medemagroup Mini Crosser X2 4W Cabin User manual

Service Manual Mini Crosser X2
1533-2002-S ver. 1.0.5 - Marts 2021 GB
medemagroup

Service manual 1533-2002-S 2 of 122 Version 1.0.5 - 2021
Medema 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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Medema A/S
Contents
Introduction...........................................................................5
Intended occupant................................................................6
Help for the visually impaired .............................................6
FSN (Field Safety Notice).....................................................6
Symbols.................................................................................7
Warning!................................................................................7
Alarm .....................................................................................7
Contagion!.............................................................................7
Safe servicing.......................................................................8
Tool list..................................................................................9
Storage..................................................................................10
Cleaning ................................................................................10
Declaration of conformity....................................................11
Medema A/S Warranty..........................................................12
Maintenance..........................................................................13
Control panel ........................................................................14
User menu.............................................................................15
Programming the User Menu ..............................................18
Preparations / Adjustments prior to use............................20
Electric seat adjustment......................................................22
Seat rotation..........................................................................23
Steering column ...................................................................24
Serial number........................................................................25
Driving the Mini Crosser X2 ................................................26
Lap belt..................................................................................29
Specic driving situations...................................................31
Long hills/di󰀩cult ground ...................................................33
Anti-tilt wheels / stabilisers.................................................34
General care and maintenance ...........................................35
Insurance...............................................................................36
Batteries................................................................................37
Battery weight.......................................................................37
Charging................................................................................37
Battery disposal....................................................................38
Standby power......................................................................39
Storage..................................................................................41
Cleaning ................................................................................41
Brakes....................................................................................42
Disengagement.....................................................................43
Transporting by motor vehicle............................................44
Securing to vehicle oor with belts....................................45
Transporting by plane..........................................................48
Towing...................................................................................48
Dimensioned drawing, Mini Crosser X2 3W.......................49

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Dimensioned drawing, Mini Crosser X2 4W.......................50
Service summary for Mini Crosser X2 Model ....................51
Programming the technician menu ....................................57
Display charge curve ...........................................................64
Troubleshooting ...................................................................67
Driving characteristics.........................................................71
Changing the wheels............................................................72
Checking and replacing the X2 head..................................77
Replace the Shadow.............................................................85
Replace headlights...............................................................86
Replace gas spring for steering collumn...........................88
Replace the front springs....................................................89
Replace rear spring..............................................................90
Replace tail light...................................................................91
Replace batteries..................................................................92
Replace transaxle.................................................................93
Replace cable for hand brake..............................................96
Replace the magnetic brake................................................98
Replace fuses .......................................................................100
Replace coal..........................................................................101
Introduction to the Ergo2 seat ............................................103
Basket on seatback..............................................................108
Introduction to the Eblo seat...............................................109
Flame resistance ..................................................................110
Front wheel alignment, 4W..................................................111
Programming........................................................................111
Technical data.......................................................................112
Appendix A - Electric faults.................................................118

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Introduction
This manual contains servicing instructions for the Mini Crosser
X2 Model 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 X2 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 of operation. 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 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 tra󰀩c sig-
nals and other road users when driving in tra󰀩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 175 kg.
Help for the visually impaired
If you have di󰀩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 di󰀩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 X2 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.
Alarm
Temperature sensor, alarm system and tilt alarm are built into
the same box that can be acquired as an option for the Mini
Crosser X2.
Note!
The alarm is always turned o󰀨 on delivery. See the chapter
about ”Programming the User Menu” to turn on the alarm.
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 o󰀨 on oor coverings, particularly linoleum. Medema A/S as-
sumes 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 o󰀨 at the main switch. If electri-
cal 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 mo-
tor gear incorrectly or drop them.
• Make sure to raise one rear wheel o󰀨 the ground so that the
scooter cannot drive o󰀨 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
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 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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Declaration of conformity
Model: Mini Crosser X2
Medema-A/S declares on our sole responsibility that the product
range mentioned below are manufactured in accordance with our
incorporated standards and are in conformity with the following direc-
tives and standards if they are used according to our instructions:
Regulation (EU) 2017/745 of the European Parliament and of the
Council of 5 April 2017 on medical devices.
EN 12184:2014 Electrically powered wheelchairs, scooters and
their chargers - Requirements and test methods
Risk analysed according to ISO 14971:2012, Medical devices –
Application of risk management to medical devices.
Type of use : Transporting walking disabled people
Risk Class : I
The product range in the Mini Crosser model-X2 includes the fol-
lowing items
Product name Basic UDI-DI
Mini Crosser X2 3W 10 km/h 5707299MCX2-3W106A
Mini Crosser X2 3W 13 km/h 5707299MCX2-3W136G
Mini Crosser X2 3W 15 km/h 5707299MCX2-3W156L
Mini Crosser X2 4W 10 km/h 5707299MCX2-4W106H
Mini Crosser X2 4W 13 km/h 5707299MCX2-4W136P
Mini Crosser X2 4W 15 km/h 5707299MCX2-4W156T
Mini Crosser X2 HD 4W 10 km/h 5707299MCX2-4WHD105S
Mini Crosser X2 CAB 10 km/h 5707299MCX2-CAB10KA
Mini Crosser X2 CAB 13 km/h 5707299MCX2-CAB13KG
Mini Crosser X2 CAB 15 km/h 5707299MCX2-CAB15KL
The Mini Crosser or parts (fx. batteries) af the Mini Crosser can,
for a fee, be taken to the nearest dealer for disposal in accordance
with current environmental regulations.
Manufacturer: Medema A/S
Address: Enggårdvej 7, DK-7400 Herning
Tel. [phone]
Date: 16.03.2020 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 pack-
aged to prevent damage during transport. Items damaged
during transport due to poor packaging will not covered by the
warranty.
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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Maintenance
Daily: (User)
• Test the lights and indicators before using the scooter in the dark
or poor visibility.
Every three months: (User)
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 indi-
cator should ash error 9.
When the disengagement lever is up and the scooter has been
switched o󰀨 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 o󰀨, 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 Technician
The Mini Crosser X2 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 op-
eration. The service must be carried out either by MedemaA/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.

