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Service Manual

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2. 84 7 Technical product information seine 86 7 1 CE Declaration and standards 86 7 2 Technical specifications 86 7 3 Controller settings PG Drives 88 7 4 Data sheet 92 4 Trophy 20 7 5 Electrical diagram Trophy 20 7 6 Service information transaxles MERCIER 8 1 Provisions of warranty 8 2 Statement of liability 93 95 96 96 97 Trophy 20 Introduction Service manual Trophy 20 5 1 Introduction Service manual Trophy 20 1 1 This manual This manual contains the instructions for repairs and general maintenance of the Trophy 20 Scooter Mechanics who do repairs on this wheelchair must be well trained and familiar with the repair methods and the maintenance of the Trophy 20 scooter Always make sure that the work is carried out safely particularly with respect to procedures requiring the scooter to be lifted up We advise that you contact our service department before doing repair work on a scooter that has been involved in an accident The following specifications are important when ordering parts Model Year of manufacture Colour D number Part number Name of the part concerned This information is provided on the identification plate See Identification of the product Available documentation The following technical documentation is available required to service this scooter User manual Service manual Service and technical support For informatio
3. 20 Ny handicare 2 Trophy 20 2011 Handicare All rights reserved The information provided herein may not be reproduced and or published in any form by print photo print microfilm or any other means whatsoever electronically or mechanically without the prior written authorisation of Handicare The information provided is based on general data concerning the constructions known at the time of the publication of this manual Handicare executes a policy of continuous improvement and reserves the right to changes and modifications The information provided is valid for the product in its standard version Handicare cannot be held liable for possible damage resulting from specifications of the product deviating from the standard configuration The available information has been prepared with all possible diligence but Handicare cannot be held liable for possible errors in the information or the consequences thereof Handicare accepts no liability for loss resulting from work executed by third parties Names trade names etc used by Handicare may not as per the legislation concerning the protection of trade names be considered as being available Trophy 20 3 1 Introduction Service manual Trophy 20 gasi 5 1 1 This manual 5 1 2 Identification of the product 5 1 3 Symbols used in this manual 6 PE LE N ated Se ate Pea 7 2 1 Personnel qualification 7 2 2 Identificat
4. N N 110448 04 052 64 Service instructions Trophy 20 Replacing the tiller PCB Preparation Switch off the scooter with the ignition key Disconnect the batteries Instructions The following operations are required to replace the tiller PCB Note Suitable work area required Remove the basket and the mounting bracket for the mirrors Remove the two bolts and remove the front tiller cover Remove the nut the four Ejot screws and the dashboard Disconnect all connectors from the tiller PCB Remove the three Ejot screws to remove the tiller PCB Mount the new tiller PCB Rebuild the scooter in the reverse order Relevant article numbers 9007265 Tiller PCB ID no PBxxxxx only 9007572 Tiller PCB Basic ID no QBxxxxx onwards 9007374 Tiller PCB Dual control ID no QBxxxxx onwards 9007373 Tiller PCB Full option ID no QBxxxxx onwards Tools used Socket 10 mm e Screwdriver crosshead Notice Make sure the scooter is switched off 110448 04 001 110448 04 041 110448 04 042 Trophy 20 Service instructions 65 110448 04 053 66 Service instructions Trophy 20 Replacing the stop switch Preparation Switch off the scooter with the ignition key Disconnect the batteries Instructions The following operations are required to replace the stop Switch
