Medema Mini Crosser M1 Service Manual
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Medema Mini Crosser M1 Service Manual

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P9-0155-S ver. 2.0.2 - August 2011

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Summary of Contents for Medema Mini Crosser M1

  • Page 1 medemagroup medemagroup P9-0155-S ver. 2.0.2 - August 2011...
  • Page 2 Medema Production A/S Serial number: ___-______________-______-_______ Delivery date: ________________ Year 20______ This vehicle was supplied by: Date: Service Manual P9-0155-S 2 of 62 Version 2.0.2/2011...

  • Page 3: Table Of Contents

    Medema Production A/S Table of contents Table of contents ..............3 Introduction ................4 Symbols.................. 5 Warning! ................. 5 Safe servicing ................ 6 Tool list ................... 7 Storage ................... 8 Cleaning ................. 8 Declaration of conformity ............. 9 Maintenance ................10 Service summary for Mini Crosser M Model .......

  • Page 4: Introduction

    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...

  • 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 user of the scooter, it is important to get to know the product before servicing it. • Be particularly aware of the following: •...

  • Page 7: Tool List

    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 •...

  • 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

    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...

  • Page 11: 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 12 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 13 Medema Production A/S Area Component Check and remedy Motor / gear / Wear Check: That the motor runs smoothly brake and evenly. If not, the carbon brushes (Transaxle) in the motor usually need to be replaced. The minimum length of the brushes is 1-1.5 cm.
  • Page 14 Medema Production A/S Area Component Check and remedy Braking distance 10 km/h - 2.0 m (9) 15 km/h - 3.5 m (9) The fi gures in brackets indicate the normal braking parameter when the scooter leaves the factory. It can be changed with the programming unit (forward deceleration).
  • Page 15 Medema Production A/S Area Component Check and remedy Chassis / seat / Seat Check that: covers (contd) The release lever locks the seat properly. The seat is fi 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.

  • Page 16: Troubleshooting

    Medema Production A/S Troubleshooting The following is a list of various problems that we are frequently asked about. Possible causes and solutions are given. Problem Possible causes Solution The Mini Crosser will not The key has not been Turn the key and wait 5 turned to start.
  • Page 17 Medema Production A/S Problem Possible causes Solution The ready lamp on the There has been a power Reconnect the charger charger does not light up cut. and repeat the charging even though the charger process. has been on for 10-12...
  • Page 18 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.

  • Page 19: Programming Unit

    Medema Production A/S Programming unit The Mini Crosser’s running characteristics can be partially altered using a type SP1B programming unit via PC and the PC programming package for S180. NB! SP1B cannot be used to change the speed, which can only be done using the PC program.

  • Page 20: Programming Via Pc

    Medema Production A/S Programming via PC There are two different versions of the PC program, an OEM version and a dealer version. The OEM version gives complete access to all settings parameters. The dealer version gives limited access. Before programming can commence, the fi...
  • Page 21 Medema Production A/S Note that the programming connection in the red circle is led out of the S-180 controller via a short cable with a 4-pin Molex connector on the end. Connect the PC using the 4-pin Molex connector, PC cable and USB for serial adapter.

  • Page 22: Information About The Vehicle Via Pc

    Medema Production A/S Information about the vehicle via PC Double-clicking on the S-180 program icon displays the following screen. Press Continue to continue. The red down arrow shows that the program can see that the controller is connected. Press the red arrow to load the program from the controller.
  • Page 23 Medema Production A/S If you do not wish to load the fi le from the controller but instead a program in the PC, select “Files”, “Open”. Select the desired program, and press “Open”. Having made changes to the program, use the “Program”...
  • Page 24 Medema Production A/S System log The system log shows details about which controls are presently connected to the PC. The log shows the last eight system errors registered. Every error has a Trip Code, and a short description of the error.
  • Page 25 Medema Production A/S The menus at the bottom of the screen enable you to: “Copy” – copy the log to another fi le. “Warning” – It is important to read and understand warnings before attempting to correct any errors. “Print” – print out to a printer “Clear System Log”...
  • Page 26 Medema Production A/S The vehicle identity Controller Info shows the controller’s number, software version and serial number. For additional information about the use of the PC program, refer to the online manual from PG Drives Technology. This may be found on the CD-ROM from which the program was installed.