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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
Accelerator
(four-nger control)
Indicator lights, R/L
Horn
Indicator lights,
R/L
Horn
Speed selector
Hazard warning lights
Battery indicator
Handbrake
Light switch
Actual speed
Accelerator
(four-nger control)
Speed
regulation
Menu / information
Trip meter
Mileage
Light sensor
Extra Switch
Can be used
for optional
functions.
anti-theft alarm

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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 af-
fected 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/o󰀨 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 ap-
prox. 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 ash-
ing 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.

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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 o󰀨 ashing
lights.
Horn Electric horn which can be programmed in volume in
the User Menu. Activated by pressing the horn button.
Charging socket Turn o󰀨 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.”

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Term Description
Extras
Anti-theft alarm (Extra) With this parameter set to ON, the anti-theft
alarm is turned on every time you turn o󰀨 the Mini
Crosser. An activated alarm is turned o󰀨 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 Mini Crosser 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.

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Programming the User Menu
Access the menu by holding the Menu/information button for
approx. 3 sec. Scroll up and down with the + / -button under the
display. The active parameter is highlighted with yellow writing
and blue background. Access the value of the selected param-
eter by pressing Enter. Change the value using the +/- button.
Conrm with Enter and exit with the Menu/information button.
Parameter description
Date Format Choose between:
ddmmyy - day/month/year
mmddyy - month/day/year
yymmdd - year/month/day
Temp. unit
(Temp. unit is extra) Choose between Celsius or Fahrenheit. Displays ambient temperature.
Limited speed
(On/O󰀨)
Limited speed On/O󰀨.
To edit this function you will be asked for a 4 digit code.
From the factory this code is set to be 1234, but it can be
altered by a service technician.
Use the +/- button to each digit. Go to the next digit with the
“Next” button. Conrm with “Enter” Turn this parameter On/
O󰀨 – Conrm with “Enter”.
Limited speed (value) Limited speed - value.
To edit this function you will be asked for a 4 digit code.
From the factory this code is set to be 1234, but it can be
altered by a service technician. Use the +/- button to set
% value, that you want the Mini Crosseres max speed
reduced to. Move in increments of 5%.
Backlight (value) The displays backlight can be changed in increments of
5%. Typically used in winter or when driving in darkness,
where the intense light from the display may seem annoy-
ing.
Backlight auto
(On/O󰀨) Selecting ”On” reduced intensity of the backlight automatically when darkness falls or when driving into
a tunnel or similar. Light sensor sits just above the light
switch. See the Control panel.
Backlight threshold Here max. light intensity is shown in%. Move in increments
of 5%.
Reverse Buzzer (O󰀨/
Beep/Buzze) Same warning horn as it is known from trucks in reverse gear.
Choose from ”O󰀨”, ”Beep” - low horns, or ”Buzzer” - sharp
horns.
Keyboard sound
(On/O󰀨)
With ON / OFF select whether to be acknowledged with a
little beep when you press the contacts on the dashboard.
These are: ashing, lights, hazard, menu, arrows and
MENU keys.
Blinker sound (O󰀨/
Beep/Buzze) Choose whether you want a sound when ashing lights on the Mini Crosser is on. Just as we know it from a car. You
can
select ”O󰀨”, ”Beep” - low horns, or ”Buzzer” - sharp horns.

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Parameter description
Clock Set time and date using the up / down with arrows. Moving
to the next digit by pressing the ”next” button. Quit with the
”Enter”
Hazard enabled
(On/O󰀨) By default hazard (emergency lights) is operable even if the Mini Crosser is switched o󰀨 and the key is removed.
If you wish the hazard not be activated with the Mini
Crosser
turned o󰀨, you should select ”O󰀨.” here.
Alarm enabled
(On/O󰀨) Extra
With this switch ”On”, the burglar alarm is turned on every
time you turn o󰀨 the Mini Crosser. The small lamp next to
the
”Trip meter” will  ash a few seconds interval.
An activated alarm is turned o󰀨 by switching the key on the
Mini Crosser. If you have no opportunity to get to the Mini
Crosser
with the key, the alarm will switch o󰀨 after approx. 20th
seconds. Shake / move the Mini Crosser again, the alarm
will be
activated again.
Tilt Present (On/O󰀨)
Extra With this parameter set to ”On”, will turn the tilt icons to red and blinking, and there will be a whining tone (if enabled) if
you are running on a slope that is steeper than allowed.
P&G fault log Here are the faults that P & G engine management has
registered. The system can record 8 di󰀨erent types of
faults. Each fault can be recorded up to 30 times.
The newest registered fault is written at the top of the list.
They are shown as follows:
[1502] 2
None
None
None
None
None
None
In this case, the fault 1502 appeared twice. If you press
ENTER on the fault you will get an explanatory text. In this
case, ”Solenoid brake fault”
None means that there have not been other faults.
In case of fault on the Mini Crosser, it will be a great help if
the fault type can be given to the Mini Crosser or his
representative during troubleshooting.
Temperature sensor, alarm system and tilt alarm are built into
the same box that can be acquired as an option for the Mini
Crosser X2.

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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 o󰀨.
Make sure you keep your back straight when lifting the seat,
which is very heavy.
Lift the seat o the seat tube.