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medemagroup

Mini Crosser X2
Service Manual

1533-2002-S ver. 1.0.0 - 2018-06 GB


Medema A/S

Serial number: ___-______________-______-_______

Delivery date: ________________ Year 20______

This vehicle was supplied by: Date: /

Dealer:

For this product You can expect to find the following documentation:

• User manual
• Service manual
• Spare parts list
• Presell information.

Medema A/S

Enggårdvej 7
Snejbjerg
DK-7400 Herning
Denmark

Phone: +45 70 10 17 55
Mail: info@medema.com

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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
Specific driving situations....................................................31
Long hills/difficult 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 floor with belts.....................................45
Transporting by plane...........................................................48
Towing....................................................................................48
Dimensioned drawing, Mini Crosser X2 3W.......................49

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Medema A/S

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..........................................................70
Changing the wheels.............................................................71
Replace the circuit board.....................................................76
Replace the Shadow.............................................................78
Replace headlights................................................................79
Replace gas spring for steering collumn............................81
Replace the front springs.....................................................82
Replace rear spring...............................................................83
Replace tail light....................................................................84
Replace batteries...................................................................85
Replace transaxle..................................................................86
Replace cable for hand brake..............................................89
Replace the magnetic brake.................................................91
Replace fuses........................................................................93
Replace coal..........................................................................94
Introduction to the Ergo2 seat.............................................96
Basket on seatback...............................................................101
Introduction to the Eblo seat................................................102
Flame resistance...................................................................103
Front wheel alignment, 4W...................................................104
Programming.........................................................................105
Technical data........................................................................105
Appendix A - Electric faults..................................................110

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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 classifica-
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 fire.

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: +45 70 10 17 55
E-mail: info@medema.com
Internet: www.medema.dk

NB: Errors and omissions excepted. Specifications subject to change.

Medema A/S also reserves the right to update the service manual
in line with any modifications 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 traffic sig-


nals and other road users when driving in traffic. 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 difficulty 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 find it difficult to understand the manual and have general


questions about the product, please feel free to contact us. You
can find our contact info on page two in this user manual.

You can find 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 off 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 off on floor coverings, particularly linoleum. Medema A/S as-
sumes no responsibility in case of contagion.

To prevent this, we recommend that you protect delicate floors


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 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 off the ground so that the
scooter cannot drive off accidentally.

• Use professionally maintained tools.

• Where lock nuts are used, NEW ones MUST be fitted when the
scooter is reassembled.

• Take care to fit 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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Medema 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 X2

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. +45 7010 1755

Date: 31.01.2018 Signature: _____________________

Managing director Finn Dose

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Medema A/S

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 specification, 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 flash error 9.
When the disengagement lever is up and the scooter has been
switched off and on, the scooter should be able to go again. It
must not be possible to push it.

• Test the accelerator.


With the scooter turned off, activate the accelerator while turning
the scooter on. The scooter must not be able to go. The battery
indicator should show running lights from the center and out.
With the scooter turned on, press the accelerator forward a touch.
When it is released, the scooter should stop completely and the
brake should click. It must not be possible to push the scooter.
Perform the same test again, but pressing the accelerator back.

• Lubricate the lever arm on the front brake hub with acid-free oil.

• Check the tyre pressure and tread.

Service 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 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 wiring, which could generate heat and cause a fire.

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Medema 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 unauthor-


ised opening, adjustment or modification of the control panel.

Menu / information
Actual speed Mileage
Battery indicator Hazard warning lights
Light sensor
Speed selector
Light switch
Handbrake
Indicator lights, R/L

Accelerator
(four-finger control)

anti-theft alarm
Indicator lights,
R/L

Horn Extra Switch Speed Trip meter Horn


Can be used regulation
for optional
functions.

Lever for adjusting the angle of the


handlebars

Charging socket

Key switch

Accelerator
(four-finger control)

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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 first 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/off from the
User menu.

Battery indicator The left side of the display shows battery level indicator.
Indicates that after approx. ½ seconds, the battery state
of
charge. Provides a more accurate indication after 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 flash-
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 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 flips 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
Forw. / Backw. will strike at standstill, corresponding to the parking
brake on a car. With speed regulation, speed can also
be regulated downhill. The engine will then act as a
brake.
Light switch Turns on the front and rear lights. The key switch must
however be turned to position 1 (drive).

Hazard warning lights Turns on all lamps at once. Also works when the key
is removed, or turned to 0 (stop position).

Indicator lights switch Arrow left: lamp left side. Arrow Right: lamp right side.
Activate the same button again to turn off flashing
lights.

Horn Electric horn which can be programmed in volume in


the User Menu. Activated by pressing the horn button.

Charging socket Turn off the Mini Crosser (key in position 0) during
charging. Note that it is not possible to run while the
batteries recharge. See also the section ”Batteries
and Charging.”

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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 off the Mini
Crosser. An activated alarm is turned off by turning the
key to 1 (drive).
If you have no opportunity to get to the Mini Crosser
with the key, the alarm will stop after approx. 20
seconds. Shake the Mini Crosser again, the alarm will
be
activated again.
Tilt Tilt-symbols.

Tilt Alarm sideways By exceeding the preset value, the symbol flashes 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 flashes 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.
Confirm 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 Choose between Celsius or Fahrenheit. Displays ambient
(Temp. unit is extra) temperature.
Limited speed Limited speed On/Off.
(On/Off) 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. Confirm with “Enter” Turn this parameter On/
Off – Confirm 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 Selecting ”On” reduced intensity of the backlight
(On/Off) 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 (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
(On/Off) little beep when you press the contacts on the dashboard.
These are: flashing, lights, hazard, menu, arrows and
MENU keys.
Blinker sound (Off/ Choose whether you want a sound when flashing lights on
Beep/Buzze) the Mini Crosser is on. Just as we know it from a car. You
can
select ”Off”, ”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 By default hazard (emergency lights) is operable even if the
(On/Off) Mini Crosser is switched off and the key is removed.
If you wish the hazard not be activated with the Mini
Crosser
turned off, you should select ”Off.” here.
Alarm enabled With this switch ”On”, the burglar alarm is turned on every
(On/Off) Extra time you turn off the Mini Crosser. The small lamp next to
the
”Trip meter” will fl ash a few seconds interval.
An activated alarm is turned off 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 off after approx. 20th
seconds. Shake / move the Mini Crosser again, the alarm
will be
activated again.
Tilt Present (On/Off) With this parameter set to ”On”, will turn the tilt icons to red
Extra 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 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
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 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

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)

The release button pressed in. Press the Release button pressed out. Now the
button out to release the seat tube. seat tube can be moved up/down to
the height you wish. Press the release
button again and make sure it is fitted in
one of the 5 holes in the seat tube.

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Seat tube

Release

Seat tube in top position. There are five


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 fitted 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 figure 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.

Switch for electric


seat adjustment

Electric seat adjustment. If the switch is pressed up, the seat


is raised. If the switch is pressed down, the seat is lowered.

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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.

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.

Release lever for seat rotation. Release lever for seat forward/back.

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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 height 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

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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 the front of the User Manual.

Please quote this number when making inquiries about servic-


ing, spare parts, etc.

Maximum user weight


Model description

X2 Vehicle’s unladen weight incl.


2018 169,5 batteries and seat
15

Serial number Year of production Max. speed

Position of serial number plate on vehicle.

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Driving the Mini Crosser X2

Getting in and out

It is important to learn a safe technique for getting in and out of


the Mini Crosser.

In general the following method should be followed:

• Make sure that the Mini Crosser X2 is off (switch turned to 0)


when getting in and out, otherwise the Mini Crosser could start if
the accelerator was touched inadvertently.
• Make sure that the brake is on. (Lever for disengaging motor in
top position.)
• Put the steering column in vertical position.
• If necessary, turn the seat through 45° or 90° and make sure that
it is locked in position (clicked into place).
• If necessary, raise the armrest.

For some users the assistance of an attendant can be recom-


mended. The attendant should:

• Take care not to injure him/herself when lifting/lowering/supporting


the user.
• Make sure that the Mini Crosser is stable and unable to move.
Turn off the Mini Crosser and check that the brake is on and the
seat has been rotated until it clicks into place at either 45° or 90°.
• Make sure that the seat the user is being moved to is stable.

IMPORTANT!
The Mini Crosser will turn itself
off automatically after it has
been stationary for 10 min-
utes even if the key has been
turned to driving position. The
battery indicator flashes with
6 lamps at a rate of about 3
seconds.

To restart the vehicle, the key


must be turned to stop posi-
tion (0) and then to driving Turn the Mini Crosser off, return the
steering column to upright position, rotate
position (1). the seat and raise the armrest.

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General safety advice

Make sure that the backrest is upright and the seat is as low as
possible.

Positioning belts are recommended if the user is unable to


maintain a good driving posture independently.

Adjust your driving to road conditions. Take light, traffic and


weather into account. Be particularly careful when driving in
the dark or in bad weather, such as rain or snow. Avoid driving
on inclines with poor surfaces, such as: snow, ice, new-mown
grass, wet grass and wet leaves.

Never drive when under the influence. This applies not only to
alcohol, but also to drugs and medicines.

Reduce speed immediately if you feel you are losing control.

Always use the indicators when changing direction.

Check that lights and indicators are working before driving off.
Use your lights when driving after lighting-up time.

As far as possible, grip the handlebars firmly with both hands.

Take care not to have anything in the basket at the front that
might inadvertently operate the accelerator.