  • Page 27: Fuses And Bulbs

    Medema Production A/S Fuses and bulbs Fuse locations Fuse 1 1 x 20 A fuse Charging Item No. SR-00066 (40 A) Fuse 2 1 x 10 A fuse Control system Item No. SR-00066 (10 A) Main fuses, 100 A, fuse type DIN 2581 - 100 A Item No. SR-...

  • Page 28: Sockets And Control Panel

    Medema Production A/S Sockets and control panel MiniCrosser A/S T-127-5-002 Issue 2.0 Some of the sockets on the card are for optional extras. Some of them are connected at the factory and wired instead to the areas on the scooter where they are to be used.
  • Page 29 Medema Production A/S The below numbers refer to the socket on the printed circuit in the control panel. Key switch Reverse Emergency stop Headlight Cable trunk Hazard warning lights Cable trunk Indicator card R Electric seat adjustment Max. speed pot.

  • Page 30: Batteries

    Used batteries must be disposed of through your supplier or at a recycling centre. Take care when handling any leaky batteries, as they contain corrosive acid. INFO! New batteries can be purchased from Medema Danmark A/S. Service Manual P9-0155-S 30 of 62 Version 2.0.2/2011...

  • Page 31: 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 specifi ed in “Technical data”. Charging takes around 60% longer at +5°C than at +20°C. This is because the battery fi...
  • Page 32 Medema Production A/S It is important to fi t the batteries correctly. The battery terminals and snap locks are marked +/-. They must be fi tted as shown in the sketch below. Make sure that the snap locks are properly closed.

  • Page 33: 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). • Twist grip accelerator on right and left (single-ended). • Twist grip accelerator and foot pedal (single-ended).
  • Page 34 Medema Production A/S Fit the two accelerators. Accelerator cable. Fit the switch so it points to the right Fit the control panel. Avoid trapping/ side. stretching the wires. Turn the scooter on and check that the magnetic brake clicks when the accelerator is activated.

  • Page 35: Fitting A Speedometer

    Medema Production A/S Fitting a speedometer The kit contains these parts. Take the seat and cover off, then remove the left rear wheel. Screw the bolt in until it sticks 2-3 mm Plug the connector at the other end into out through the backplate.
  • Page 36 Medema Production A/S Fit the speedometer with the mounting Find the connector marked KM in the strap provided. rubber bellows. Plug the connector in and put the The fi nished result. connector and cable back in under the rubber bellows.

  • Page 37: Fitting Corner Speed Reduction, 3W

    Medema Production A/S Fitting corner speed reduction, 3W The kit contains these parts. Take the plastic lever off the gas spring release. Remove the back plastic cover by Take the front wheel off. undoing the six plastic bolts. Sensor mounted on head tube - 3W Plug the sensor into connector no.

  • Page 38: 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 fi tting and using the pre-drilled holes. bolt on the steering column. Please note that the distance to the magnet should be approx.

  • Page 39: Parent Potentiometer

    Medema Production A/S Parent potentiometer Potentiometer with connector and Remove the seat and cover. Fit the jumper. potentiometer. Remove the speed control. Fit the forward/reverse switch. Turn the scooter on and check that the magnetic brake clicks when the accelerator is activated.

  • Page 40: Fitting An Hour Counter

    Medema Production A/S Fitting an hour counter Take the plastic cover off the steering Replace with a plastic cover that has an column. hour counter fi tted. Plug into connector no. 6. Fit the plastic Panel with hour counter. cover. Take care not to trap any cables.

  • Page 41: Fitting A Parent Key

    Medema Production A/S Fitting a parent key Parent key. Remove the rubber plug in the plastic cover. Remove the plastic lever. Remove the back plastic cover by undoing the six plastic bolts. Plug the key into connector no. 3. Put the plastic cover back on.

