Medema Mini Crosser M1 Cabin Service Manual Download Page 8

Page: 8 / 66

Service manual P9-0151-S

8 of 66

Version 1.0.3/2018

Medema Production A/S

Tool list

The following tools are needed to service the scooter:

Circlip pliers

Allen keys

Box spanners, 7-17 mm

Open-ended spanners, 7-17 mm

Phillips and torx screwdrivers, 10/15/20/25 slot

Needle-nose pliers

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 406 / 603

Cable ties

PC Programming package for S180

Summary of Contents for Mini Crosser M1 Cabin

Page 1: ...Service Manual Mini Crosser M1 Cabin P9 0151 S ver 1 0 3 October 2018 GB medemagroup...

Page 2: ...Service manual P9 0151 S 2 of 66 Version 1 0 3 2018 Medema Production A S...

Page 3: ...and bulbs 33 Summary of battery connections 33 Sockets and control panel 34 Batteries 36 Battery disposal 36 Charging 37 Fuel for heater 39 Heater 39 Windscreen wiper washer 40 Replacing the wiper bl...

Page 4: ...Service manual P9 0151 S 4 of 66 Version 1 0 3 2018 Medema Production A S...

Page 5: ...nd short circuits in the wiring 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 see...

Page 6: ...must not be lent to persons who are not completely familiar with it The vehicle is designed for one person only The Mini Crosser M1 Cabin has been designed for users weighing max 175 kg Can be supplie...

Page 7: ...not to lift heavy parts such as the seat battery and motor gear incorrectly or drop them Make sure to raise one rear wheel off the ground so that the scooter cannot drive off accidentally Use profess...

Page 8: ...ips 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...

Page 9: ...M1 Cabin is not going to be used for a long time it is advisable 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...

Page 10: ...ndard EN 12184 Electrically powered wheelchairs scooters and their chargers The product is risk analysed in accordance with the harmonized standard DS EN ISO 14971 2007 04 10 2 edition Medical devices...

Page 11: ...or visibility Every three months 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 With the...

Page 12: ...rly Check the tyre pressure and tread Annual Safety checks The Mini Crosser M1 Cabin is designed for safe travel for at least 10 years up to a max of 5 000 hours provided it is serviced and safety che...

Page 13: ...hitting obstacles The manufacturer accepts no liability in respect of the unauthorised opening adjustment or modification of the control panel Lever for adjusting the angle of the handlebars Charging...

Page 14: ...Service manual P9 0151 S 14 of 66 Version 1 0 3 2018 Medema Production A S Accelerator four finger control Air channel Windscreen wiper washer Heat regulation...

Page 15: ...more the arm is pressed the faster the Mini Crosser will move When the arm is released it will flip back to starting position of its own accord and the Mini Crosser will stop Activating the rear arm w...

Page 16: ...sition Use the lever again and push the steering column forward 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 coverin...

Page 17: ...ue for disassembly NB The rear and front wheels on the 4W MUST always be removed using the five bolts NEVER undo the actual flange using the bolt in the centre See the Spare Parts Catalogue NB ALWAYS...

Page 18: ...nes if necessary Check that the sign on the control panel is straight Accelerator and handlebars Check that the accelerator is mounted securely on the potentiometer shaft Function test Turn the scoote...

Page 19: ...n one of the battery cables using a clip on ammeter Brakes and disengagement Check function When the disengagement lever is up It must not be possible to push the scooter It must be possible to drive...

Page 20: ...ium section Contact Medema Production 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 C...

Page 21: ...lace and not sticking out in such a way as to catch on something or get trapped Check that the plugs are firmly in place Lights blinkers Check that lights and blinkers are working properly Batteries c...

Page 22: ...51 S 22 of 66 Version 1 0 3 2018 Medema Production A S Check if the carbon is okay or needs replacing Whether it is a Schmid or Mini Crosser transaxle the carbon must be replaced when it has been worn...

Page 23: ...turned off See section about fuses Release the handbrake Contact supplier Contact supplier Remove the charging plug Driving speed is too low The speed selector is on slow The electronics are overloade...