WARNING! Do not lower the handlebars so far that the accel-


erator can hit you on the leg when you turn the vehicle and so
be operated in advertently. If the handlebars need to be very
low, a twist grip accelerator is recommended. This is particularly
relevant if leg supports are being used.

ALWAYS switch the Mini Crosser off when it is not in use. Turn
the key to 0.

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Driving

Even though the Mini Crosser is very stable, it can tip over.
Avoid sudden changes of speed and direction when travelling at
high speed, on poor surfaces and, not least, on slopes.

For short distances the Mini Crosser can drive up steeper


inclines than it has been tested as dynamically stable for. The
same applies to driving down such inclines. In such cases there
is an increased risk of the Mini Crosser tilting and even tip-
ping over. So be extra careful in following the driving tips given
below.

Anti-tilt wheels are recommended for driving in very hilly terrain.


(Optional extra)

New users are urged to practise the following in an area where


there is no other traffic:

• Set the Mini Crosser to low speed. Drive forwards and backwards.
Gradually turn the speed selector up and feel the change in the
speed of the Mini Crosser.

• Practise starting and braking. Get used to the Mini Crosser’s


response time.

• Practise driving in a narrow space, similar to inside a shop or


through a door.

• Practise turning, and get a sense of how much space is required.


Always drive slowly when turning. Practise reversing too.

• Practise cornering and driving over obstacles and on slopes. Al-


ways drive straight up/down kerbs and ramps. Never at an angle.
See the illustrations on the following pages.

• Try braking at different speeds and notice the stopping distances.

• If possible, try driving on different surfaces (road, grass and gra-


vel).

• Practise assessing how far you can drive on a single battery char-
ge. Note how quickly the battery indicator changes from green to
yellow to red.

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Note!
The driving distance of the Mini Crosser will be reduced when
driving in hilly areas, into a head wind, in cold weather and with
low tyre pressure.

Traffic regulations

The traffic legislation for Mini Crossers varies from country to


country. Before starting to use the vehicle outdoors, it is the
user’s responsibility to familiarise him/herself with the relevant
legislation.

Lap belt

If there is a need for it you can,


as an accessory, mount a lap
belt or harness belt on MC 1124.

The belt is designed to stay safe


to use for at least 10 years.

Lap belt

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Electromagnetic compatibility

If the Mini Crosser starts making involuntary movements or if


the brakes are released, turn the Mini Crosser off as soon as it
is safe to do so. In certain circumstances a Mini Crosser can set
off shop alarms.

The Mini Crosser satisfies the requirements for the use of Mini
Crossers in an environment with electromagnetic noise. There
may, however, be rare situations in which electromagnetic noise
can affect the Mini Crosser. Sources of such noise include radio
and television stations, amateur radio transmitters and mobile
phones.

If such equipment is being used close by, it is recommended


that the Mini Crosser is switched off. Mobile phones should not
be used while driving.

When driving in traffic...

Be particularly aware of the following when driving in traffic:

• The Mini Crosser is a low vehicle and not always easy for other
road users to see. Make quite sure that other road users have
seen you before driving onto the highway.

• Keep an eye on traffic behind you. Keep well over to the side of
the road when driving on busy roads.

• Turning right and left at crossroads. Be aware of cyclists and pe-


destrians. Follow the rules of the road for cyclists.

• How quickly things are happening. How long do the lights stay
green? How quickly are cars approaching? etc.

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Specific driving situations


Up kerbs

• Stop at right angles to the kerbstone about 5-10 cm away from it.
Keep an eye on other road users.
• Lean forwards.
• Accelerate moderately so that your vehicle can overcome the
obstacle. Do not stop halfway, but reduce speed once the vehicle
is up.
• If the kerb is too high, do not try again, but find an alternative
route.

Down kerbs

• Lean back.
• If you are driving onto a road with traffic, keep an eye on other
road users.
• Drive forwards and down the kerb at low speed. Make sure that
your anti-tilt wheels (if fitted) do not catch on the edge.

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Up a ramp/hill

• There is a risk of tipping over backwards if the seat is pushed


back when you start driving up a slope, e.g. a ramp.
• Pull the seat forward! Check that any ramp is stable.
• Lean forwards.
• Accelerate moderately so that your vehicle can overcome the
obstacle. Do not stop halfway. Reduce speed once the vehicle is
up. If you need to start on a hill, accelerate slowly so as not to tip
over backwards.

Down a ramp/hill

• Check that any ramp is stable.


• Lean back.
• Drive slowly down. Avoid stopping midway on short, steep slopes.
On long hills, it is advisable to stop every now and again if you
feel your speed is getting too high.

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Across a slope

• Lean into the slope.


• Avoid sudden and sharp movements. This is particularly relevant
when reversing.
• Always drive at low speed.

Long hills/difficult ground


The Mini Crosser is at risk of overheating on very long and
steep hills or on very soft ground, possibly also combined with
high user weight.

To protect the Mini Crosser motor from overheating, there is a


built-in thermo switch, which initially sets the Mini Crosser to
half speed.

However, if you carry on moving over difficult ground, the Mini


Crosser will at some stage stop completely. The Mini Crosser
must be left to cool down for 3-5 minutes before it can start
again.

To reset the fault, switch off the Mini Crosser then turn it on
again.

If the Mini Crosser has not had long enough to cool down when
it is restarted, it will initially only run at half speed.

Note:
The situation described above will never happen in normal use.
It only happens if the conditions are extremely challenging.

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Anti-tilt wheels / stabilisers


The Mini Crosser is a very stable vehicle. HOWEVER, in the
case of incorrect weight distribution or careless driving there is
a risk of tipping over.

We therefore recommend fitting anti-tilt wheels in such circum-


stances. (See picture below). Contact Medema for more info.
Find contact information on page two in this manual.

Anti-tilt wheels

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General care and maintenance


A Mini Crosser X2 does not require much maintenance. It
should be kept in a generally good condition, however. The fol-
lowing should be checked regularly:

• Tyre pressure (if pneumatic tyres are fitted)


• Tyre wear
• Keep the control panel, the charging socket and the electronics
box under the seat dry.
• Battery charging

Never wash the Mini Crosser with a high-pressure cleaner or di-


rect water jet! This could damage the Mini Crosser’s electronics.

To keep the Mini Crosser in good condition safety-wise, we rec-


ommend the following regular checks:

Daily:(User)

• Test the indicators and driving lights before using the Mini Crosser
in the dark or poor visibility.

Every three months: (User)

Test the brakes and motor disengagement


With the disengagement lever up, it must not be possible to
push the Mini Crosser.

Test the brake disengagement function


When the brake disengagement lever is down, the battery indi-
cator should flash to show an error if the Mini Crosser is turned
on. In this case the Mini Crosser must not be able to move
when the accelerator is activated.

Test the handbrake


Apply the handbrake for a couple of seconds at low speed. This
will ensure that the lever arm and brake shoes do not seize up.

Lubricate the lever arm on the brake hub with acid-free oil - left-
hand rear wheel.

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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 third year, corresponding to 1500 hours
of operation. The service must be carried out by 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 fire.

(For further information see the Service Manual.)

Insurance
In the eyes of the law a Mini Crosser X2 with a maximum speed
of 15 km/h is a cycle, so separate insurance is not required.

Most contents/home insurance policies include third-party li-


ability insurance for cyclists and so also cover Mini Crosser X2
users.

We recommend that you talk to your insurance company about


this when the vehicle is delivered.
If necessary, comprehensive insurance will have to be taken out
separately.

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Batteries
The Mini Crosser uses sealed, maintenance-free GEL or AGM
batteries.

They do not generate gas and do not have to be topped up with


water.

Battery weight
56 Ah = 21 kg
85 Ah = 26 kg

Charging
Please NOTE that the Mini Crosser can be equipped with sev-
eral types of charger (ask your dealer for information on the
various types).

IMPORTANT! Only ever use a charger designed for charging


dry maintenance-free batteries. The max. charging current is
12 A.

If charging is to take place outdoors, an enclosed charger with-


out a fan should be chosen.

The battery indicator shows how much power is available to the


Mini Crosser.

• Red, yellow and green indicate that the batteries are fully
charged.
• Red and yellow indicate that the batteries will soon need recharg-
ing.
• Red indicates that the batteries need to be recharged as soon as
possible, otherwise the Mini Crosser will cut out.

The battery manufacturer recommends that the batteries are


charged at a temperature of + 10° to +30° C in order to achieve
a charging time as specified in the section Technical data.

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The charging time will be extended by approximately 60% at


a temperature of +5° C compared to a temperature of +20° C.
This is because it is chemically more difficult for the battery to
absorb the current.

It is recommended to charge the Mini Crosser in a heated room.


If it is not possible every day, then at least once a week.

Be aware that the capacity of the battery decreases with time,


as well as at low temperatures. The battery capacity at -10°C is
half of the capacity at +20°C.

New batteries only achieve full capacity after about 20 charge/


discharge cycles.

Note!
The Mini Crosser should be charged when the vehicle is not in
use. The type of charger supplied by the factory works in a way
that it automatically switches over to trickle charging (very little
electricity consumption) when the batteries are fully charged.

The charger will flash until it is finished. Then the indicator on


the charger will be constantly lit.

The charger CANNOT overcharge the batteries! So let the


charger stay connected until the Mini Crosser is used again.

Note!
Since the Mini Crosser also uses some power even when it is
turned off and the ignition key is turned to 0, it is recommended
that it is always connected to the charger when not in use.

Battery disposal
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 A/S.

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Note!
The Mini Crosser X2 uses a little power, even when the key
is turned to 0. We therefore recommend that the Mini Crosser
always be connected to the charger when not in use.

