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Table of Contents
Troubleshooting
Related Manuals for medemagroup Mini Crosser M2
Summary of Contents for medemagroup Mini Crosser M2
- Page 1 P9-0157-S ver. 1.0.3 - October 2018...
- Page 2 Medema Production A/S Service manual P9-0157-S 2 of 68 Version 1.0.3/2018...
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Page 3: Table Of Contents
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 ....... -
Page 4: Introduction
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. -
Page 5: Symbols
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. -
Page 6: Safe Servicing
Medema Production A/S Safe servicing To avoid injuries to both the service engineer and the subsequent Š user of the scooter, it is important to get to know the product before servicing it. Be particularly aware of the following: Š The Mini Crosser MUST be turned off at the main switch. -
Page 7: Tool List
Medema Production A/S Tool list The following tools are needed to service the scooter: Circlip pliers Š Allen keys Š Box spanners, 7-17 mm Š Open-ended spanners, 7-17 mm Š Phillips and torx screwdrivers, 10/15/20/25 slot Š Needle-nose pliers Š Side-cutting pliers Š... -
Page 8: Storage
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. -
Page 9: Declaration Of Conformity
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: 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. -
Page 10: Maintenance
Medema Production A/S Maintenance Daily: Test the lights and indicators before using the scooter in the dark Š 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. - Page 11 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.
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Page 12: User Menu
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. - Page 13 Medema Production A/S Term Description Accelerator 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 fl ips itself back to the starting position and Mini Crosser stops. Upon activation of the posterior arm, the Mini Crosser run backward.
- Page 14 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.
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Page 15: Service Summary For Mini Crosser M Model
Medema Production A/S Service summary for Mini Crosser M Model Area Component Check and remedy Suspension and Rear suspension Check whether the rear of the wheels 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. - Page 16 Medema Production A/S Area Component Check and remedy Suspension and Front wheel Check that the guide rods and balls wheels (contd) suspension. are in good condition and properly tightened. Check the ball bearings in the front wheels and guide spindles for play/ wear.
- Page 17 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.
- Page 18 Medema Production A/S Area Component Check and remedy Steering column (*) On models with an 8 mm bolt (contd) 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.
- Page 19 Medema Production A/S Area Component Check and remedy Electrical Control card Check that it is dry and in a good components 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.
- Page 20 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 10 mm Service manual P9-0157-S 20 of 68 Version 1.0.3/2018...
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Page 21: Control Panel
Medema Production A/S 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 unauthorised opening, adjustment or modification of the control panel. Menu / information Actual speed Mileage... -
Page 22: Programming The Technician Menu
Medema Production A/S Programming the technician menu Access to the menu is achieved by holding down the up arrow and menu button for approx. 3 seconds. Enter password (contact Medema Production) using the +/- button and Next to move to next digit. Press Enter. You can scroll through the parameters with the +/- button below the display. - Page 23 Medema Production A/S Parameter description Reverse Buzzer (Off/ Same warning horn as it is known from trucks in reverse Beep/Buzze) gear. Choose from ”Off”, ”Beep” - low horns, or ”Buzzer” - sharp horns. Keyboard sound With ON / OFF select whether to be acknowledged with a little (On/Off) beep when you press the contacts on the dashboard.
- Page 24 Medema Production A/S Parameter description Battery indicator You can choose whether you want the battery indicator to be shown with 10 small compartments (6 green, 2 yellow and 2 red) or with 3 large compartments (1 green, 1 yellow and 1 red). The three-part display may be preferable for users who feel unsafe even after a couple of green lights have been turned off on the 10-compartment display.
- Page 25 Medema Production A/S Parameter description Service PIN Password for the Technician/Service menu. Enter a four-digit PIN code. The value can be changed using +/-. Move on to the next digit using the button under Next. Accept by pressing Enter. Display charge curve See the following section for further details.
- Page 26 Medema Production A/S Parameter description Acknowledge You can choose between no sound and a low or high horn blast to signal whether the alarm has been activated. The indicators will always flash once when the alarm is activated. The alarm lasts for 15 seconds before switching off. Any further disturbance will trigger it again.
- Page 27 Medema Production A/S Parameter description Max fwd speed slow This value is used when the ”slow/fast” switch is set to ”slow” Min fwd speed fast This value is used when the ”slow/fast” switch is set to ”fast” Min fwd speed slow This value is used when the ”slow/fast”...
- Page 28 Medema Production A/S Parameter description P&G fault log Here are the faults that P & G engine management have registered. The system can record 8 different 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...
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Page 29: Display Charge Curve
Medema Production A/S Display charge curve Find the Show Charging Graph item in the technician menu. A picture showing the current day is displayed by pressing enter. A red graph indicates when a battery charger has been connected. See the picture below: 21/01/09 A battery charger has been connected, which was removed from the scooter at approximately 8:30 am on 21 January 2009. - Page 30 Medema Production A/S You can use the Medema PC programme to download stored charging data to a computer by connecting a cable to the USB socket at the front of the controller. Use the CSV Export button to export loading data from the PCB.