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6. 7 3 Controller settings PG Drives PGDT S Drive 90A ID no PBxxxxx only Speed Settings Fast Slow Motor Settings Forward Acceleration 0 1 Seconds 35 35 Current Limit Max Amps 60 Forward Deceleration 0 1 Seconds 16 16 Boost Drive Current Amps 90 Reverse Acceleration 0 1 Seconds 40 40 Boost Drive Time Seconds 10 Reverse Deceleration 0 1 Seconds 35 99 Current Foldback Threshold Amps 60 Max Forward Speed 96 100 100 Current Foldback Time Seconds 70 Min Forward Speed 10 10 Current Foldback Level 59 Max Reverse Speed 96 25 25 Motor Cooling Time Seconds 660 Min Reverse Speed 90 9 5 Current Foldback Temperature Deg C 80 Speed Limit Pot Enabled On Current Limit Min Amps 10 Motor Stall Timeout Seconds 0 Mk II only Operation Settings Motor Compensation milli Ohms 25 Sleep timer minutes 0 Anti Rollback Level 12 Throttle Invert Yes Pull away Delay centi Seconds 0 Slope Factor 900 Battery Settings Anti Rollback Velocity 0 Low battery Flash Level Bars 0 Bracking current limit Amps 90 Mk II only Cable Resistance milli Ohms 50 Time foldback bracking current Amps 90 Mk only Calibration Factor 100 Time foldback speed 96 100 MkII only Low Battery Alarm Off Enhanced motor compensation up 96 190 Mkll only Trucharge Reset Voltage Deci Volts 200 Enhanced motor compensation down 180 MkII only MK only 96 Enhanced motor compensation up gain 90 Mk on
7. It is recommended that the dealer carries out a service on the scooter at least once a year If the scooter is used intensively the service should be carried out every six months Maintenance requirement for re use Disinfect surfaces with commercially available disinfectants and clean the surfaces with damp cloths and cleaners tuned Warning Do not use high pressure cleaners or similar to clean the product The followina work most be carried out before re use Annual inspection 1 2 3 4 5 6 7 Electronics On off switch Output connector Operation Brake Programmable settings Batteries Level Connections Capacity test Wheels and tyres Tread depth Pressure Bearings Wheel fixing nuts Motors Cables Noise Connections Brake Brushes 32 Service instructions Trophy 20 Annual inspection 1 2 3 4 5 6 7 Chassis Condition Steering Seating Seat Backrest Armrests Electrical Harnesses Connections Lighting system Test Forwards Backwards Emergency stop Left turn Right turn Uphill downhill Obstacle Brake List of necessary repairs Warning Pull the charge cable out of the battery charging connection of the scooter before carrying out any maintenance on the scoot
8. Loosen the battery strap Disconnect all connectors from the battery Remove the battery Readthe table for more information about the adjustment of shock absorbers Use the special adjustment tool to adjust the shock absorber as desired Rebuild the scooter in the reverse order Relevant article numbers Na Tools used 9000825 Suspension adjustment key Notice Make sure the scooter is switched off 110448 04 001 54 Serviceinstructions Trophy 20 110448 04 030 Standard suspension max 130kg Load User weight Adjust position lt 80kg 0 standard 80 105kg 1 105 130kg 2 Heavy suspension 115 160kg Load User weight Adjust position 115 130kg 0 130 145kg 1 145 160kg 2 standard Position 0 Position 1 Position 2 110448 04 031 Trophy 20 Service instructions 55 Replacing the shock absorber rear Preparation Relevant article numbers Switch off the scooter with the ignition key 9000603 Shock absorber standard 9000683 Shock absorber heavy duty Instructions The following operations are required to replace the shock Tools used absorber rear Socket 7 mm 17 mm Note Suitable work area required Allen key 8 mm Remove the seat 9000825 Suspension adjustment key Liftthe scooter to raise the wheels clear from the ground Notice Remove the rear cover Make sure the scooter is
9. Mount the new front wheel in the reverse order Relevant article numbers 9004511 Front wheel 4W Tools used Screwdriver medium Torque wrench socket bit 6 mm Notice Na 110448 04 001 110448 04 002 110448 04 004 110448 04 005 Trophy 20 Service instructions 37 Adjustment shock absorber front Preparation Tools used Switch off the scooter with the ignition key 9000825 Suspension adjustment key Instructions Notice The following operations are required to adjust the shock Position 0 soft and position 4 hard absorber front Readthe table for more information about the adjustment of shock absorbers Usethe suspention adjustment key to adjust the shock absorber as desired Relevant article numbers Na Position 0 standard Position 2 Position 3 Position 4 110448 04 035 38 Service instructions Trophy 20 Replacing the shock absorber front Preparation Switch off the scooter with the ignition key Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the shock absorber front Note Suitable work area required Remove the basket the front tiller cover the mounting bracket for the mirrors the front cover the front spoiler the front cover rear part the front fender L R the front cover bottom a