Standby power
The X2 Mini Crosser is equipped with an advanced display so-
lution. The system requires that there is always a small standby
power consumption of 70 mA.

If you do not make sure that the Mini Crosser is set to charge at
appropriate intervals, the batteries will fully discharge over time.

For this reason, we recommend that the Mini Crosser is always


set to charge when it is not being used.

Below is a recommended schedule of how many days before


a brand new battery is 100% discharged. The discharge time
depends on factors such as the ambient temperature, age and
how many Ah the battery has been rated in C20.

Ah in C20 100% discharged after


85 Ah 47 days
110 Ah 65 days

The calculations in the table is only guiding!

Note
If the battery is 100% discharged, it is not possible for the
charger to start charging the battery.

There is no warranty on batteries that have been damaged as a


result of deep discharging.

If you are not using the Mini Crosser for a longer period of time,
for example during winter storage, you can choose to discon-
nect the one pole to the fully charged batteries. This way there
will be no consumption of standby power.

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It is important to fit the batteries correctly. The battery terminals


are marked +/-. They must be fitted as shown in the sketch be-
low. Make sure that the terminals are properly tightend. For the
same reason there must not be any burrs on the cable termi-
nals.

Be aware that the Mini Crosser can varies types of chargers.


Contact your dealer for more information about the different
types.

Do NEVER use other chargers than the one from the factory
without contacting your dealer first.

NEVER use a charger that are not intended for charging dense,
maintenance-free batteries.

Polarity of charging plug

NEUTRIK NC3MX charging plug Connect the charging plug to the 3-pin
socket on the steering column. The
charging socket is located under the
protective cover.

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Note
If the battery is 100% discharged, it is not possible for the
charger to start charging the battery.

There is no warranty on batteries that have been damaged as a


result of deep discharging.

If you are not using the Mini Crosser for a longer period of time,
for example during winter storage, you can choose to discon-
nect the one pole to the fully charged batteries. This way there
will be no consumption of standby power.

Storage
The Mini Crosser should be stored and charged under cover
preferably at temperatures above 0°C.

Note!
The charger must be kept dry, but should not be covered when
in use.

In the case of long-term storage we recommend covering the


Mini Crosser to protect it from dust, rain and sunlight.

Cleaning
Clean the Mini Crosser X2 with a damp cloth. If necessary, wipe
dry with a chamois leather.

Wipe the covers dry and polish with car wax.

IMPORTANT! Never use high-pressure cleaner or hose, as it


could damage the Mini Crosser’s electronics.

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Brakes
There are four braking systems on the Mini Crosser:

• Motor brake - adjusts vehicle speed also when going downhill.

• Magnetic brake - the magnetic brake is automatic and engages


when the Mini Crosser stops. In an emergency, the Mini Crosser
can be stopped instantaneously by turning the key switch. Please
note that this will cause very sharp braking.The brake must never
be disengaged mechanically using the disengagement lever on
a slope. This function is only designed for use when pushing the
Mini Crosser on a flat road.

• Electric safety brake - if the brake is somehow disengaged on


a slope/hill, the Mini Crosser will brake automatically when it
reaches a certain speed. There is an electric safety feature in the
control system, which works even if the battery is disconnected.
This is also the reason why the Mini Crosser cannot be towed at
more than 5 km/h. See the section about towing.

• Hand brake - intended as an emergency brake and parking brake.


It must be operated with caution when driving in slippery condi-
tions and downhill.

When using the handbrake as a parking


brake, lock it in braking position by
pressing the button in while applying the
brake.
To release the brake, press the button
again.

Handbrake lock

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Disengagement
Manual
The manual disengagement lever is placed underneath the
back cover. Follow this procedure to use it.

• Turn the key to (0) position.

• Push the disengagement lever down.


The motor brake is now disengaged and the vehicle can be
pushed or towed, but not drive itself.

Electronic
The yellow electronic disengagement button is placed on the back
of the vehicle. This only works when the scooter is turned on.

NOTE!
Don’t ever disengage on sloping terrain.

If the brake is somehow disengaged on a slope/hill, the Mini


Crosser will brake automatically when it reaches a certain
speed. There is an electric safety feature in the control system,
which works even if the battery is disconnected. This is also the
reason why the Mini Crosser cannot be towed at more than 5
km/h. See the section about towing.

Once the motor brake has been disengaged, the Mini


Crosser can only be stopped with the hand brake.

Push the disengagement lever down to Disengagement lever


disengage (only hand brake works) and
push up to reactivate the motor (normal
driving now possible).

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Electronic disengagement. Works only


when the scooter is turned on.

Disengagement button.

Transporting by motor vehicle


The Mini Crosser must always be restrained and the hand
brake locked during transport in a motor vehicle or trailer.

Avoid lifting by the seat, covers, handlebars and armrests

If you just need to lift the Mini Crosser slightly, take hold of it
between the rear lights and by the front bumper.

Important!
If you drop the Mini Crosser from a height of half a metre or
more, there is a risk that the gears in the transaxle will be de-
stroyed.

Secure it in the vehicle with belts attached to the two eyes at


the front and two at the back. All the eyes are marked in yellow.
See the section entitled “Securing to vehicle floor with belts”.

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Securing to vehicle floor with belts


Dahl Engineering belt set for securing in motor vehicles.

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.

The belts MUST be attached within the angles shown in the


picture for optimum security.

45˚ 45˚

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Attachment point

Attachment point
Greater than
the anchorage
points on the Greater than
Mini Crosser the anchorage
Centre line points on the
Mini Crosser

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For transport in an estate car, the


seat can be folded and the han-
dlebars folded down. This reduces
the maximum height to 69 cm.

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 pro-
vided on the Mini Crosser.
The Mini Crosser’s restraint points have been tested and ap-
proved in accordance with ISO 7176-19.

The user must also always be independently restrained in the


actual motor vehicle in accordance with traffic legislation rules.

Example

Restraining the
passenger with a static
3-point seat belt:

Secure to the rearmost


retractors.

The shoulder belt must rest


against the collar bone and
fall diagonally to the hip,
where it is secured.

Tighten the belt by pulling


on the loose strap. Undo it again by lifting the buckle. This is the
same as on an aircraft.

Retractor Male and fe-


with belt male parts of
belt done up

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Remember to turn the Mini Crosser off during transport. Turn


the key to 0.

However, if at all possible, we recommend that the user occu-


pies 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:

• the batteries to be flight-approved


• the air to be let out of the tyres
• the battery leads to be disconnected (not always, but frequently)

The seat and cover have to be removed to disconnect the bat-


tery leads.

A battery declaration for air travel can be requisitioned from Me-


dema A/S. See contact informations on page two.

Towing
If you should be unfortunate enough to break down, the Mini
Crosser can be towed or pushed. The Mini Crosser must al-
ways be turned off and the motor brake disengaged during tow-
ing. See the section on Brakes.

If the Mini Crosser is to be towed, secure a rope to the tow fit-


ting on the front - marked with a yellow “hook mark”. Do not tow
faster than 5 km/h. The scooter will generate electricity when
it is towed, with the motor acting as a dynamo. If it is towed
at more than 5 km/h, there is a risk of the motor generating
enough electricity to damage the scooter and, in the worst case,
cause a fire.

The Mini Crosser will try to brake if it is towed at more than 5


km/h.

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Dimensioned drawing, Mini Crosser X2 3W

1090 mm

X2: 305 mm
X2+:225 mm

625 mm
450 mm
135 mm
175 mm
980 mm

1340 mm
680 mm

460 mm

526 mm

X2+ : Equipped with extra large batteries, the foots pace will be
reduced.

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Dimensioned drawing, Mini Crosser X2 4W

1090 mm

X2: 400 mm
X2+: 320 mm

610 mm
490 mm
135 mm

175 mm
1030 mm
1400 mm
680 mm

526 mm
460 mm

X2 : Equipped with extra large batteries, the foots pace will be reduced.

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Service summary for Mini Crosser X2 Model

Area Component Check and remedy


Suspension and Rear suspension Check whether the rear of the scooter is
wheels drooping. The rear wheel must not rub
on the mudguard with a load on the seat.
Replace the shock absorbers/springs be-
hind the batteries. See the Spare Parts
Catalogue.

Check the shock absorbers for oil leaks.

Check that the swivel axle/transaxle is


securely mounted. Retighten or fit bolts/
nuts.
Check that no cables Fit cable ties.
can be trapped by
moving parts.
Check the wheels Check the fastenings and the condition
of the rims.
Check the tyre pres- Recommended tyre pressure: 2.8 bar
sure and tread. (50 psi)
The minimum tread depth for good grip
is approx. 1 mm.
See the Spare Parts Catalogue for disas-
sembly. NB! The rear and front wheels
on the 4W MUST always be removed
using the five bolts. NEVER undo the
actual flange using the bold in the centre.
See the Spare Parts Catalogue. NB!
ALWAYS let the air out of the inner tube
before taking a wheel apart!
Check that the hand- Lubricate the lever arm on the brake hub
brake is working. with acid-free oil. Adjust the cable length
using the adjusting nipple. If parts are
defective: See the Spare Parts Cata-
logue.
3W: Front fork. Sus- Check that the front fork can bounce. Is
pension and straight- it crooked?
ness. Is there an oil leak?
If there is a defect that needs to be re-
paired, replace the entire front fork. See
the Spare Parts Catalogue.
3W: Front wheel. Check the ball bearings for play and
wear.
4W: Front suspension. Check that the front wheels do not hit the
underside of the front mudguards.
Check that the rubber dampers are
secure. They should just touch the axle
beam. See the Spare Parts Catalogue.
Check that the T-suspension block is
working and does not droop.