- Page 31 Medema Production A/S Choose the diagram type shown. You will see a picture similar to the one you see on the Mini Crosser or PC. Only people who have been trained by Medema should use graphs in connection with charge curves. Service manual P9-0157-S 31 of 68 Version 1.0.3/2018...
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Page 32: Troubleshooting
Medema Production A/S Troubleshooting The following is a list of various problems that, in our experience, may occur. The list gives possible causes and remedies. Problem Possible causes Remedy The Mini Crosser will not The key has not been Turn the key and wait 5 turned to start. - Page 33 Medema Production A/S Possible causes Remedy Problem The “ready” lamp on the The fuse in the charger Contact supplier. charger lights up even has blown. when partly discharged The switch in the charging Contact suppliers - read batteries are connected. plug is malfunctioning.
- Page 34 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. Lamps Causes Remedy...
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Page 35: The Vehicle's Driving Characteristics
Medema Production A/S The vehicle’s driving characteristics Below are the default values of the P & G parameters. If parameter changes not seen in P & G parameter menu are required, contact Medema for further information. Please note that the values for speed, deceleration, throttle gain and motor compensation may not be increased. -
Page 36: Batteries
Medema Production A/S Batteries The battery indicator shows how much power is available to the scooter. Red, amber and green indicate that the batteries are fully Š charged. Red and amber indicate that the batteries will soon need Š recharging. Red indicates that the batteries need to be recharged as soon as Š... -
Page 37: Charging
Medema Production A/S Charging The battery manufacturer recommends charging the batteries at temperatures between +10° and +30°C in order to achieve the charging times specified in “Technical data”. Charging takes around 60% longer at +5°C than at +20°C. This is because the battery finds it more difficult chemically to absorb the current. - Page 38 Medema Production A/S It is important to fit the batteries correctly. The battery terminals and snap locks are marked +/-. They must be fitted as shown in the sketch below. Make sure that the snap locks are properly closed. For the same reason there must not be any burrs on the terminals.
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Page 39: Fuel For Heater
Medema Production A/S Fuel for heater The tank for fuel is placed behind the seat, and filled from the outside. Use ONLY paraffin or diesel. In the front, right side of the Mini Crosser M Cabin, you find the the exhaustion from the heater. -
Page 40: Windscreen Wiper / Washer
Medema Production A/S IMPORTANT! The heating ribs by the window and by the legs should NOT be covered up when the heating is on. That will cause overheating of the heater Windscreen wiper / washer Start the windscreen wiper by turning this knob. -
Page 41: Replacing The Wiper Blade
Medema Production A/S Replacing the wiper blade To exchange the wiper blade, do the following: Screw this screw out. Lift carefully, so you can pull the wiper blade over the pin. Mount a new in reverse order. Replacing the bulb - headlight Open the front cover, by turning the handle 90°... - Page 42 Medema Production A/S Press down and turn counter clockwise.- and lift out. Now you have access to the bulb. take the bulb out. Mount a new in reverse order. NOTE! Be aware that drain list are not trapped when the front cover is closed.
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Page 43: Fitting An Accelerator Switch
Medema Production A/S Fitting an accelerator switch Connecting two accelerators at the same time. Options: Standard accelerator on left and right (wig-wag). Š Twist grip accelerator on right and left (single-ended). Š Twist grip accelerator and foot pedal (single-ended). Š What they all have in common is a change-over switch for selecting which to use. - Page 44 Medema Production A/S Fit the throttle cable. Throttle cable. Mount the switch so it points in the The display will now show REVERSE correct direction. Install the dashboard. in the lower left corner. Use the button Avoid pinching/stretching the cables. below to change to REVERSE.
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Page 45: Fitting Corner Speed Reduction, 4W
Medema Production A/S Fitting corner speed reduction, 4W The kit contains these parts. Take the front cover off. Attach the bracket to the body frame Mount the U-shackle with pipe fitting and using the pre-drilled holes. bolt on the steering column. Please note that the distance to the magnet should be approx. -
Page 46: Fitting A Foot Pedal
Medema Production A/S Fitting a foot pedal Complete foot pedal. Decide where the foot throttle should be fitted. Drill a 13mm hole for the foot throttle cable. Lined with the rubber lining provided. The foot throttle must be pulled through The petrol plug in the controller must be the hole and up the steering column. - Page 47 Medema Production A/S The forward and reverse foot throttle Secure the foot throttle with the screws pedal. Can be placed on the right, left provided. or in the middle. Must be installed as described on the previous page. The programming must be changed from wigwag to single-ended control.
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Page 48: Fitting A Twist Grip Accelerator, Right & Left
Medema Production A/S Fitting a twist grip accelerator, right & left Left-hand twist grip accelerator kit. Right-hand twist grip accelerator kit. Remove the plastic cover. Remove the throttle lever. Remove the handle. Refit the throttle lever. Service manual P9-0157-S 48 of 68 Version 1.0.3/2018... - Page 49 Medema Production A/S The plug and fuse must be fitted into Use Loctite 406 for fitting the throttle. the hole. Remember to also install the 2 small fuses again. Connect the hand throttle to the 3-pin Tighten the screws. plug where the standard potentiometer was connected.
