S 2 of 108 Version 1.0.2/2020
Medema Production A/S
Serial number: ___-______________-______-_______
Delivery date: ________________ Year 20______
This vehicle was supplied by: Date: /
Medema A/S
Enggårdvej 7
Snejbjerg
DK-7400 Herning
Denmark
Phone: [phone]
Mail: [email protected]
Dealer:
For this product You can expect to nd the following documentation:
• User manual
• Service manual
• Spare parts list
• Presell information.

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Content
Introduction...........................................................................5
Intended occupant................................................................6
Help for the visually impaired .............................................6
FSN (Field Safety Notice).....................................................6
Symbols.................................................................................7
Warning! ................................................................................7
Contagion!.............................................................................7
Safe servicing .......................................................................8
Tool list ..................................................................................9
Storage ..................................................................................10
Cleaning ................................................................................10
Declaration of conformity....................................................11
Preparations / Adjustments prior to use ............................12
Electric seat adjustment ......................................................14
Seat rotation..........................................................................15
Steering column ...................................................................16
Serial number........................................................................17
Driving the Mini Crosser X1 HD .........................................18
Lap belt..................................................................................21
Specic driving situations...................................................23
Long hills/difcult ground ...................................................25
Anti-tilt wheels / stabilisers .................................................26
General care and maintenance ...........................................27
Insurance...............................................................................28
Batteries ................................................................................29
Battery weight.......................................................................29
Charging................................................................................29
Battery disposal....................................................................30
Storage ..................................................................................32
Cleaning ................................................................................32
Service summary for Mini Crosser X1 HD..........................33
Troubleshooting ...................................................................38
Programming unit.................................................................41
Programming via PC ............................................................42
Information about the vehicle via PC .................................44
Fuses .....................................................................................49
Fuses .....................................................................................50
Summary of battery connections........................................50
Sockets and control panel...................................................51
Brakes....................................................................................52
Disengagement.....................................................................53
Transporting by motor vehicle ............................................54
Securing to vehicle oor with belts....................................55
Transporting by plane ..........................................................58

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Towing ...................................................................................58
Changing the wheels............................................................59
Replace the wigwag potentiometer ....................................61
Replace the speed potentiometer.......................................63
Replace the head..................................................................65
Replace the circuit board.....................................................66
Replace headlights...............................................................68
Replace gas spring for steering collumn...........................70
Replace the front springs ....................................................71
Replace rear spring..............................................................72
Replace tail light...................................................................73
Replace batteries..................................................................74
Replace transaxle.................................................................75
Replace cable for hand brake..............................................78
Replace the magnetic brake................................................80
Replace fuses .......................................................................82
Replace coal..........................................................................83
Replace the controller..........................................................85
Dimensioned drawing, Mini Crosser X1 HD.......................87
Front wheel alignment, 4W..................................................88
Technical data.......................................................................89
Checklist for servicing X1 HD: ...........................................92

Service manual 1533-2003-S 5 of 108 Version 1.0.2/2020
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Introduction
This manual contains servicing instructions for the Mini Crosser
X1 HD mobility scooter.
The Service Manual is a supplement to our Spare Parts Cata-
logue and User Manual.
You have now taken possession of an electric mobility Mini
Crosser developed for outdoor driving by active users. It is what is
called a Class C vehicle in according to the European classica-
tion of electric wheelchairs.
The Mini Crosser X1 HD is designed for safe travel for at least 10
years, up to a max. of 5,000 hours, providing it has service and
safety inspections every third year, which is equivalent to around
1500 operating hours. The service must be carried out either by
Medema 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 wir-
ing, 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 con-
tacting 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 A/S
Phone: [phone]
E-mail: [email protected]
Internet: www.medema.dk
NB: Errors and omissions excepted. Specications subject to change.
Medema A/S also reserves the right to update the service manual
in line with any modications or improvements to the product.

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Intended occupant
The intended occupant of the Mini Crosser X is a person with
limited ability of walking themselves.
The occupant must be able to see in order to register trafc sig-
nals and other road users when driving in trafc. The occupant
can be deaf and/or speechless.
The occupant must have a cognitive ability to understand the
operation of a scooter and its buttons and icons.
The Mini Crosser can be driven with only one hand either left or
right.
The maximum occupant weight is 250 kg.
Help for the visually impaired
If you have difculty reading small print in the user manual, we
recommend that you visit our website, where you can read this
manual in PDF format. You can enlarge the PDF manual on
your PC monitor to suit your needs and preferences.
If you nd it difcult to understand the manual and have general
questions about the product, please feel free to contact us. You
can nd our contact info on page two in this user manual.
You can nd manuals for all our products on our web page
www.medema.dk. Or contact Medema A/S, and we can send
the manuals in a mail for you. Find the contact information on
page two in this manual.
FSN (Field Safety Notice)
All information concerning safety can be found at www.mede-
ma.com, which is always updated with the latest safety informa-
tion. In the event of important safety-related changes, we will
notify our customers directly (FSN).