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12. 9003417 00000 2003 00000 1702 9002341 Description Hexagon head cap screwM10x40 Fender mounting bracket right Fender mounting bracket left Hexagon bolt M6x12 Rear frame Washer flat M8 Lock nut M8 Button head screw M8x30 16 Spare parts Trophy 20 04 Steering column mirror and basket 3 I N Ag amp 6 Trophy20 EV 04 Pos Qty Article number Description 1a 1 9001135 Basket standard 1b 1 9006137 Basket large only without locking mechanism 1c 1 9000703 Front Bag for std bracket with locking mechanism 2 2 00000 3612 Screw M4x10 9 1 9000704 Basket holder 4 2 00000 4307 Hexagon bolt M6x12 5 2 00000 2202 Spring washer M6 6 2 9006129 Rubber strip 78 1 9006128 Mounting bracket for std basket amp bag with locking mechanism 7b 1 9006130 Mounting bracket for large basket without locking mechanism 8 2 00000 4307 Hexagon bolt M6x12 9 2 00000 2202 Spring washer M6 10 1 9006544 Mounting bracket for mirrors 11a 1 1009250 Mirror left 11b 1 1009251 Mirror right 112 2 00000 2203 Spring washer M8 13 2 00000 1502 Hexagon nut M8 14 1 9004126 Cover plate steering adjustment 15 2 9002792 Screw Ejot K30x6 16 1 1012531 Assy Tiller bearing du 1 9004169 Cylinder steering column 18 4 9004174 Bush bearing tiller 19 3 9004163 Hinge pin 12x5 2 M8 20 2 00000 1702 Lock nut M8 24 1 9004181 Bracket steering adjustment 22 1 9004164 Hinge pin 12x8 M8 23 2 00000
13. BAT 24v 104 mox BK 4 S drive MC Mr REF SD Prut e ALARM ns s S F sw wr 4 Key On Off MC PP 5 INHIBIT 2 MC leLr 6 Not Connected T REF SD m SNE EE SPEED POT MC jen r 9 Transaxle incl STATUS SD BN 10 wiring Not connected R SV Br 18 I GND sk 5 menne ul M 9 4 Normally closed 1j8 3 4 5 6 7 freewheel switch 8 9 10 11 18 13 14 EM Brake 24V 1 25A motor i eme J MOTOR SD POS 26V 1404 BL e MOTOR SD NEG 26V 1404 RD BRAKE SD POS 24V 054 MOTOR SD POS 26V 1404 BL BRAKE SD NEG OV OSA YL MOTOR SD NEG 26V 1404 RD BRAKE SD POS 24V 054 BRAKE SD NEG OV OSA Bet SAVE IW nee LAE Bat 24V 104 mox rn 2 BAT 24v 104 max E BAT 24v 104 max BK 4 POWER SD POS 30v RD POWER SD NEG 30V 3K e BATTERY POS 30V 140A RD BATTERY NEG 30V 140A sk CHARGER POS 24V 164 RD ICHARGER OV 164 EX in INHIBIT CHARGER 113 9 batt pos 9 harness batt neg harness fuse 10A BATTERY PUS 30V 1404 RD CHARGER Pos 164 RD 1 CHARGER OV 164 BATTERY NEG 30V 1404 BK Charge INHIBIT CHARGER 3 connector Elec Trophy 20 S drive rical circuit diagram Drawing number 9006194 B Trophy 20 Technical product information 95 7 6 Service information transaxles Regula
14. 1460 57 5 1810 71 3 Obstacle height max user weight mm inches 80 3 1 80 3 1 Ground clearance max user weight loaded mm inches 70 2 8 70 2 8 Trophy 20 Technical product information 87 Test data Test weight 160 kg 25 2 stone Operating force Drive lever operation 20 N Resetting the automatic fuse circuit breaker 60 N Electronic switches 13 5 N Connecting the charger plug 60 N Technical specifications for wheels Front wheel diameter 3W mm inches 320 x 60 12 5 x 2 25 Front wheel diameter 4W mm inches 320 x 60 12 5 x 2 25 Rear wheel diameter mm inches 360 x 80 14 2 x 3 1 Tyre pressure 4W front wheel bar psi 2 5 36 3 Tyre pressure 4W rear wheel bar psi 3 5 50 8 Tyre pressure 3W front wheel bar psi 2 5 36 3 Tyre pressure 3W rear wheel bar psi 3 5 50 8 Batteries Maximum dimensions of batteries Ixbxh mm inches 262 x 173 x 211 10 3 x 6 8 x 8 3 Max battery capacity C20 Ah 74 Max battery capacity C5 Ah 63 Maximum permitted charging current Amp re 8 RMS height of steering column collapsed excluding seat range dependent on user weight condition of tyres type of terrain condition of battery and weather conditions with 74 Ah C20 seat height lt 425 mm an elevated footplate is required or by removing the slider 88 Technical product information Trophy 20
15. A 2 9006106 Indicator switch 18 9004502 Steering wheel cover bottom 5 1 9004301 Steering wheel cover top 20 1 9005802 Srew Ejot K40x12 21 1 9004197 Rear cover steering column 22 2 00000 2106 Washer flat M4 3xD 23 2 9005802 Screw Ejot K40x12 24 2 00000 1662 Hexagon Nut thin M4 25 2 00000 3218 Recessed buttonhead screw M4x12 26 1 1012536 Assy Dashboard speed knob 27 1 9007365 Assy top 28 1 9006110 Speed switch 29 3 1001730 Screw Ejot K30x10 30 1 9007265 Tiller PCB Trophy 20 Spare parts 19 Continued from 058 Console printed circuit board and throttle control ID no PBxxxxx only Pos Qty Article number Description 31 11 19007223 Console bottom 32 14 9005802 Srew Ejot K40x12 33 2 00000 3200 Recessed buttonhead screw M5x12 34 11 19004641 Throttle harness 35 5 11015323 Cable clips set 25 20 Spare parts Trophy 20 05b Console printed circuit board and throttle control ID no QBxxxxx onwards Pos Qty Article number Description 1 1 9004425 Drumbrake actuator cable 2 1 9006191 Extension cable for microswitch 3 1 00000 3719 Buttonhead screw M5x10 4 1 9004330 Brake lever 5 1 9004185 Steering wheel 6 1 00000 3200 Recessed buttonhead screw M5x12 7 1 9006138 Stop switch 8 1 9000904 Stop switch dummy 9 2 1008055 Throttle potentiometer 10 1 9007423 Cover steering wheel 11 4 00000 3307 Sheet metal screw 2 9x13 2 1 9004331 Cover brake position 18 1 00000