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Page 50: Elevated Footrest
Medema Production A/S Elevated footrest Drill two holes through the bottom plate Screw together with the screws using the holes shown as a template. provided. Anti-theft alarm, tilt alarm and temperature sensor. The box with the anti-theft alarm, tilt Fitted to the electric plate with Velcro. alarm and temperature sensor. -
Page 51: Securing To Vehicle Floor With Belts
Medema Production A/S Securing to vehicle floor with belts Dahl Engineering belt set for securing in motor vehicles. Item No. C2-0242 ALWAYS use four belts at the back and two at the front. The belts must always be attached to approved fittings in the vehicle and the four eyes welded to the scooter. - Page 52 Medema Production A/S Attachment point Attachment point Greater than the anchorage points on the Greater than scooter the anchorage points on the Centre line scooter Service manual P9-0157-S 52 of 68 Version 1.0.3/2018...
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Page 53: Transporting By Plane
Medema Production A/S Remember to turn the Mini Crosser off during transport. Turn the key to 0. However, if at all possible, we recommend that the user occupies one of the seats in the motor vehicle. All other things being equal, this is safer. Transporting by plane If the Mini Crosser is to be transported by plane, the airlines require:... - Page 54 Medema Production A/S 1030 mm 1610 mm Service manual P9-0157-S 54 of 68 Version 1.0.3/2018...
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Page 55: Front Wheel Alignment, 4W
Medema Production A/S Front wheel alignment, 4W Front wheel alignment (toe-in), 4W Service manual P9-0157-S 55 of 68 Version 1.0.3/2018... -
Page 56: Troubleshooting
Medema Production A/S Troubleshooting The following is a list of various problems that, in our experience, may occur. The list gives possible causes and remedies. Problem Possible causes Remedy The Mini Crosser will not The key has not been Turn the key and wait 5 turned to start. - Page 57 Medema Production A/S Problem Possible causes Remedy The “ready” lamp on the The fuse in the charger Contact supplier. charger lights up even has blown. when partly discharged The switch in the charging Contact suppliers - read the batteries are connected. plug is malfunctioning.
- Page 58 Medema Production A/S If there is an electronic fault, a number of lamps in the battery indicator will light up. The following table shows what they mean. Lamps Causes Remedy 1 lamp The batteries need charging or Check all connections between the connection to a battery is the controller and batteries.
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Page 59: Programming
Medema Production A/S Programming NOTE! For safety reasons, modifications may only be made by trained personnel, such as Mini Crosser service engineers and consultants or authorised service personnel at mobility centres, etc. Technical data M2 3W M2 4W General information: Transport height without seat 69 cm 69 cm... - Page 60 Medema Production A/S M2 3W M2 4W Seats: Effective seat width: Ergo Standard 40,45,50,55,60 cm 40,45,50,55,60 cm Spinalus 40, 45, 50 cm 40, 45, 50 cm Mando 48 cm 48 cm HD (user weight max 250 kg) ------ 60, 65, 70 cm Ergo child / junior 35, 37 cm 35, 37 cm...
- Page 61 Medema Production A/S M2 3W M2 4W Max. battery dimensions in cm. 26.5 x 17 x 22 26.5 x 17 x 22 28.4 x 26.7 x 23 28.4 x 26.7 x 23 Battery weight, 2 batteries 56 Ah 43 kg 43 kg 75/80 Ah 50 kg...
- Page 62 Medema Production A/S Service manual P9-0157-S 62 of 68 Version 1.0.3/2018...
- Page 63 Medema Production A/S Service manual P9-0157-S 63 of 68 Version 1.0.3/2018...
- Page 64 Medema Production A/S Appendix A: Code Description Action Bars Comments 0003 EEProm cache checksum trip Trip EEProm contents corrupted. Possible Controller Fault 0100 ROM checksum trip Trip Performed on Startup. Possible Controller Fault 0200 EEProm cache checksum trip Trip Performed on Startup. Possible Controller Fault 0300 Parallel Speed pot wiper o/c...
- Page 65 Medema Production A/S Code Description Action Bars Comments 1C10 Motor negative current trip Trip Possible controller Fault 1C12 Reverse overcurrent trip Trip Possible controller Fault 1E08 Inhibit active Note 1 Note 2 Note 1 - trip or speed limit depends on programming Note 2 - trucharge display depends on programming...
- Page 66 Medema Production A/S Code Description Action Bars Comments 4401 Generic internal fault code Generic code for logging controller / internal faults to system log. These are faults that cannot be categorically classed as system faults. The control log will break down these codes into their relevant trip code(s).
- Page 67 Medema Production A/S Service manual P9-0157-S 67 of 68 Version 1.0.3/2018...
- Page 68 medemagroup...
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