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Area Component Check and remedy


Suspension and Front wheel suspen- Check that the guide rods and balls are
wheels (contd) sion. in good condition and properly tightened.
Check the ball bearings in the front
wheels and guide spindles for play/wear.
Front wheel tracking. See the sketch
for correct tracking if uneven tyre wear
shows that adjustment is necessary.
Steering/Control Lights, indicators, haz- Check functioning and the condition of
panel ard warning and horn the switches.
If an indicator is not working: Check the
connectors and the fuse in the control
panel.
Or change the bulb.
Seals Check that the rubber switch covers are
intact and in good condition.
Check that all the holes have plugs. Fit
new ones if necessary.
Check that the sign on the control panel
is straight.
Accelerator and han- Check that the accelerator is mounted
dlebars securely on the potentiometer shaft.

Function test: Turn the scooter on while


the accelerator is activated. The scooter
must not be able to go. The battery indi-
cator 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 press-
ing the accelerator back.
Max. speed potenti- Check that all the lamps come on when
ometer the batteries are fully charged. If there is
(Battery indicator) no indication at all, check the batteries. If
they are okay, the card or the S-180 will
have to be replaced.
Motor / gear / Wear Check: That the motor runs smoothly
brake and evenly. If not, the carbon brushes in
(Transaxle) the motor usually need to be replaced.
The minimum length of the brushes is 10
mm. See the Spare Parts Catalogue for
replacement.

Check: The gear wheel in the transaxle


for wear. Lift one rear wheel and meas-
ure the play around the periphery of the
tyre. On a new machine the play is 16-18
mm. If the play is much bigger, replace
the whole unit. See the Spare Parts
Catalogue for replacement.

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Area Component Check and remedy


Motor / gear / Check: The rear wheel bearings in the
brake gear for wear. Lift the rear of the scooter.
(Transaxle) Get hold of one wheel at a time. Lift it up
(contd) and down to see if there is any play in
the bearings in the transaxle. If there is,
the whole unit should be replaced.
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 = 20 - 25 A
13 km/h = 22 - 27 A
15 km/h = 24 - 29 A
Measure on one of the battery cables
using a clip-on ammeter.
Power consumption when the scooter is
turned off and the key turned to 0 = 50
mA
Brakes and disengage- When the disengagement lever is up:
ment It must not be possible to push the
Check function scooter.
It must be possible to drive normally
when the scooter is turned on.

When the disengagement lever is down:


It must be possible to push the scooter.
The scooter must not be able to go. Error
9 should appear when the accelerator is
activated.

The brake must be able to hold the


scooter on a 15° (26%) slope with 75 -
100 kg on the seat.
If not, it must be adjusted or replaced,
depending on how much wear there is.
Braking distance 10 km/h - 2,0 m (10)
13 km/h - 2,8 m (10)
15 km/h - 3,5 m (10)
Please note that the braking distance
must not be longer than specified in or-
der to comply with official requirements.
Steering column Play/wear Check the following:
- Universal joint
- Pins in steering shaft/front fork
- That the aluminium bottom section of
the steering column is firmly secured to
the steering shaft. (*)

Wear/rust on the bearings in the steer-


ing column. Top support bearing. The
bearings in the head tube are protected
by seal rings. If the front fork is a bit stiff,
the seal rings can be lubricated with a
little grease.

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Area Component Check and remedy


Steering column (*) On models with an 8 mm bolt going
(contd) into the steering shaft from the alu-
minium bottom section of the steering
column. The bolt can work loose if the
steering column is twisted/knocked hard.
This can be remedied by drilling a hole
for a split pin between the steering shaft
and the aluminium section. Contact
Medema A/S.
Cables Check that the cables cannot become
trapped or be subjected to strain when
the handlebars are turned or the steering
column is folded down.
Gas spring Check:
That the gas spring locks the steering
column securely.

Check that there is no play in the release


lever and the bolts/bushes securing the
gas spring.
Key switch / charging Check that the key switch does not wob-
socket ble.

Clean with a damp cloth or compressed


air if dirty. If the contacts are corroded,
clean them with contact spray or replace
the charging sockets.
Chassis / seat / Footplate Check the plastic rivets securing the mat.
covers Fit new ones if necessary.
Seat post Check that it is properly secured and in
good condition.
Chassis / seat / Seat Check that:
covers (contd) The release lever locks the seat properly.

The seat is firmly secured on the seat


frame/plate.

The seat tube is in good condition. If


necessary, lubricate the tube with a little
acid-free grease.

The armrests are in good condition.


Covers Check that the plastic covers are in good
conditions. Parts with sharp or project-
ing edges should be replaced. The same
applies to covers with an operational
function, e.g. the splash guard and bat-
tery cover. (water in the controller)
Cleaning: See the section on Cleaning.
Other mechanical Check that the other components work
components properly.
Electrical compo- Control card Check that it is dry and in a good condi-
nents tion.
Check that all the connectors are firmly
in place.

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Area Component Check and remedy


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.
Check that the plugs are firmly in place.
Battery straps Check that they are properly secured.
Batteries/charger Batteries Check that there are no cracks in the
(see also the sec- batteries, that batteries look good and
tion on Batteries) that the battery connections are firmly in
place.
Battery capacity Check this with a battery tester. Mount
new batteries if needed. Apply a little
acid-free vaseline to the battery termi-
nals before connecting them.
Battery charger Check that the indicator lamp on the
battery charger changes to CHARGING
when the scooter is connected.
If necessary, measure the charging volt-
age during charging. It should be approx.
28.8 V.
Leave the scooter to charge overnight.
Disconnect the charger and measure the
battery voltage after about 15 minutes.
It should be approx. 27.6 V for fresh
batteries.
Check that the scooter cannot go while
the battery charger is connected.
Brakes Magnetic brake Check the distance between the brake
plate and the magnet using a feeler
gauge blade. The distance should be
between 0.15 mm and 0.30 mm. If the
distance is larger, the friction disc will
be worn and the magnet brake must be
replaced. See page 53.

See the carbon specification overleaf.

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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

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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 +/- but-


ton and Next to move to next digit. Press Enter.

You can scroll through the parameters with the +/- button below
the display. The active parameters are highlighted with yellow
letters and blue background.

The parameter is selected by pressing Enter. The actual value


is changed using the +/- key. Confirm by pressing Enter and exit
by pressing the menu button once; wait a moment.

See the summary of the service panel on previous page.

Parameter description
Date Format Choose between:
ddmmyy - day/month/year
mmddyy - month/day/year
yymmdd - year/month/day
Temp. unit Choose between Celsius or Fahrenheit. Displays ambient
(Temp. unit is extra) temperature.
Limited speed Limited speed On/Off.
(On/Off) 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. Confirm with “Enter” Turn this parameter On/
Off – Confirm 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 scooteres 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 Selecting ”On” reduced intensity of the backlight
(On/Off) 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%.

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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
(On/Off) little beep when you press the contacts on the dashboard.
These are: fl ashing, lights, hazard, menu, arrows and
MENU keys.
Blinker sound (Off/ Choose whether you want a sound when fl ashing lights on
Beep/Buzze) the scooter is on. Just as we know it from a car. You can
select ”Off”, ”Beep” - low horns, or ”Buzzer” - sharp horns.
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 By default hazard (emergency lights) is operable even if the
(On/Off) scooter is switched off and the key is removed.
If you wish the hazard not be activated with the scooter
turned off, you should select ”Off.” here.
Alarm enabled With this switch ”On”, the burglar alarm is turned on every
(On/Off) Extra time you turn off the scooter. The small lamp next to the
”Trip meter” will fl ash a few seconds interval.
An activated alarm is turned off by switching the key on the
scooter. If you have no opportunity to get to the scooter
with the key, the alarm will switch off after approx. 20th
seconds. Shake / move the scooter again, the alarm will be
activated again.
Tilt Present (On/Off) With this parameter set to ”On”, will turn the tilt icons to red
Extra and blinking, and there will be a whining tone (if enabled) if
you are running on a slope that is steeper than allowed.
Configuration
Dist. unit You can choose between kilometres and miles. Used for
showing distance and speed on the display.
Single-ended control NB! Before changing this parameter, it is recommended
you lift the scooter’s rear wheel from the ground with a
jacking bracket, so that it can rotate freely.
By switching the single-ended control ON, you change
the setup of the engine management so that it requires a
one-way speed provider, e.g. a throttle, or a motorcycle
hand throttle. At the same time, the text Reverse will ap-
pear above the left button below the display. This must be
activated when you wish to reverse the scooter.
Then change the wig-wag throttle the scooter is supplied
with as standard. See how in the scooter service manual.
Power cycle the scooter. Turn the throttle and make sure
that the scooter’s lifted back wheel rotates in the right
direction,direction and that it stops when you release the
throttle. Press the REVERSE button and check that the
wheel rotates backwards.

If you change from single-ended to wig-wag throttling, the


procedure is the same, you only need to turn single-ended
OFF.