16. Note Suitable work area required Remove the basket and the mounting bracket for the mirrors Remove the two bolts and remove the front tiller cover Remove the nut the four Ejot screws and the dashboard Disconnect all connectors from the tiller PCB Remove the two recessed button head screws to remove the console bottom Disconnect the connectors of the console bottom Remove the recessed button head and Ejot screws disconnect the connectors the stop switch and remove the top and bottom steering wheel covers Mount the new stop switch Rebuild the scooter in the reverse order Remove the three Ejot screws to remove the tiller PCB Relevant article numbers 9006138 Emergency stop Tools used Socket 10 mm Screwdriver crosshead Notice Make sure the scooter is switched off 110448 04 001 110448 04 006 Trophy 20 Service instructions 67 110448 04 054 68 Service instructions Trophy 20 5 4 6 Electronics Replacing the controller ID no PBxxxxx only Preparation Switch off the scooter with the ignition key Disconnect the batteries Instructions The following operations are required to replace the controller Note Suitable work area required Remove the rear cover Remove the S drive cover Disconnect all connectors from the S drive controller Remove the two hexagon
17. Seconds 0 Mk Il only Operation Settings Motor Compensation milli Ohms 25 Sleep timer minutes 0 Anti Rollback Level 12 Throttle Invert Yes Pull away Delay centi Seconds 0 Slope Factor 900 Battery Settings Anti Rollback Velocity 0 Low battery Flash Level Bars 0 Bracking current limit Amps 90 Mk only Cable Resistance milli Ohms 50 Time foldback bracking current Amps 90 Mk only Calibration Factor 100 Time foldback speed 100 Mk only Low Battery Alarm Off Enhanced motor compensation up 190 Mk only Trucharge Reset Voltage Deci Volts 200 Enhanced motor compensation down 180 Mk only Mk II only Enhanced motor compensation up gain 90 Mk only Inhibit Settings Factory Settings Max Min Inhibit 1 Mode 1 Acceleration 0 1 Seconds 100 1 Inhibit 1 Operation Latching Deceleration 0 1 Seconds 100 11 Inhibit 1 Speed 96 0 Forward Speed 96 100 0 Inhibit 2 Mode 1 Reverse Speed 90 100 10 Inhibit 2 Operation Latching Inhibit 2 Speed 96 0 Throttle Settings Inhibit 3 Mode 1 Throttle Type 1 Inhibit 3 Operation Non Throttle Deadband 96 15 Latching Inhibit 3 Speed 96 0 Throttle Gain 96 140 Aux Output Mode 1 Throttle Operated at Power up 2 0 Drive 1 7 Inhibit 2 Trip Throttle Reference Test On Iso Test Resistor Off General Settings Soft Stop On Brake Time milli seconds 1500 Output Voltage Volts 24 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Dia
18. Suitable work area required Loosen the two bolts to remove the front cover e Disconnect the connector of the headlight Take the head light cover out of the front cover Putthe head light cover back in the new front cover Rebuild the scooter in the reverse order Relevant article numbers 1015363 1015364 1015365 1015366 1015367 Front cover Tools used e Screwdriver crosshead Notice Make sure the scooter is switched off 110448 04 001 110448 04 057 110448 04 058 Note After you have removed the screws push the locking clip at the top pull at the bottom the cover with a loud CLICK from the front cover rear part Trophy 20 Service instructions 71 5 4 8 Covers rear Replacing the rear cover Preparation e Switch off the scooter with the ignition key Instructions The following operations are required to replace the rear cover Note Suitable work area required Remove the rear cover Place the new rear cover Relevant article numbers 1012537 1012538 1012539 1012540 1012541 Rear cover Tools used Na Notice Na 110448 04 001 110448 04 019 72 Service instructions Trophy 20 5 49 Accessories Mount the crutch holder horizontal Preparation Switch off the scooter with the ignition key Instructions The following operations are required to mount the horizontal crutch ho