Page 24: ...serted or there is a mains fault The battery voltage is too low for charging to start Push the charger plug in or contact the supplier Contact supplier Read the operating instructions for the charger...

Page 25: ...ed 10 lamps The controller has been supplied with a high voltage in excess of 38 V Usually seen in the case of a poor connection Check all connections from the batteries to the controller Running ligh...

Page 26: ...PC program an OEM version and a dealer version The OEM version gives complete access to all settings parameters The dealer version gives limited access Before programming can commence the five pin pl...

Page 27: ...ould be switched off with the key After reassembling the 5 pin connector the scooter can be switched on There is a complete package available containing PC program cable and USB to serial adapter SR 0...

Page 28: ...formation about the vehicle via PC Double clicking on the S 180 program icon displays the following screen Press Continue to continue The red down arrow shows that the program can see that the control...

Page 29: ...m has been driven Controller Info Displays control system specific information such as the identification number Protect Allows PC Programmer to be secured using a password Once the program has been p...

Page 30: ...plays control system specific information such as the identification number Protect Allows PC Programmer to be secured using a password Once the program has been protected can only Open Close Read Fro...

Page 31: ...nformation such as the identification number Protect Allows PC Programmer to be secured using a password Once the program has been protected can only Open Close Read From Write To and Program attached...

Page 32: ...control system specific information such as the identification number Protect Allows PC Programmer to be secured using a password Once the program has been protected can only Open Close Read From Wri...

Page 33: ...x 20 A fuse Charging Item No SR 00066 40 A Fuse 2 1 x 10 A fuse Control system Item No SR 00066 10 A Main fuses 100 A fuse type DIN 2581 100 A Item No SR 00977 Summary of battery connections Fuses and...

Page 34: ...on the card are for optional extras Some of them are connected at the factory and wired instead to the areas on the scooter where they are to be used The table on the next page Open panel for access...

Page 35: ...Cable trunk 7 Hazard warning lights 8 Cable trunk 9 Indicator card R 10 Electric seat adjustment 11 Max speed pot 12 Corner speed reduction 13 Accelerator pot 15 24 V horn 16 Light switch 17 Indicator...

Page 36: ...ossible otherwise the scooter will cut out The Mini Crosser uses sealed maintenance free GEL batteries Exide 12 V 56 Ah or AGM type 12 V 71 Ah They do not normally generate gas and do not have to be t...

Page 37: ...that at 20 C New batteries do not reach full capacity until they have been charged and discharged about 20 times If the Mini Crosser is not going to be used for an extended period charging once a mont...

Page 38: ...roperly closed For the same reason there must not be any burrs on the terminals Please note that the Mini Crosser can be equipped with several types of charger ask your dealer for information on the v...

Page 39: ...the seat and filled from the outside Use ONLY paraffin or diesel In the front right side of the Mini Crosser M1 Cabin you find the the exhaustion from the heater NOTE It gets VERY hot Exhaustion from...

Page 40: ...OT be covered up when the heating is on That will cause overheating of the heater Windscreen wiper washer Start the windscreen wiper by turning this knob Notice the smooth speed ajusting Windscreen wi...

Page 41: ...er blade To exchange the wiper blade do the following Screw this screw out Lift carefully so you can pull the wiper blade over the pin Mount a new in reverse order Replacing the bulb headlight Open th...

Page 42: ...oduction A S Press down and turn counter clockwise and lift out Now you have access to the bulb take the bulb out Mount a new in reverse order NOTE Be aware that drain list are not trapped when the fr...

Page 43: ...rator on left and right wig wag Twist grip accelerator on right and left single ended Twist grip accelerator and foot pedal single ended What they all have in common is a change over switch for select...

Page 44: ...rs Accelerator cable Fit the switch so it points to the right side Fit the control panel Avoid trapping stretching the wires Turn the scooter on and check that the magnetic brake clicks when the accel...

Page 45: ...he kit contains these parts Take the seat and cover off then remove the left rear wheel Screw the bolt in until it sticks 2 3 mm out through the backplate Plug the connector at the other end into the...