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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.
You must be consistent when searching for charges,
whether it is one or the other display type. See the scoot-
er’s user manual.
Wheel radius Used to correctly display the speed and distance driven on
the display, according to the cycle computers.
Wheel radius is up-loaded in increments of 5mm. The most
precise measurement is achieved by measuring the height
from the ground to the centre of the rear wheel, with the
correct tyre pressure and the user on the seat.
Language You can choose between the following languages: Danish,
Swedish, Norwegian, Finnish, German, English, French
and Flemish.
Note that the chosen language is located just below wheel
radius, if you have chosen an incomprehensible language.
Turtle/Hare on Select OFF if you do not want small pictures of the hare
and tortoise displayed on the speedometer.
Parent PIN Is used, among other things, to change the maximum
speed. Enter a four-digit PIN. The value is changed using
the up/down arrows, and you move on to next figure using
the Next button. Accept by pressing Enter.
Auto off Determines the amount of time the scooter is permitted
to remain in standby before switching itself off. Can be
adjusted to 5 to 60 minute intervals.
Aux 12V If ON is selected, you may access a secure power supply
of 12VDC/0.5A on the J15 connector on the main PCB. 0V
on pin 1 and 12VDC on pin 2.
User menu active This determines whether it is possible for the user to enter
the user menu.
User menu pause The number of seconds you hold down the menu button
before the user menu is activated is determined here.
Service
Reset By pressing Enter on the Reset menu, the two counters are
reset, each of which may cause the spanner icon on the
display to flash. The flashing spanner is a warning that the
scooter needs its regular service.
If you use the Menu button above the display to access the
SERVICE text, the address of the service centre the user
must return to will be displayed. The counter that reaches
its entered value first will activate the service key.
Hour interval The scooter counts the number of hours it has been driven.
Not just the hours it has been running, but the actual driv-
ing hours. The value can be changed in increments of 5
hours at a time.
Month interval With its built-in calendar, the scooter keeps track of how
many months have passed since the counter was last
reset. The value may be changed by 1 month at a time.

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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.
Horn
Button 1-4 Each of the four horn switches, two on the left and two on
the right of the handlebars, can be programmed individually
to the volume you require. The contacts are numbered from
1 to 4 from right to left:
You can choose between: None, Low and High.
NB! Do not put your head beside the large auto horn when
testing. The volume is 115dB.
Light
Auto on If you switch this ON, the scooter will automatically light
the rear light when daylight drops below a certain level and
remains there for several seconds. When the light rises
above the level set, the light will switch off automatically.
It can also be switched off with the light switch.
On limit Here you can set the level of light (lux) at which the light
will switch on.
On delay Here you can specify how long (in seconds) the level of
light must be at the selected level before the light switches
on automatically.
Actual The actual level of light is shown here. It can be used to
gain an idea of when you wish the light to switch on auto-
matically.
Blinker
Auto off If you select Auto, the indicators will switch on automatically
after several seconds, which you can determine yourself.
Alternatively, they will switch off when the handlebars
are straight again when you have finished turning. This
requires the installation of a sensor to detect this.
The first option to be met will switch off the indicators. The
sensor is an additional part.
Auto off time This is where you specify the number of seconds the indi-
cators will flash when you have switched them on.
Alarm (Extra)
Present This is where you switch ON the anti-theft alarm, after the
scooter’s wiring arrangement has been connected at the
back of the scooter. See the scooter’s diagram or service
manual.
On delay Determination of the time that passes from when you
switch off the scooter with the key until the anti-theft alarm
is activated. This is the time you have to move away from
the scooter without setting off the alarm by mistake.
Can be set to 10 seconds and longer.

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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.
An activated alarm is turned off by turning on the scooter
with the key.
Sensitivity This value adjust the sensitivity of the alarm. The sensitivity
value is set between 0-100, where 100 is the most sensi-
tive.
Tilt (Extra)
Present Here you can switch ON the tilt indicator, after the sensor
unit has been connected to the cable network at the back
of the scooter.
X Maximum UP/DOWNHILL tilt. Enter the tilt at which the
user should be warned not to continue. The value must be
entered in degrees.
Y Maximum SIDEWAYS tilt. Enter the tilt at which the user
should be warned not to continue. The value must be
entered in degrees.
Actual X Displays the current up/downhill tilt of the scooter on the
display.
Actual Y The same as the Current X, only sideways.
Tilt time Enter the length of time the tilt threshold must be exceeded
before the warning horn is activated (0.5 - 2.5 seconds)
Warning buzzer You can choose Off, Beep or Buzzer. Since the sensor is
a simple accelerometer, it will be possible to generate a
warning beep during sharp turns or when driving on very
rough terrain. It is recommended in such cases to mute the
sound and just watch out for warnings on the display.
Calibrate Before an installed tilt module can be used, it must be cali-
brated so that it shows 0 degrees on level ground with the
user on the seat. This is because differently sized users do
not put equal amounts of pressure on the shock absorbers.
Select On while the user sits quietly in the seated position
on the seat.
P&G
The PC programme should only be used by fully trained personnel, and should not
be disclosed to unauthorised personnel. By using this software, the operator takes
full responsibility for the programme’s settings and performance following setting
changes.
Forward acc fast This value is used when the ”slow/fast” switch is set to
”fast”
Forward acc slow This value is used when the ”slow/fast” switch is set to
”slow”
Reverse acc fast This value is used when the ”slow/fast” switch is set to
”fast”
Reverse acc slow This value is used when the ”slow/fast” switch is set to
”slow”
Forward dec fast This value is used when the ”slow/fast” switch is set to
”fast”

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Parameter description
Forward dec slow This value is used when the ”slow/fast” switch is set to
”slow”
Reverse dec fast This value is used when the ”slow/fast” switch is set to
”fast”
Reverse dec slow This value is used when the ”slow/fast” switch is set to
”slow”
Max fwd speed fast This value is used when the ”slow/fast” switch is set to
”fast”
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” switch is set to
”slow”
Max rev speed fast This value is used when the ”slow/fast” switch is set to
”fast”
Max rev speed slow This value is used when the ”slow/fast” switch is set to
”slow”
Min rev speed fast This value is used when the throttle potentiometer is set to
”slow” and the ”slow/fast” switch is set to ”fast”
Min rev speed slow This value is used when the throttle potentiometer is set to
”slow” and the ”slow/fast” switch is set to ”slow”
Speed limit pot. If the value is set to ON, the S-180 will check for the pres-
enabled ence of a valid throttle potentiometer signal on pin 9. If a
valid signal is not detected, S-180 will use the programmed
minimum speeds.
Throttle invert Wig-wag: If the value is set to OFF it means you must use
the four-finger grip for driving forward. And the thumb grip
for reversing. The ON value means the opposite.
Single-ended: A switch is used to switch between driving
forward and reversing.
Sleep timer A value of 0-20 minutes is entered here. If the handlebars
are idle for longer than the number of minutes entered, it
will go into sleep mode. If the value set to 0, sleep mode is
switched off.
Throttle type Wig-wag - four finger grip/thumb grip
Single ended - hand throttle
Throttle deadband Indicates in percentages the proportion of the throttle’s po-
tentiometer which should be the zero-zone, i.e. the range
the scooter does not run in the event of a slight activation.
Ensures that the scooter’s main potentiometer always
returns to zero, and thus the scooter stops when it should.
Should normally not be adjusted, but may be necessary if,
for example, you switch from Wig-wag to foot throttle, or
similar.
Throttle gain Used to set the throttle, so that the scooter achieves maxi-
mum speed just before the throttle reaches its fully open
position.
If a user has limited hand function, this parameter can
be used to set the scooter to run at full speed by turning
the throttle e.g. 50-60%. For this, Throttle Gain must be
increased.

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Parameter description
Throttle operated at Drive: S-180 will run if the throttle is open when the scooter
power-up is started.

Inhibit: S-180 will run if the throttle is open when the scoot-
er is started. If the throttle is closed, Inhibit is disengaged
and the scooter can run again.

Trip: S-180 will not run if the throttle is open when the
scooter is started. It will record it as a mistake, which can
be seen in the error log under a trip code. The key must be
turned to 0 and back to 1 before it can run again.
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
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 been other fault.

In case of fault on the scooter, it will be a great help if


the fault type can be given to the Mini Crosser or his
representative during troubleshooting.
Clear error log Deletes the list of electronic errors the controller has regis-
tered. Look under User parameters.
Ver: xx.xx.xxxxg Shows which software is used in the display electronics.

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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Display charge curve


Find the Show Charging Graph item in the technician menu.

A picture showing the current day is displayed by pressing en-


ter.

A red graph indicates when a battery charger has been con-


nected. See the picture below:

30V

20V

10V

06 12 18
21/01/09

A battery charger has been connected, which was removed


from the scooter at approximately 8:30 am on 21 January 2009.
The charging voltage was approximately 28V. A battery charger
was connected again at approximately 10:00 pm.

You can scroll back in time by using the two square buttons
below the display or by using the +/- button. The memory recalls
up to approximately 30 days.

The charging graph can be exited by pressing the menu button


above the display.

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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. Open this file in Excel.

A graph can be generated, as shown below. You can also zoom


into specific areas of the charge cycle if you wish.

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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.