19. Type il 1 Wig Wag 2 Unipolar Inhibit 3 Operation Throttle Deadband 06 15 atching Inhibit 3 Speed 0 Throttle Gain 140 0 Drive Aux Output Mode 1 Throttle Operated at Power up 2 1 Inhibit 2 Trip Throttle Reference Test On Iso Test Resistor Off General Settings Soft Stop On Brake Time milli seconds 1000 Output Voltage Volts 24 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Diagnostic Flash Sequence 2 Reverse Alarm Off Pulsed Reverse Alarm Off Diagnostic Alarm Off Brake Disconnected Alarm Off Brake Fault Detect On Brake Light On Push too Fast Threshold 10 Push too Fast Timeout 1 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off 90 Technical product information Trophy 20 PGDT S Drive 90A ID no QBxxxxx onwards Speed Settings Fast Slow Motor Settings Forward Acceleration 0 1 Seconds 35 35 Current Limit Max Amps 60 Forward Deceleration 0 1 Seconds 16 16 Boost Drive Current Amps 90 Reverse Acceleration 0 1 Seconds 40 40 Boost Drive Time Seconds 10 Reverse Deceleration 0 1 Seconds 35 35 Current Foldback Threshold Amps 60 Max Forward Speed 100 100 Current Foldback Time Seconds 70 Min Forward Speed 10 10 Current Foldback Level 59 Max Reverse Speed 25 25 Motor Cooling Time Seconds 660 Min Reverse Speed 5 5 Current Foldback Temperature Deg C 80 Speed Limit Pot Enabled On Current Limit Min Amps 10 Motor Stall Timeout
20. Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the mechanical brake Note Suitable work area required Remove the cap and hexagon flange bolt to remove the rear wheel Remove the brake cable Remove the two hexagon head cap screw and remove the brake Mount the new brake Rebuild the scooter in the reverse order Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm Relevant article numbers 9004141 Brake left Tools used Screwdriver Torque wrench socket 16 mm Allen key 4 mm Loctite 243 Notice Na 110448 04 001 110448 04 002 Loctite 243 110448 04 016 110448 04 017 Note Use Loctite 243 at the indicated locations during assembling the wheelchair Trophy 20 44 Service instructions Trophy 20 Service instructions 45 Replacing the carbon brushes Preparation Switch off the scooter with the ignition key Disconnect the batteries Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the carbon brushes Note Suitable work area required Remove the rear cover Disconnect all motor connectors from the S drive controller Lock the freewheel lever Remove four hexagon bolts and remove the motor cover Remove t
21. as described in this manual and for the quality of the material of which the product is made and the manner in which the product is manufactured 2 Repairs or replacement of parts of the product that may be necessary as a result of faults that are based on qualitatively faulty material or manufacturing errors shall be carried out free of charge as long as such faults occurred within one 1 year of the date of delivery of the product to the Customer The parts to be replaced must be shipped post paid to Handicare Disassembly or assembly of these parts shall be at the expense of the Customer Therefore the following cases are not eligible for free repair or replacement as meant above The repair or replacement that is necessary in connection with faults that arise after one 1 year after the date of delivery of the Product to the Customer The repair or replacement that is required in connection with faults due to improper or careless use of the Product or that are based on the Product being used for another purpose than the one for which it is intended in which regard it applies that if the Customer is a Dealer this Dealer will indemnify Handicare against possible claims from Users or other third parties for faults based on an incorrect or careless use of the Product Parts that are subject to wear and the need for repair or replacement of the parts are the actual consequence of normal wear These can include but are not limited to tyres
22. bears the CE mark This product complies with the regulations of the Medical Devices Directive and therefore Standard Definition description Weight test dummy EU guideline 93 42 Applicable as mentioned in Appendix 1 N A The requirements from EN12182 as mentioned in NEN EN 12184 1999 NEN EN 12182 2009 Technical aids for the handicapped General requirements and test methods 160 kg October 1997 NEN EN 12184 2009 Electric wheelchairs scooters and accompanying battery chargers 160 kg Class B Requirements and test methods 2009 ISO 7176 8 Sn and test methods for static impact and fatigue strengths July 160 kg ISO 7176 9 Climate tests for electric wheelchairs and scooters N A ISO 7176 14 P and test methods for control systems for electric wheelchairs N A ISO 7176 16 Requirements for resistance to ignition of upholstered parts May 1997 N A 7 2 Technical specifications Manufacturer Handicare Model Trophy 20 3 wheels 3W Trophy 20 4 wheels 4W Maximum user weight 160 kg 25 2 stone Description 3W 4W Total length mm inches 1265 49 8 1265 49 8 Total width mm inches 660 26 660 26 Minimum height mm inches 740 29 1 740 29 1 Total weight excluding batteries kg stones 92 14 5 102 16 1 Total weight including batteries 74 Ah C20 kg stones 140 22 150 23 6 Weight of heaviest component kg stones 70 11 80 12 6 Static stability in the downwar