  • Page 42: Fitting A Foot Pedal

    Medema Production A/S Fitting a foot pedal Complete foot pedal. Open the control panel to connect the forward/reverse switch. Cut a hole for the forward/reverse Plug the forward/reverse switch into switch. contact no. 2. The foot pedal can be located on the Forward/reverse switch mounted on the right- or left-hand side, or in the centre.
  • Page 43 Medema Production A/S Foot pedal for forward and reverse. It can be located on the right- or left-hand side, or in the centre. Programming must be Wig Wag with this pedal. After completing installation, turn the scooter on and check that the magnetic brake clicks when the accelerator is activated.

  • Page 44: 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. Take the plastic cover off. Remove the rubber plug. Remove the lever. Remove the potentiometer. Service Manual P9-0155-S 44 of 62...
  • Page 45 Medema Production A/S Fit the connector and plug in the hole. Fit the twist grip accelerator on the handlebars. Tighten the screws. Plug the twist grip accelerator into the 3-pin connecter used for the standard potentiometer. Fit the forward/reverse switch.
  • Page 46 Medema Production A/S Change programming to “Single-ended” via SP1, SP2 or PC. See separate description of programming. Mount the switch and lable as shown above. Turn the scooter on and check that the magnetic brake clicks when the accelerator is activated.

  • Page 47: Fitting Accessories On The C-Rail

    Medema Production A/S Fitting accessories on the C-rail Examples Knock the plug off one end. Remove the strip. Cut the strip to length. Fit the stick The holder for an oxygen cylinder can holder on the C-rail. Put the plug back be fi...

  • Page 48: Replacing Bulb In Headlight

    Medema Production A/S Replacing bulb in headlight The bulb in the headlight is held in place Push the shackle down. The bulb by a shackle. and fi tting can now be taken out and replaced. On the 4W model the bulb can be...

  • Page 49: Fitting A Side-View Mirror

    Medema Production A/S Fitting a side-view mirror Take the rubber plug out of the threaded Put the plug back in and press the bush on the handlebars. Twist the knob rubber edge down around the bush. in the middle off.

  • Page 50: Electrical Seat Turning From Right To Left

    Medema Production A/S Electrical seat turning from right to left Seat with electrical turning. By default, electrical seat turning is installed so the seat turns to the right. 1. Lift the seat The electrical seat turn will now turn to 2.

  • Page 51: Securing To Vehicle Fl Oor With Belts

    Medema Production A/S Securing to vehicle fl oor with belts Q’Straint belt set for securing in motor vehicles. Item No. C2- 0234 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.
  • 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 P9-0155-S 52 of 62 Version 2.0.2/2011...
  • Page 53 Medema Production A/S For transport in an estate car, the seat can be lifted off and the handlebars folded down. This reduces the maximum height to 68 The Mini Crosser can be used as a seat during transport in a van or bus, provided it is securely anchored to the vehicle with approved four-point belts attached to the restraint points provided on the Mini Crosser.

  • Page 54: 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.

  • Page 55: Front Wheel Alignment, 4W

    Medema Production A/S Front wheel alignment, 4W Front wheel alignment (toe-in), 4W Service Manual P9-0155-S 55 of 62 Version 2.0.2/2011...

  • Page 56: Technical Data

    Medema Production A/S Technical data General information: Transport height without seat 69 cm 69 cm (Steering column folded down) Total length: 134 cm 140 cm Total length incl. anti-tilt wheel: 143 cm 148,5 cm Total width: 68 cm 68 cm Total weight incl.
  • Page 57 Medema Production A/S Height of backrest Ergo standrad / HD 48 cm 48 cm Spinalus 56 cm 56 cm Mando 53 cm 53 cm Ergo child / junior 36-41 cm 36-41 cm Height: front edge of seat to ground Ergo Standard with slide rail...