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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 X1 HD has been designed for users weighing
max. weight of 250 kg.
Contagion!
A standard Mini Crosser is equipped with tyres that does not
contage, but if another type of tyres are used, it can sometimes
rub off on oor coverings, particularly linoleum. Medema A/S
assumes no responsibility in case of contagion.
To prevent this, we recommend that you protect delicate oors
with some sort of driving surface.

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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 be-
fore servicing it.
• Be particularly aware of the following:
• The Mini Crosser MUST be turned off at the main switch. If elec-
trical 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 troubleshoot-
ing, 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.

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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 El-zink = 2400, A2 = 2700, bearings = 6300
• Cable ties
• PC
• PC Programming package for S200

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Storage
The Mini Crosser is designed for use in all types of weather.
The scooter should, however, be stored and charged under cov-
er 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 advis-
able 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.

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Medema Production A/S
Declaration of conformity
Medema A/S hereby declares that:
Machine: Electric mobility scooter
Use: Transport of walking-disabled people
Model No: Mini Crosser X1 HD
Type of use Class C
Complies with the Medical Device Directive 93/42/EEC
The product is accredited according to standard DS/EN 12184
- Electrically powered wheelchairs, scooters and their chargers -
Requirements and test methods.
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.
The Mini Crosser or parts (fx. batteries) af the Mini Crosser can,
for a fee, be taken to the nearest dealer for disposal in accord-
ance with current environmental regulations.
Manufacturer: Medema A/S
Address: Enggårdvej 7, DK-7400 Herning
Tel. [phone]
Date: 31.01.2018 Signature: _____________________
Managing director Finn Dose

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Medema A/S Warranty
1:
There is a 2-year warranty, with the exception of worn parts
such as tires, hoses, fuses, light bulbs, bushings and brake
pads.
2:
If you want to make a claim for a part under the warranty, it
must be intact. The warranty will be void if the product has been
removed or appears to have been mishandled.
3:
There is a 5-year warranty against breakage and corrosion of
the undercarriage.
4:
For the warranty to cover batteries, the charger used must be
sold by Medema A/S.
The fabric, type and serial number must be indicated on the
warranty specication, otherwise, warranty coverage may be
denied.
5:
Items returned under a warranty claim must be suitably packa-
ged to prevent damage during transport. Items damaged during
transport due to poor packaging will not covered by the war-
ranty.
6:
The warranty does not cover freight costs.
7:
The warranty requires annual inspection and maintenance of
the Mini Crosser by authorised professionals.

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Control panel
Avoid subjecting the control panel to jarring and knocks. Take
care when driving and avoid hitting obstacles.
The manufacturer accepts no liability in respect of the unauthor-
ised opening, adjustment or modication of the control panel.
Lever for adjusting the angle of the
handlebars
Charging socket
Key switch
Indicator lights, R/L
Horn
Accelerator
(four-nger control)
Indicator lights,
R/L
Horn
Speed selector
Hazard warning lights
Battery indicator
Handbrake
Light switch

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Key switch To start the vehicle:
Turn the key to driving position (1) When the Mini Crosser is
turned on, the control system performs a safety check of the
electrical system. The check lasts half a second. If the accel-
erator is operated during this time, the Mini Crosser will not be
able to move until you have turned the key to 0 and back to 1.
Speed selector The tortoise in minimum position indicates the lowest speed
range. 0-6 km/h
The hare in maximum position indicates the highest speed
range. Up to 15 km/h
Battery indicator
Lights up when the key is turned. Indicates, after half a second,
the battery charge level. It gives a more precise indication after
approx. 1 minute of driving. When the red, amber and green
sections are lit, the batteries are fully charged. When the indi-
cator is at the bottom of the amber section, the batteries should
be charged as soon as possible. If only the red section is lit or
ashing, the batteries must be charged immediately.
Hand brake Acts on the rear wheel and should only be used as an extra
/emergency brake and parking brake. It can be secured in
locked position.
Accelerator
(See picture
below)
Activate the arm at the front slowly and the Mini Crosser will
start to move forwards. The more the arm is pressed, the
faster the Mini Crosser will move. When the arm is released,
it will ip back to starting position of its own accord and the
Mini Crosser will stop. Activating the rear arm will cause the
Mini Crosser to reverse. The magnetic brake on the rear
wheels will engage when the Mini Crosser is stationary and is
equivalent to the parking brake on a car. The accelerator can
also be used to control speed downhill. In this case the motor
will act as a brake.
Light switch Turns on the front and rear lights. The key switch must be in
position 1 (driving position).
Hazard warning
lights
Turns on all the indicator lights at once. Also works when the
key is removed or turned to position 0 (stop position).
Indicator switch
Left arrow: indicator, left-hand side. Right arrow: indicator, right-
hand side. Activate the same switch to turn the indicators off.
Horn Powerful electric horn. Press the horn switch to activate.
Charging socket
Turn off the key switch during charging. Please note that it is
not possible to drive the Mini Crosser while the batteries are
charging. See also the section entitled “Batteries and charging”.
Accelerator back (thumb control)
Accelerator (four-nger control)
The accelerator forward and backwards
are physically connected, which means
that when one or the other is activated,
the other will move the opposite way.
Warning!
When the handlebar is moved closer to
your body, there is a risk for the leg to
touch the accelerator by mistake.