23. dirt and water can cause leaks as a result of which battery capacity can be reduced Clean the battery terminals and then grease them using acid free Vaseline 5 3 Tyres To ensure that your scooter performs well it is of great importance for the tyres to be kept at the right pressure Inflating the tyres The tyres are equipped with a car tyre valve Remove the caps from the valves before inflating the tyres If the tyres are not adequately inflated the range of the scooter may be reduced and the tread may wear more quickly Warning When inflating tyres never exceed the maximum recommended tyre pressure which is stated on the tyres 2 5 bar front and 3 5 bar rear Never forget to replace the valve cap after inflating the tyres The valve cap prevents dirt and sand from getting into the valve See the Maintenance table regarding tyre checks 5 4 Assembly replacement and adjustment instructions This chapter covers illustrated assembly replacement and adjustment instructions Every separate visual instruction is prefaced with Preparations Instructions suggestions and advice to help you carry out tasks or procedures more easily Notices extra notes covering information you need when executing the specific task Relevant article numbers Tools used The tools for the specific task are illustrated in the visual instructions 34 Service instructions Trophy 20 5 4 1 Front frame 3W Replacing the
24. motor cover Remove the cover and hexagon flange bolt to remove the rear wheel Remove the two hexagon head cap screws to remove the brake mounting key and brake Remove the hexagon screw and remove the free wheel lever Remove the four lock nuts and remove the transaxle and rubber mounting strips Mount the new the transaxle Rebuild the scooter in the reverse order Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm Relevant article numbers 1012530 Transaxle standard 1012529 Transaxle heavy duty Tools used Socket 7 mm Torque wrench socket 16 mm Screwdriver Allen key 4 mm Ring spanner 17 mm Loctite 243 Notice Some parts need to be replaced the replacement is indicated by a symbol Make sure the scooter is switched off 110448 04 001 110448 04 002 52 Service instructions Trophy 20 110448 04 021 110448 04 022 110448 04 023 110448 04 025 Note Use Loctite 243 at the indicated locations during assembling the wheelchair Trophy 20 Service instructions 53 Adjustment the shock absorber rear Preparation Switch off the scooter with the ignition key Instructions The following operations are required to adjust the shock absorber rear Note Suitable work area required Remove the seat Remove the battery cover
25. scooter clear of the ground Instructions The following operations are required to replace the free wheel lever Note Suitable work area required Remove the rear cover Disconnect all motor connectors from the S drive controller and the speed sensor cable Lock the freewheel lever Remove the four hexagon bolts and remove the motor cover Remove the hexagon screws and remove the free wheel lever Mount the new free wheel lever Rebuild the scooter in the reverse order Relevant article numbers 1012104 Motor brake Tools used Screwdriver Socket 7 mm Allen key 4 mm Notice Some parts need to be replaced the replacement is indicated by a tJ symbol Make sure the scooter is switched off 110448 04 001 110448 04 002 Trophy 20 50 Service instructions Trophy 20 Trophy 20 Service instructions 51 Replacing the transaxle Preparation Switch off the scooter with the ignition key Disconnect the batteries Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the transaxle Note Suitable work area required Remove the rear cover Disconnect all motor connectors from the S drive controller and the speed sensor cable Lock the freewheel lever Remove the four hexagon bolts and remove the