Page 46: ...0 3 2018 Medema Production A S Fit the speedometer with the mounting strap provided Find the connector marked KM in the rubber bellows Plug the connector in and put the connector and cable back in un...

Page 47: ...ame using the pre drilled holes Mount the U shackle with pipe fitting and bolt on the steering column Please note that the distance to the magnet should be approx 3 mm Plug into connector no 5 Put the...

Page 48: ...entiometer Fit the jumper on the connector for the forward reverse switch Put the control panel back on Parent potentiometer Fit the forward reverse switch Remove the speed control Turn the scooter on...

Page 49: ...lumn Replace with a plastic cover that has an hour counter fitted Plug into connector no 6 Fit the plastic cover Take care not to trap any cables Panel with hour counter Turn the scooter on and check...

Page 50: ...Fitting a parent key Parent key Remove the rubber plug in the plastic cover Remove the plastic lever Remove the back plastic cover by undoing the six plastic bolts Plug the key into connector no 3 Put...

Page 51: ...Open the control panel to connect the forward reverse switch Cut a hole for the forward reverse switch Plug the forward reverse switch into contact no 2 The foot pedal can be located on the right or...

Page 52: ...t can be located on the right or left hand side or in the centre Programming must be Wig Wag with this pedal After completing installation turn the scooter on and check that the magnetic brake clicks...

Page 53: ...0 3 2018 Medema Production A S Left hand twist grip accelerator kit Right hand twist grip accelerator kit Take the plastic cover off Remove the rubber plug Remove the lever Remove the potentiometer F...

Page 54: ...ug in the hole Fit the twist grip accelerator on the handlebars Tighten the screws Plug the twist grip accelerator into the 3 pin connecter used for the standard potentiometer Fit the forward reverse...

Page 55: ...hen the accelerator is released it must not be possible to push the scooter To ensure that the handlebars are watertight it is important to fit new plugs in the holes for the side view mirrors Use a c...

Page 56: ...l Engineering belt set for securing in motor vehicles Item No C2 0242 ALWAYS use four belts at the back and two at the front The belts must always be attached to approved fittings in the vehicle and t...

Page 57: ...vice manual P9 0151 S 57 of 66 Version 1 0 3 2018 Medema Production A S Greater than the anchorage points on the scooter Attachment point Attachment point Greater than the anchorage points on the scoo...

Page 58: ...sp Towing If you should be unfortunate enough to break down the Mini Crosser M1 Cabin can be towed or pushed The Mini Crosser M1 Cabin must always be turned off and the motor brake disengaged during t...

Page 59: ...1030 mm 1610 mm 1600 mm 175 mm 730 mm 1050 mm Service manual P9 0151 S 59 of 66 Version 1 0 3 2018 Medema Production A S Dimensioned drawing Mini Crosser M1 Cabin...

Page 60: ...Service manual P9 0151 S 60 of 66 Version 1 0 3 2018 Medema Production A S Front wheel alignment Front wheel alignment toe in...

Page 61: ...17 Kerb climbing 11 cm Max speed 15 km h Braking distance 10 km h 15 km h 2 0 metres 3 5 metres Controller S 180 KW transaxle 0 7 kW Turning radius 184 cm Max user weight standard 175 kg Max user wei...

Page 62: ...74 cm 61 61 cm Height footplate to front edge of seat Ergo Standard with slide rail Ergo Standard without slide rail Mando seat with slide rail Mando seat without slide rail 45 55 cm 41 51 cm 45 55 c...

Page 63: ...2 batteries 56 Ah 75 80 Ah 110 115 Ah 43 kg 50 kg 80 kg Energy consumption in kWh when charging from empty 56 Ah 75 80 Ah 110 115 Ah Approx 1 5 Approx 1 5 Approx 3 0 Charging device 24 V DC 56 Ah 75...

Page 64: ...Service manual P9 0151 S 64 of 66 Version 1 0 3 2018 Medema Production A S...

Page 65: ...Service manual P9 0151 S 65 of 66 Version 1 0 3 2018 Medema Production A S...

Page 66: ...medemagroup...

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