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Troubleshooting
The following is a list of various problems that, in our experi-
ence, 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
go. turned to start. sec. before activating the
accelerator.
The battery indicator is The batteries are com- Charge the batteries.
not lit. pletely flat.
The control fuse has Change the fuse.
blown. Contact supplier.
The main fuses have
blown.
The Mini Crosser will not The Mini Crosser has Wait approx. 1 min. before
go. been overloaded. trying again. The vehicle
must be turned off.
The battery indicator is lit.
The hand brake is on. Release the hand brake.
There is a fault in the Contact supplier.
electronics.
The batteries are flat. Contact supplier.
The charging plug has not Remove the charging
been removed. plug.
The Mini Crosser goes May be due to poor con- Turn off the Mini Crosser
uneven, choppy while nection in the electricity. immediately and search
driving. for authorized workshops.
If you continue to drive,
heat development may
occur in the poor connec-
tion, with a risk of fire.
The driving speed is too The speed selector is on Change to a faster speed.
low. slow.
The electronics are over- Stop and wait 3-5 minutes
loaded. before starting.
There is too little air in the Pump the tyres up to the
tyres. right pressure.
The driving distance per There is a problem with Charge the batteries and
charge is too short. the batteries. check that the green lamp
Low temperature. on the charger lights up
before driving off.
There is a problem with Contact supplier.
the charger.
There is too little air in the Pump the tyres up to the
tyres. right pressure.
The charging method is Read the section on
wrong. Charging in the User
Manual.
The charging lamp on the No power to the switch. Turn the switch on.
charger does not light up Fault in cable. Contact supplier.
when the charger is con- Fault in charger. Read the operating in-
nected to the mains and structions for the charger.
the Mini Crosser. Contact supplier.

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Problem Possible causes Remedy


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 The charger is doing a Check again half an hour
hours. top-up charge. later.
There is a problem with Contact supplier.
(Read the operating in- the batteries.
structions for the charger). There is a fault in the Push the charging plug all
charging plug for the Mini the way in and repeat the
Crosser X2. charging process. Read
the operating instructions
for the charger.
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. the operating instructions
for the charger.
(Read the operating in-
structions for the charger)
The charger lamp is The charging plug has not Push the charger plug in
showing an error. been inserted or there is a or contact the supplier.
mains fault.
Read the operating in- The battery voltage is too Read the operating in-
structions for the charger. low for charging to start. structions for the charger
- or contact the supplier.
Thermometer symbol is The motor is overheating Immediately pull over at a
half-red and flashes. The and has reached the limit safe distance from other
scooter is running at half of when the first safety traffic and stop the Mini
speed. switch responds. Crosser. Wait until the
temperature icon disap-
pears, ca. 3-5 min. Turn
the Mini Crosser off and
on again to continue at full
speed.
Thermometer symbol is The motor is overheat- If the Mini Crosser has
red and alluminated. The ing and has reached the stopped at an inappropri-
scooter has stopped. limit for when the security ate place in traffic, turn
swithc shuts the motor off on the emergency lights.
completely. If possible disengage
the scooter and push it
away from traffic. Let Mini
Crosser cool until the
temperature icon disap-
pears - approx. 3-5 min.
Turn the Mini Crosser off
and on again. Now it can
run normally again.
Mini Crosser can not Battery on main circuit Change the battery on the
remember the time. board has run out of main circuit board.
power.

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Electric faults

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


1 lamp The batteries need charging or Check all connections between the
the connection to a battery is controller and batteries. If these
poor. are fine, try charging the batteries
2 lamps Poor connection to the motor. Check the connection between
the motor and controller. Contact
supplier.
3 lamps Short-circuit between the motor Contact supplier - say how many
and a battery connection. lamps are lit.
4 lamps Not in use
5 lamps Not in use
6 lamps Not in use
7 lamps Accelerator fault. Contact supplier.
8 lamps Controller fault. Contact supplier.
9 lamps Poor connection to motor Check the connections from brake
brake. to controller, or push the brake
lever up.
Magnetic brake is disengaged. Check that the vehicle is not disen-
gaged.
10 lamps The controller has been sup- Check all connections from the bat-
plied with a high voltage in teries to the controller.
excess of 38 V. Usually seen in
the case of a poor connection.
Running Charger is connected. Remove Remove charger.
lights charger.
Running The accelerator has been akti- Turn the key back to 0 and to 1 to
lights from vated during start up. reset the fault.
the center
and out.

See also. Appendix A for an expanded list.

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Medema A/S

Driving characteristics
If you want to change parameters for P & G parameters, contact
Medema A/S for further information.

Keep in mind that the values for speed, braking, throttle gain
and engine compensation are not allowed to be increased.
They have major impact on user safety and product durability.

For the acceleration and braking parameters, the lower the


speed, the faster accelerates / brakes the scooter. The higher
the value, the slower the response from the scooter. For speed
forward and backward, the higher the value, the higher speed.

The setting may only be changed by authorized personnel. If


the setting changes, the operator assumes full responsibility for
the driver’s driving and operation.

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Changing the wheels


If you get a puncture in one of the pneumatic tyres or if a tyre
is so badly worn that it needs to be replaced, follow the instruc-
tions below.

Tyres and inner tubes can be purchased from the authorised


dealer who supplied the Mini Crosser.

The Mini Crosser must be TURNED OFF before you start.

Changing the wheels on


the 4W model
Remove the hubcap.
5 mm Allen key
• Undo the five bolts.
• Take the wheel off.
• When the wheel is put
back on, the spring
washers must be refitted
between the wheel rim
and bolts.
The bolts must be done
up tightly.

Remove the valve cap


and use a screwdriver or
similar to open the valve
so that the air can be
released.

Important!
There is a risk of
explosion of the
wheel, if the two
REMEMBER! rims are being
• to let all the air out before taking taken apart with air
the wheel apart to repair a punc- in the tire.
ture
• to secure the bolts with spring
washers

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Remove the flange with


the 5 screws (5 mm Allen
key).

Replace or patch the tube.


Ensure that there are no
foreign objects in the tyre
before the tube is re-
placed.
Pump air into the tube so
that it is positioned cor-
rectly in the tyre, but do
not fill it up completely yet.

In this way the tube will


not get jammed, when the
flange is mounted again.

Put the flange back on.

Pump up the tyre to the


correct pressure. (See
technical data)

Put the wheel onto the


Mini Crosser again.

REMEMBER!
The spring washers be-
tween the screws and the
wheel rim.

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Changing the wheels on


the 3W model

Rear wheels: Take off


in the same way as de-
scribed in the section
Changing the wheels on
the 4W model.

Front wheels:
17 mm fork spanner
6 mm Allen key
5 mm Allen key

Unscrew on both sides.

Remove the centre axle


by unscrewing the 5
screws here.

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The centre axle removed.

Remove the valve cap


and use a screwdriver or
similar to open the valve
so that the air can be
released.

Important!
There is a risk of
explosion of the
wheel, if the two
rims are being
REMEMBER! taken apart with air
• to let all the air out before taking in the tire.
the wheel apart to repair a punc-
ture
• to secure the bolts with spring
washers

Remove the flange with


the 5 screws (5 mm Allen
key).

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Replace or patch the tube.


Ensure that there are no
foreign objects in the tyre
before the tube is re-
placed.
Pump air into the tube so
that it is positioned cor-
rectly in the tyre, but do
not fill it up completely yet.

In this way the tube will


not get jammed, when the
flange is mounted again.

Put the flange back on.

Pump up the tyre to the


correct pressure. (See
technical data)

Put the centre axle on


again.

Put the wheel onto the


Mini Crosser again.

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Replace the circuit board

X2 Controll panel with the shadow. Four screws are removed.

The panel can now be lifted. Lower the column so that the cables can
reach when the display are lifted.

Remove the bracket that keep the main Dismantle the plugs on the circuit board.
cable in place. All plugs are numbered. Follow the
Scheme on the inside of the head.

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Dismantle the plugs for lights, warning Remove the two nuts that keeps the
blinkers, blinkers and horn. circuit board in place. Note that they also
keep the buttons for lights and warning
blinkers in place.

Lossa kontakterna till ljus, The circuit board is now free. Mount a
varningsblinkers, blinkers och tuta. new print in reverse order.

Remember the plastic washers under the New circuit board mounted.
nuts when mounting. Mount the plugs in the circuit board
again. Follow the Scheme on the inside
of the head.

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Replace the Shadow

Remove two screws. The Shadow is free. Mount a new in


reverse order.

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Replace headlights

If the headlight stops working, replace The headlight is attached with a fitting
the entire headlight. on the back of the screen. A single finger
screw holds it firmly in place. Remove
the screw.

Remove the headlight. Detach the plug, New headlight set.


and it is free to change.

Mount the plug. Note that the bracket is facing the short
side up when the lamp is mounted again.
Place the bracket on the inside of the
cover.

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Mount the finger screw again. The headlight can be adjusted up/down
by turning this screw.

Adjust the headlight so it isn’t blinding,


but lights up well.

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Replace gas spring for steering collumn

Remove the six screws that keep the When the cover is loosened, turn it
cover in place. almost 90°, and slide it of the handle.
The cover is still attached by a cable, but
there is access to the gas spring.

Dismantle the gas spring in the top area. And in the bottom.

New gas spring. Mount en reverse order. Mount the cover again.

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Replace the front springs

It is not necessary to remove any covers


to replace the front springs.
Remove the screws at the top.

And on the bottom. Now the spring can Mount a new spring in reverse order.
be replaced. Don’t remove both front
springs at the same time. It will cause
the vehicle to collapse.

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Replace rear spring

Remove the rear cover. Remove the Avoid removing both springs at once. It
stopper, and slide of the rubber. Unscrew will cause the vehicle to collapse.
the three screws. Unplug all electric
connectors and the cover is free.

Remove the screws in the top. And then in the bottom.

The spring can now be removed and Mount the new spring in reverse order.
replaced with a new.

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Replace tail light

Lift the armrests up, and fold the seat Remove the thumbscrew and remove
completely. Release the seat turn - turn the battery cover.
the seat a little and lift it of.

Turn the nut until the tail light is loose. Remove the plug and pull the cables
through the hole.

Mount the new light in reverse order. Connect the plug again.

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Replace batteries

Lift the armrests up, and fold the seat Remove the thumbscrew and remove
completely. Release the seat turn - turn the battery cover.
the seat a little and lift it of.