26. shrouds arm pads seatings etc 3 Irrespective of that stipulated under 2 it applies as far as an electric Product is concerned that with regard to the battery that forms part of the Product warranty is only given in case of faults or non functioning of the battery that are demonstrably the direct consequence of material or manufacturing errors A fault or non functioning of the battery as a result of normal wear is not covered by the warranty as meant in these warranty stipulations Similarly not covered by the warranty are faults or non functioning that are the consequence of improper or unprofessional use of the Product or the battery that is part of the Product including the incorrect charging of the battery and the failure to carry out timely and good maintenance in which context it also applies that if the Customer is a Dealer this Dealer will indemnify Handicare against possible claims from Users or other third parties that are based on the above mentioned improper or unprofessional use of the Product or the battery that is part of the Product Handicare does not guarantee batteries provided by dealers or purchased by the customer 4 The warranty conditions as mentioned in above stipulations in any case become null and void if The guidelines of Handicare for the maintenance of the Product are not or insufficiently followed A necessary repair or replacement of parts is based on neglect damage or abuse of the Product or a use of the Produ
27. 1701 Lock nut M6 24 2 9004493 Hinge pin 8x16 M6 25 1 9007360 Gas spring operating mechanism Trophy 20 Spare parts 17 Continued from 04 Steering column mirror and basket Pos Qty Article number 26 1 9007359 27 2 9005802 28 1012532 29 1 9006559 30 l 9005607 Sil 1 9004175 32 1 00000 2203 39 1 00000 4041 34 1 9004190 35 1 9004191 36 1 9004185 Description Gas spring 300N Screw Ejot K40x12 Assy Slider Gas spring Gas spring actuator cable Spiral pin heavy duty 6x32 Steering column adjustment tube Spring washer M8 Hexagon head cap screwM8x55 Spacer Handle steering adjustment Steering wheel see 05a and 05b 18 Spare parts Trophy 20 05a Console printed circuit board and throttle control ID no PBxxxxx only CE S 6 8 c 8 69 ie OY Oo A 1 o 9 A Buran EV 05a Pos Qty Article number Description 1 1 9004425 Drumbrake actuator cable 2 1 9006191 Extension cable for microswitch 3 1 00000 3719 Buttonhead screw M5x10 4 1 9004330 Brake lever 5 1 9004185 Steering wheel 6 1 00000 3200 Recessed buttonhead screw M5x12 8 1 9000904 Stop switch dummy 9 2 1008055 Throttle potentiometer 10 1 9007425 Cover steering wheel 11 4 00000 3307 Sheet metal screw 2 9x13 12 1 9004331 Cover brake position 18 1 00000 3719 Buttonhead screw M5x10 14 1 9005810 Ignition key 5 1 9006111 Ignition switch 16 2 9004303 Cover for indicator switch
28. 3 mm spring Screwdriver crosshead Note Suitable work area required Hammer plastic Remove the basket the mounting bracket for the Chaser mirrors the front cover and the front cover rear part Loctite 243 Pull the handle for steering adjustment upwards and move the steering column downwards Notice Remove the four hinge pins and the spiral pin Na Disconnect the gas spring actuator remove the hinge pin and remove the two bolts from the gas spring slider Remove the gas spring slider and loosen the hinge pin and lock nut Mount the new gas spring Rebuild the scooter in the reverse order Note Be sure you fasten all bolts and nuts with the correct torque 110448 04 001 110448 04 006 Trophy 20 Trophy 20 Service instructions 63 5 4 5 Console Replacing the throtile Preparation Switch off the scooter with the ignition key Instructions The following operations are required to replace the throttle Note Suitable work area required Remove the two sheet metal screws and the throttle disconnect in between the connector of the throttle Mount the new throttle Rebuild the scooter in the reverse order Relevant article numbers 1008055 Throttle potentiometer Tools used Screwdriver crosshead Notice Na 110448 04 001
29. 3210 3211 3212 3213 3600 3601 3602 3603 3608 3609 360a 360b 360c 360d 360e 4401 1500 1502 1600 Salty finger ref error Both clamps measuring current Progres counter error Front end spec change trip Battery bridge difference error 1 Temperature settings incorrect No internal timers Internal timer out of range Atod readings not finished before next read Unknown mux channel Hardware error Test trip latch 1 Test trip latch 2 Test trip latch 3 Test trip latch 8 Test trip latch 9 Test trip latch 10 Test trip latch 11 Test trip latch 12 Test trip latch 13 Test trip latch 14 Generic ctrl error Brake fault 1 Brake over current error High battery error Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Solenoid brake fault Solenoid brake fault High battery voltage 86 Technical product information Trophy 20 7 Technical product information 7 1 CE Declaration and standards CE