  • Page 58: Checklist For Servicing M

    Diode, indicator 24 V - 2 W 24 V - 2 W Standard colour Grey - metallic Grey - metallic Checklist for servicing M Mini Crosser M1 - 3W and 4W Date Sign. performed Area: Suspension and wheels Rear suspension No cables caught in moving parts Wheels –...
  • Page 59 Medema Production A/S Mini Crosser M1 - 3W and 4W Date Sign. performed Brush length Transaxle – oil leaks/noise Steering column Play/wear Cables Gas springs Keylock switch/charging plug Chassis / seat / covers Footplate Seat column Seat Windscreen Other mechanical components...
  • Page 60 Medema Production A/S Service Manual P9-0155-S 60 of 62 Version 2.0.2/2011...
  • Page 61 Medema Production A/S Service Manual P9-0155-S 61 of 62 Version 2.0.2/2011...
  • Page 62 Mini Crosser M1-3W Styrestolpe komplet Steering column complete 2 / 20...
  • Page 63 Mini Crosser M1-3W Styrestolpe komplet Steering column complete Pos. Del/part no. Benævnelse Part name Antal/ quant. E-130-3-015 Nav forhjul udenbremsetromle 3W. Hub frontwheel without breakdrum 3W M-127-03-003 Forhjulsnav, komplet Front-heel hub M-127-03-025 Holder for kurv, komplet sæt Holder for basket, complete set M-127-03-011 Kronrør komplet...
  • Page 64 Mini Crosser M1-3W Stel og sæderør. Chassis frame and seat column. 4 / 20...
  • Page 65 Mini Crosser M1-3W Stel og sæderør. Chassis frame and seat column. Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-02-003 Sædestolpe komplet Seat column complete M127-02-006 Friktionsstykker for sædestolpe, komplet Friction pieces of the seat post, com- sæt plete set...
  • Page 66 Mini Crosser M1-3W Transaksler Transaxles Fedt Grease Fedt Grease Fedt Grease Fedt Grease 6 / 20...
  • Page 67 Mini Crosser M1-3W Transaksler Transaxles Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-02-007 Transaksel 10 km, komplet m/motor (Solo Transaxle assembly 10 km/h (Solo styring) Controller) M-127-02-008 Transaksel 15 km, komplet m/motor (Solo Transaxle assembly 15 km/h (Solo...
  • Page 68 Mini Crosser M1-3W Skærme - blå metalic Covers - blue metalic 8 / 20...
  • Page 69 Mini Crosser M1-3W Skærme - blå metalic Covers - blue metalic Antal/ Pos. Del/part no. Benævnelse Part name quant. CR-00067 Håndgreb 83Ø40 8x40/30 Threaded knop 8x40/30 M-127-01-003 Batteriskærm lang, komplet. (Blue metal- Battery cover long, complete. (Blue lic) metallic) M-127-01-004 Batteriskærm kort, komplet.
  • Page 70 Mini Crosser M1-3W Skærme - grå metalic Covers - grey metalic 10 / 20...
  • Page 71 Mini Crosser M1-3W Skærme - grå metalic Covers - grey metalic Antal/ Pos. Del/part no. Benævnelse Part name quant. CR-00067 Håndgreb M8x20 - Ø40 Threaded knop M8x20 Ø40 M-127-01-021 Fodmåtte med blindnitter, 3W Foot mat with blind rivets, 3W M-127-01-023 Batterikåbe lang model (Grey metallic)
  • Page 72 Mini Crosser M1-3W EL-dele for Solo styring Electric parts for Solo Controller 12 / 20...
  • Page 73 Mini Crosser M1-3W EL-dele for Solo styring Electric parts for Solo Controller Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-03-022 Forlygte. komplet 4w Headlamp. complete 4w M-127-03-024 Forlygte. komplet 3w Headlamp. complete 3w M-127-5-015 Rød diode baglygte, klar linse...
  • Page 74 Mini Crosser M1-3W El-dele for S-180 styring Electric parts for S-180 Controller 14 / 20...
  • Page 75 Mini Crosser M1-3W El-dele for S-180 styring Electric parts for S-180 Controller Antal/ Pos. Del/part no. Benævnelse Part name quant. E-130-5-007 Mellemkabel, batteri Cabel, between battery M-127-03-006 Brugerpanel komplet User panel cover compl M-127-03-022 Forlygte. komplet 4w Headlamp. complete 4w M-127-03-024 Forlygte.