Disconnect the poles. Remove the battery straps.

Tilt the spacer, and pull the strap trough. The batteries are now free to be
replaced with new ones. Mount in
reverse order.

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Replace transaxle

Lift the armrests up, and fold the seat Remove the thumbscrew and remove
completely. Release the seat turn - turn the battery cover.
the seat a little and lift it of.

For safety reasons - disconnect one of Raise the rear end so the wheels are
the poles. lifted of the ground.

Disconnect M- and M+. Disconnect the main cable plugs.

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Cut the cable ties that keep the cable in The cable is free.
place. Remember new cable ties when
mounting again.

Remove both rear wheels. Remove the cover (key 17)

Remove the three screws that hold the Use a long cable tie, to keep the brake
brake disc. dick away from the working area.

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In one side the transaxle is laying on When all four screws are removed, the
top of the rear suspension. In the other transaxle can be removed and replaced
side it is fixed from beneath. Remove the with a new one. Mount in reverse order.
screws from this side first.

On a new transaxle, the note is taped in Remove the tape and coat it with bearing
place. grease.

Remount the brake disc. The three The plugs should be tightened with 5 Nm.
screws should be tightened with 4 Nm. Remember to mount new cable ties.

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Replace cable for hand brake

Raise the rear end so the wheels are Cut the brake cable.
lifted of the ground. Remove the rear
wheel.

Press the hand brake once. The brake A new bake cable. Mostly only the inner
cable will poke out. Grab the cable and cable need to be replaced. Pull the inner
pull it out. cable out.

Cut the end stop off. Pusch the cable through the hand brake
handle and into the outer cable. Loosen
the outer cable from the hand brake, for
easier access.

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Mount the outer cable again. Push the cable all the way through the
outer cable until it is visible by the rear
wheel.

Lead the cable through the adjustment And through the small hole. Adjust the
screw. brake with the tool, while turning the hub.
There must be no sound from the hub.
When the hub just turn without sound,
the cable can be tightened.

Fine tune the brake with the adjustment Shorten the brake cable, and fit a
screw. cable termination. Check that the brake
function is working as it should.

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Replace the magnetic brake

Raise the rear end so the wheels are Remove the cover - three screws.
lifted of the ground.

Now there is access to the magnetic Remove the three screws to dismantle the
brake. magnetic brake. They where all greased
with locktite when they were mounted.

Check the distance to the magnet. If Disconnect the four plugs, and the
the measure is more than 0,35 mm, It magnetic is free to be removed.
is worn, and has to be replaced. The
distance on a new magnetic brake is
0,15 mm.

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When the new magnetic brake is Use locktitie on the screws. Tighten the
mounted, be aware to tuck the cable screws with 4 Nm.
away before mounting the screws. Locktite No 2400.

Mark the screws with blue paint.

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Replace fuses

Lift the armrests up, and fold the seat Remove the thumbscrew and remove
completely. Release the seat turn - turn the battery cover.
the seat a little and lift it of.

For safety reasons - disconnect one of Fuses 1A (hour meter), 5A (Horn), 10A
the poles. (light), og 20A (charging) are placed on
the electric plate.

Sikring str. Sikring for


1A Hour meter
5A Horn
10A Light
20A Charging

In both sides is a main fuse, fixed


with cable ties. When replaced a new
protection is heated in place .

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Replace coal

Lift the armrests up, and fold the seat Remove the thumbscrew and remove
completely. Release the seat turn - turn the battery cover.
the seat a little and lift it of.

For safety reasons - disconnect one of Remove the rear cover. Remove the
the poles. stopper, and slide of the rubber. Unscrew
the three screws. Unplug all electric
connectors and the cover is free.

There are four coals. Turn of the lit.

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Blow the hole clean before a new coal Ready to mount the lit again.
is fitted. The coal should move effortless
forth and back. If needed the coal can
be slightly grinded on the side until it fits
perfectly.

Check the coal length to see if it needs replacing.

No matter if it is a Schmid or Mini Crosser transaxle, the rule is, that a coal should be
replaced if worn down to 10 mm.

Full length
10 mm

Turn the lit on again.

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Introduction to the Ergo2 seat


The Ergo2 seat is designed to stay safe to use for at least 10
years.

Lever for rotating the seat

The lever must be pulled back


to rotate the seat. The seat
can then be rotated to each
side, locking at each 45°.

The lever is spring-loaded, and the seat is locked automatically


when the lever is released. This lever is located on the right side
as standard, but can also be positioned on the left side.
When the lever is located on the left-hand side, it must be
pushed forward in order to rotate the seat instead of pulling
back.

Out / in adjustment of the


lever for rotating the seat

Lift the seat off the vehicle.

Loosen the two Allen screws


and the lever can now be
adjusted out and in to the
desired position.

Placement of lever for rotating


the seat on the left-hand side

Remove the two Allen keys


and pull the lever out.
Insert the lever from the left-
hand side and tighten the
Allen screws.
When installing the lever on
the left-hand side, the lever
must be pushed forward to
rotate the seat..

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Mount the seat again

In order to ensure that the


seat returns to the correct po-
sition, the lever for rotating the
seat must be released in order
to place the seat.

Lever for fwd/bw adjustment


of the seat.

Pull the lever up to release the


seat on the slide rail.

Then the seat can be moved forward or backward as desired


with 200 mm of travel.
When the lever is released, the seat will automatically lock into
place in the closest position.

Height adjustment of armrest

Unzip the zipper on the side of


the backrest and the backrest
itself.

Unscrew the Allen screw and


the armrest can be pushed up
or down as needed.
It can be adjusted 140 mm.

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Width adjustment of armrest

Each armrest can be adjusted


25 mm on each side.
Loosen the Allen screw and
the armrest can be adjusted
longitudinally.

Adjusting the angle of the


armrests

The adjustment screw makes


it possible for the armrest to
be adjusted 60°.

The armrest can be tilted up to


facilitate entry and exit.

Adjusting the angle of the


backrest.

The angle of the backrest can


be adjusted 45° backward and
90° forward. This is done by
pulling the lever on the right-
hand side of the seat.

Backrest tilted 45° backward.

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Backrest tilted 90° forward.

This is why the seat does not


necessarily need to be re-
moved during transport, e.g. in
a car.

Backrest forward / back.

Loosen the specified screws


on both sides.

The depth of the seat can


now be adjusted by sliding the
seatback forward and back.

Shown here with 320 mm seat


depth.

The seatback can then be


moved backward to the edge
of the rail and forward to the
desired position. Tighten the
screws after adjusting.

Shown here with 550 mm seat


depth

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Height adjustment of
headrest.

Press the button and the


headrest can be raised and
lowered as needed.

Adjustment of the headrest


forward and backward.

The headrest can be tilted


forward and backward as
needed.

Basket in front

Mount the basket on the brackets (Click on) and now it is ready
for use.

Baskets are part of a wide range of accessories. Contact your


local dealer or Medema A/S. Se contact information on page two
in this manual.

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Basket on seatback

Mounting of basket on the


seat.
(Optional accessory)

Complete mounting kit for


basket.
Two brackets and four Allen
screws.

Unzip the zipper and position


the brackets in front of the two
predrilled holes.

Mount the basket on the


brackets and now it is ready
for use.
Remember to insert a locking
split after mounting.

Baskets are part of a wide range of accessories. Contact your


local dealer or Medema A/S. Se contact information on page
two in this manual.

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Introduction to the Eblo seat


The lever for turning the seat.

Pull the lever up to release


the seat. The seat can then be
rotated 90° to each side, locking
at each 45°.
The lever is spring-loaded, and
the seat is locked automatically
when the lever is released.

This lever is located on the right side as standard, but can also
be positioned on the left side.

Lever for fore/aft adjustment


of the seat.

Pull the lever up to release the


seat on the slide rail. Then the
seat can be moved forward or
backward as you wish. When
the lever is released, the seat
will automatically lock into place

in the closest position.


There is a stop on the front and the back of the slide rail.

Adjusting the angle of the


armrests

The angle of the armrests can


be adjusted by turning this
screw.

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Adjusting the angle of the


backrest
10°
The angle of the backrest can
be adjusted approximately
60° 140°. This is done by lifting
this lever.

Adjusting the lumbar


support:

The lumbar support can be


adjusted by turning the handle
counter-clockwise.

Headrest:

The headrest can be adjusted


up/down in steps.

Flame resistance
The Mini Crosser seat’s flame resistance has been tested in
accordance with DS/EN 1021-2:2014 Furniture - Assessment of
the ignitability of upholstered furniture - Part 2: Ignition source
match flame equivalent.

Warning!
The seat may become very hot if exposed to direct sunlight.
Similarly, the seat will become very cold if it is exposed to cold
temperatures, e.g., frost.