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Preparations / Adjustments prior to use
Adjusting the height of the seat
Lift both armrests up, and fold the seatback. Release the handle
so the seat can turn. Turn a little and lift the seat off.
Make sure you keep your back straight when lifting the seat,
which is very heavy.
Lift the seat off the seat tube.

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Hight adjustment seat post standard
The release button pressed in. Press the
button out to release the seat tube.
Release button pressed out. Now the
seat tube can be moved up/down to
the height you wish. Press the release
button again and make sure it is tted in
one of the 5 holes in the seat tube.
Loosen the counter nut.
Use spanner, 17 mm.
Adjust the seat post to the desired
position. The seat post is marked with a
ring at each centimetre.
Be aware that the black line is holding its position after movement, so the seat is
straight in front of the steering.
Tighten the screw, here after the counter nut.
Mount the seat. Adjust the lining if necessary.
Hight adjustment seat post with position bolt (option)

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Seat tube in top position. There are ve
holes for adjusting the seat tube. The
release must be in a hole for the seat to
be stable.
Electric seat adjustment
The Mini Crosser can be tted with electric seat adjustment as
an optional extra.
To raise the seat, press the switch up. To lower the seat, press
the switch down. If the switch is released, the seat will stop au-
tomatically. (See gure below.)
For safety reasons, a switch has been incorporated that reduc-
es the speed by 50% when the seat is raised more than 7.5 cm.
Electric seat adjustment. If the switch is pressed up, the seat
is raised. If the switch is pressed down, the seat is lowered.
Switch for electric
seat adjustment
Seat tube
Release

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IMPORTANT!
The Mini Crosser is most stable when the seat is in its lowest
position. Always drive carefully when the seat is raised. Never
use the seat adjustment when driving on an uneven surface or
in hilly terrain.
Take extra care when lowering the seat on a Mini Crosser using
electric seat adjustment. Make sure that nothing is trapped in
the space between the seat and the chassis.
Avoid trapping anything when lowering the seat.
Release lever for seat rotation. Release lever for seat forward/back.
Seat rotation
Pull the release lever back. The seat can be rotated 90° to
either side. When the lever is released, it engages with the seat
and holds it in place at 45° intervals.
Other seats that can be supplied for the Mini Crosser work on
similar principles. The release lever is normally mounted on the
right, but can be put on the left if so wished.

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Steering column
Can be adjusted forward/back with the release lever. Pull down
on the lever and pull the handlebars closer for a good driving
position. Use the lever again and push the steering column for-
ward to make it easier to get out.
The height of the steering column can be adjusted approx. 11
cm up/down. First remove the rubber plug covering the Allen
screw. Adjust the height using a 4 mm Allen key.
This applies to both the 3W and the 4W model. Remember to
retighten properly after adjusting.
Adjusting the angle of
the handlebars. Applies
to both the 3W and the
4W model.
Lever for adjusting the angle of
the handlebars
Adjusting the height of
the handlebars. Applies
to both the 3W and the
4W model.
Allen screw for height
adjustment

2018
18 X1 HD
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Serial number
All vehicles have a serial number plate showing the year of pro-
duction and serial number. The same serial number can also be
found on page two of this manual.
Please quote this number when making inquiries about servic-
ing, spare parts, etc.
Maximum user weight
Vehicle’s unladen weight incl.
batteries and seat
Position of serial number plate on vehicle.
Serial number
Model description
Year of production Max. speed
15