  • Page 76 Mini Crosser M1-3W M hjul og dæk M Wheels and Tires 16 / 20...
  • Page 77 Mini Crosser M1-3W M hjul og dæk M Wheels and Tires Antal/ Pos. Del/part no. Benævnelse Part name quant. E-115-03-065 Hjul Golf, ekstra bred 13x5.00-6 Wheel ass. ekstra wide, 13x5.00-6 E-115-03-066 Hjulfælg komplet 6” Wheel rim complete 6” E-115-3-003 Slange MC 6”...
  • Page 78 Mini Crosser M1-4W Styrestolpe komplet Steering column complete 2 / 20...
  • Page 79 Mini Crosser M1-4W Styrestolpe komplet Steering column complete Pos. Del/part no. Benævnelse Part name Antal/ quant. M-127-03-025 Holder for kurv, komplet sæt Holder for basket, complete set M-127-03-510 Forbro med affjedring, komplet (4W) Caster beam with suspension (4W) M-127-03-514...
  • Page 80 Mini Crosser M1-4W Stel og sæderør. Chassis frame and seat column. 4 / 20...
  • Page 81 Mini Crosser M1-4W Stel og sæderør. Chassis frame and seat column. Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-02-003 Sædestolpe komplet Seat column complete M127-02-006 Friktionsstykker for sædestolpe, komplet Friction pieces of the seat post, com- sæt plete set M-127-1-025 Gummiprofi...
  • Page 82 Mini Crosser M1-4W Transaksler Transaxles Fedt Grease Fedt Grease Fedt Grease Fedt Grease 6 / 20...
  • Page 83 Mini Crosser M1-4W Transaksler Transaxles Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-02-007 Transaksel 10 km, komplet m/motor (Solo Transaxle assembly 10 km/h (Solo styring) Controller) M-127-02-008 Transaksel 15 km, komplet m/motor (Solo Transaxle assembly 15 km/h (Solo...
  • Page 84 Mini Crosser M1-4W Skærme - blå metalic Covers - blue metalic 8 / 20...
  • Page 85 Mini Crosser M1-4W Skærme - blå metalic Covers - blue metalic Antal/ Pos. Del/part no. Benævnelse Part name quant. CR-00067 HÅNDGREB 83Ø40 8x40/30 Threaded knop 8x40/30 M-127-01-003 Batteriskærm lang, komplet. (Blue metal- Battery cover long, complete. (Blue lic) metallic) M-127-01-004 Batteriskærm kort, komplet.
  • Page 86 Mini Crosser M1-4W Skærme - grå metalic Covers - grey metalic 10 / 20...
  • Page 87 Mini Crosser M1-4W Skærme - grå metalic Covers - grey metalic Antal/ Pos. Del/part no. Benævnelse Part name quant. CR-00067 Håndgreb M8x20 - Ø40 Threaded knop M8x20 Ø40 M-127-01-023 Batterikåbe lang model (Grey metallic) Battery cover long, complete. (Grey...
  • Page 88 Mini Crosser M1-4W EL-dele for Solo styring Electric parts for Solo Controller 12 / 20...
  • Page 89 Mini Crosser M1-4W EL-dele for Solo styring Electric parts for Solo Controller Antal/ Pos. Del/part no. Benævnelse Part name quant. M-127-03-022 Forlygte. komplet 4w Headlamp. complete 4w M-127-03-024 Forlygte. komplet 3w Headlamp. complete 3w M-127-5-015 Rød diode baglygte, klar linse...
  • Page 90 Mini Crosser M1-4W El-dele for S-180 styring Electric parts for S-180 Controller 14 / 20...
  • Page 91 Mini Crosser M1-4W El-dele for S-180 styring Electric parts for S-180 Controller Antal/ Pos. Del/part no. Benævnelse Part name quant. E-130-5-007 Mellemkabel, batteri Cabel, between battery M-127-03-006 Brugerpanel komplet User panel cover compl M-127-03-022 Forlygte. komplet 4w Headlamp. complete 4w M-127-03-024 Forlygte.
  • Page 92 Mini Crosser M1-4W M hjul og dæk M Wheels and Tires 16 / 20...
  • Page 93 Mini Crosser M1-4W M hjul og dæk M Wheels and Tires Antal/ Pos. Del/part no. Benævnelse Part name quant. E-115-03-065 Hjul Golf, ekstra bred 13x5.00-6 Wheel ass. ekstra wide, 13x5.00-6 E-115-03-066 Hjulfælg komplet 6” Wheel rim complete 6” E-115-3-003 Slange MC 6”...
  • Page 94 medemagroup...

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