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Front wheel alignment, 4W

+2
A -0

Front wheel alignment (toe-in), 4W

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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
X2 3W X2 4W
General information
Overall length 1340 mm 1400 mm
Overall length with anti-tilt wheels 1430 mm 1485 mm
Overall width 680 mm 680 mm
Overall height: 1090 mm 1090 mm
Folded length - -
Folded width - -
Folded height 690 mm 690 mm
Total mass incl. batteries and 151 kg 168
Ergo2 seat.
Total mass incl. batteries, without 124 kg 141 kg
seat.
Mass of the heaviest part (chassis) 79 kg 90 kg
Static stability all directions 15° - 27% 15° - 27%
Energy consumption (Distance)
56 Ah 35 km (*) 35 km (*)
85 Ah 45 km (*) 45 km (*)

Maximum driving distance with


new batteries at +20° on flat, firm
surface

Optimum battery capacity is


reached after approx. 20 charges /
discharges.
Dynamic all directions 13° - 23% 13° - 23%
Obstacle climbing forward 110 mm 110 mm
Obstacle climbing rearward 110 mm 110 mm
Maximum speed forward 15 km/h 15 km/h
Minimum braking distance from
max. speed
10 km/h 2,0 meter 2,0 meter
13 km/h 2,8 meter 2,8 meter
15 km/h 3,5 meter 3,5 meter
Measured sound power level (1 m. 60db 60db
distance)
Max user weight - standard 175 kg 175 kg
Max user weight - HD version. ------ 250 kg

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X2 3W X2 4W
Weight of test dummy 175 kg 175 kg
Classification Class C Class C
Seats
Seat plane angle 0° 0°
Effective seat depth
Ergo2 child 20-43 cm 20-43 cm
Ergo2 standard + HD 32-55 cm 32-55 cm
Eblo 43 cm 43 cm
Effective seat width
Ergo2 child 35 cm 35 cm
Ergo2 standard 40, 45, 50 cm 40, 45, 50 cm
Ergo2 HD 60, 70 cm 60, 70 cm
Eblo 50 cm 50 cm
Seat surface height from footrest
to front edge
Ergo2 (barn, standard og HD) 42 - 52 cm 42 - 52 cm
Eblo 44 - 54 cm 44 - 54 cm
Seat surface height from ground to
front edge
Ergo2 (barn, standard og HD) 59 - 69 cm 59 - 69 cm
Eblo 61 - 71 cm 61 - 71 cm
Backrest angle
Ergo2 (barn, standard og HD) -90° til +48° -90° til +48°
Eblo -54° til +80° -54° til +80°
Backrest height
Ergo2 barn 44 cm 44 cm
Ergo2 standard + HD 54 cm 54 cm
Eblo 52 cm 52 cm
Seat cushion angle 3° 3°
Leg to seat surface angle 90° 90°
Armrest to seat distance 150 mm - 300 mm 150 mm - 300 mm
Front location of armrest structure 350 mm 350 mm
Minimum turning diameter / radius 265 cm / 132,5 cm 330 cm / 165 cm
Wheels
1503-1003 2,8 bar 2,8 bar
Wheel, model-X, 2,50-3,30-8”.
complete with rim and tyre.

1503-1114 4,1 bar 4,1 bar


13x5.00-6” ext. Ø325 mm
Wheel Norway black - T, E, Nordic,
MaxX, MaxX HD, M and X

1503-1115 4,1 bar 4,1 bar


13x5.00-6” ext. Ø325 mm
Wheel Norway black w/spikes - T,
E, Nordic, MaxX, MaxX HD, M and
X

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X2 3W X2 4W
1503-1336 3,5 bar 3,5 bar
13x3.00-8” ext. Ø340 mm
Wheel black - T, M and X

1503-1273 PUR PUR


13x3.00-8” ext. Ø340 mm
Wheel black puncture free - T, M
and X

Lighting:
Bulb, headlight LED LED
Diode, rear light LED LED
Diode, indicator LED LED
Standard colours
Option 1 Orange - metallic Orange - metallic
Option 2 Black - metallic Black - metallic
Miscellaneous
Front basket, max weight 8 kg 8 kg
Rear basket, max weight 15 kg 15 kg
Wheel bolt tighten max:
Dry 12 Nm 12 Nm
Greased with fat 6 Nm 6 Nm
The Mini Crosser X2 complies with the following standards:
The Mini Crosser has been tested for the requirements EN 12184
described in:
ISO 7176-15 Annex A

a) requirements and test methods for static, impact an Conforms


fatique strengths (ISO7176-8)

b) Power and control systems for electric wheelchairs, Conforms


requirements and test methods. (ISO 7176-14)

c) climatic test in accordance with ISO 7176-9 Conforms


ISO 7176-19 Wheeled mobility devices for use as seats in Conforms
motor vehicles.
Mini Crosser X2 is Crash tested with belts from Dahl Engi- Passed
neering

(*) Driving distance is depending on: temperature, wind, terrain, tyre pressure and user weight.

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Appendix A - Electric faults


Code Description Action Mode Bars Comments
0003 EEProm cache checksum Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
0100 ROM checksum trip Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
0200 EEProm cache checksum Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
0300 Parallel speed pot wiper open- Limp All modes 7 Only tested if speed pot enabled.
circuit
0704 Internal 12v supply Fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
0815 Throttle reference fault Trip All modes 7 Value checked for valid range. Tests
only if ”reference tests” enabled
0816 Throttle reference fault Trip Startup 7 Startup
0A00 Sleep timer Trip Standby 6 If active (greater than 0) then it will
pulse trucharge gauge, recycle
keyswitch to reset.
0A01 Keyswitch has been turned off Trip All modes 6 Informs of rapid power cycle on key-
switch input, controller may not reset
correctly
0E07 Throttle ISO Test Fault Trip Startup 7 Test only if ISO tests enabled, 10K
resistor, in series with wiper
Throttle ISO Test Fault Trip All modes 7 Test only if ISO tests enabled, 10K
resistor, in series with wiper
0E08 Throttle wiper fault Trip Startup 7 Trips if throttle wiper exceeds limits
Throttle wiper fault Trip All modes 7 Trips if throttle wiper exceeds limits
1310 Overcurrent fault Trip Drive 8 Internal Fault. Return to PGDT if
happening all the time.
1500 Solenoid Brake Fault Trip Drive 9 Trips if solenoid brake is short-circui-
ted, if test is enabled.
1502 Solenoid Brake Fault Trip Startup 9 Trips if solenoid brake is short-circui-
ted, if test is enabled
Solenoid Brake Fault Trip Standby 9 Trips if solenoid brake is short-circui-
ted, if test is enabled
1504 Solenoid Brake Fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
1600 Battery voltage too high Trip Startup 10 Battery voltage is greater than 35.0V
Battery voltage too high Trip All modes 10 Battery voltage has risen above
35.0V, possibly under regen.
1601 Battery overvoltage Trip Trip All mo- 10 Battery voltage has risen above
dels 35.0V, possibly under regen.
1703 Relay interlock fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
1705 Possible Relay Fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
Possible Relay Fault Trip Standby As above, but can also be caused
by intermittent loss of battery voltage
during use.

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Code Description Action Mode Bars Comments


1800 Watchdog trip Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
1B10 M+ current null fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
1B12 M+ current feedback fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
1C10 M- current null feedback Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
1C12 M- current feedback fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
1E08 Inhibit active Note 1 All modes Note 2 Note 1 - trip or speed limit depends
on programming
Note 2 - trucharge display depends
on programming
1E09 Inhibit active Note 1 Note 2 Note 1 - trip or speed limit depends
on programming
1E0A Inhibit active Note 1 All modes Note 2 Note 2 - trucharge display depends
on programming
Note 2 - trucharge display depends
on programming
2100 Software loop counter fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
2A12 M+ voltage feedback fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
2A10 M+ voltage null fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
2B10 M- voltage null fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
2B12 M- voltage feedback fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
2C00 Battery voltage too low Trip Startup 1 Battery Voltage is below 13.5V
Battery voltage too low Trip All modes 1 Battery Voltage has dipped below
13.5V
2C01 Battery voltage very low Trip Drive 1 Battery Voltage has dipped below
12.5V
2E00 Software loop ran out of time Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
Trip Startup 7 Throttle wiper is outside neutral
deadband limits at startup - trip con-
2F01 Throttle displacement fault No Startup Ripple dition depends upon programming -
latched trip of 7 bars, or rippling up/
down of 10 bars, or nothing.
Possible Controller Fault - Can also
occur if keyswitch is on, when bat-
3100 Bridge voltage too low Trip All modes 8 tery connections are connected to
Battery terminals or keyswitch is not
operating correctly.
3201 Stack overflow fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.

Service manual 1533-2002-S 111 of 114 Version 1.0.0 - 2018


Medema A/S

Code Description Action Mode Bars Comments


3240 Illegal state fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
3600 Controller fault Trip All modes 8 Internal Fault. Return to PGDT if
happening all the time.
3601 Watchdog fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
3612 Controller fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
3A00 Bad settings fault Trip Startup 8 Internal Fault. Return to PGDT if
happening all the time.
Startup Check Motor connections and/or
3B01 Motor open circuit fault Trip 2 motor brushes. NOTE: Test disabled
Standby when sol. brake test is disabled.
3D02 Motor output shorted high fault Trip Startup 3 Check Motor connections and/or
motor brushes are not shorted to
Batt +
3D03 Motor output shorted low fault Trip Startup 3 Check Motor connections and/or
motor brushes are not shorted to
Batt -
4401 Generic internal fault code N/A N/A N/A Generic code for logging internal
faults to system log
5300 Programmable setting chan- Trip All modes 8 Recycle Keyswitch to reset. Not
ged normally recorded in fault log.
7000 Push input in active state at Trip Startup 4 Freewheel (Push Input) is enabled,
startup so check Inhibit 3 input and pro-
Other trip codes can occur. If so, please contact Medema gramming.
A/S.
7001 Push input in active state in Trip Drive 4 Freewheel (Push Input) is enabled,
drive so check Inhibit 3 input and pro-
gramming.
7C00 Thermistor open or short Trip 8 Possible controller Fault
circuit trip

Service manual 1533-2002-S 112 of 114 Version 1.0.0 - 2018


Medema A/S

Service manual 1533-2002-S 113 of 114 Version 1.0.0 - 2018


medemagroup

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