30. 3719 Buttonhead screw M5x10 14 1 9005810 Ignition key 15 1 9004432 Ignition switch 16 2 9004303 Cover for indicator switch 17 2 9004435 Indicator switch 18 1 9004302 Steering wheel cover bottom 19 1 9004301 Steering wheel cover top 20 1 9005802 Srew Ejot K40x12 21 1 9004197 Rear cover steering column 22 2 00000 2106 Washer flat M4 3xD 23 2 9005802 Screw Ejot K40x12 24 2 00000 1662 Hexagon Nut thin M4 25 2 00000 3218 Recessed buttonhead screw M4x12 26 1 1012536 Assy Dashboard speed knob 2 1012535 Assy top 28 1 9004438 Speed switch 29 3 1001730 Screw Ejot K30x10 Trophy 20 Spare parts 21 Continued from 05b Console printed circuit board and throttle control ID no QBxxxxx onwards Pos Qty Article number Description 30a 1 9007572 Tiller PCB Basic 30b 1 9007374 Tiller PCB Dual control 30c 1 9007373 Tiller PCB Full option 31 1 9007223 Console bottom 92 4 9005802 Screw Ejot K40x12 33 2 00000 3200 Recessed buttonhead screw M5x12 34 2 9004641 Throttle harness 95 5 1015323 Cable clips set 25 1 9007372 Full option steering wheel 22 Spareparts Trophy 20 O6a Wiring electronics and batteries ID no PBxxxxx only 2 Trophy20 EV 06a Pos Qty Article number Description 18 2 9006563 Battery harness 60A 1b 2 9006564 Battery harness 100A 2a 1 9006097 Power harness S Drive 90A 2b 9006101 Power harness S Drive 120A for Alpine Transaxle 3a 2 9002758 Battery 34
31. 689 Cable clip 9 1 1001796 Retaining ring 20mm 10 1 9004153 Front fork 11 2 00000 2003 Washer flat M8 12 1 00000 1702 Lock nut M8 18 1 9002166 haxagon bolt M8x150 st10 9 14 15 16 1 9004159 front wheel 3W 15 1 15010 4100 Tube 16 1 9004161 Tyre Trophy 20 Spare parts 13 02 Front frame front suspension and front wheels Trophy 20 4W NN DOG Loctite 243 9 25Nm Trophy20 EV 02 Pos Qty Article number Description 1 2 9002006 Cover grey 2 2 9004569 Hexagon flange bolt M8x12 torque 25Nm use locktite 247 9 8 00000 4026 Hexagon head cap screwM8x20 4 5 6 2 9004511 Front wheel 4W 5 2 15010 4100 Tube 6 2 9004161 Tyre 7 2 9001969 Shim ring 1 0mm 16x22mm D988 8a 1 9003408 Wheel bracket right 8b 1 9003406 Wheel bracket left 9 2 9002054 Cover hexagon head cap screw M10 black 10 4 1002242 Hexagon head cap screwM10x40 11 4 00000 1703 Lock nut M10 12 13 2 1012525 Assy Shock absorber front 4W 18 4 1002840 Skiffy fixation ring 10mm 14 1 9003444 Mounting bracket front cover 15 2 9006079 Washer flat M4x20x1 2 16 2 9005928 Haxagon bolt M4x12 17 18 1 9003392 Frame with ball head bearings 4W 18 2 9000493 Ball head bearing 6004ZZE 8 8 9005689 Cable clip 20 4 00000 1702 Lock nut M8 21 2 9004459 Swing arm lower assy 22 2 9004458 Swing arm top assy 23 4 00000 1702 Lock nut M8 24 4 9001803 Axle suspension parallel bracket 25 1 9001895 Mounting plate 26 1 1001796 Retaining
32. 948 03 006 110948 03 008 80 Service instructions Trophy 20 Mount the foot throttle Preparation Switch off the scooter with the ignition key Disconnect the batteries Instructions Note This procedure is intended for the Throphy 20 with the latest electronics In case your Trophy 20 has the dashboard as above you have the latest version electronics Contact Handicare in case you have the following dashboard older version electronics The following operations are required to mount the foot throttle Note Suitable work area required Note Remove always one finger control Replace it with cover steering wheel 9007423 Loosen the floor mat from the frame Note For mounting the foot throttle on the floor mat you have to drill two holes in the floor mat and frame Be sure you will not damage any cables mounted under the frame Determine the exact laying of the cables under the frame Reposition the cables in case they will be damaged while drilling the two holes Replace the floor mat and position the foot throttle mounting plate on the floor mat Drill the holes and mount the foot throttle mounting plate Mount the foot throttle on the mounting plate Guide the cable trough and under the frame to the electronics compartment on the backside of the scooter Remove the rear cover Connect the plug to the socket in the electron
33. Ah C5 40Ah C20 3b 2 9002759 Battery 50Ah C5 60Ah C20 BC 2 9002760 Battery 63Ah C5 74Ah C20 4 5 1 1012412 Connector cover S Drive 120A 4 5 6 1 9002457 S drive controller 120A for Alpine Transaxle 2 9006080 Hexagon head cap screwM5x25 8 2 00000 3212 Recessed buttonhead screw M4x25 9 10 1 1015385 Connector cover S drive 90A 9 10 11 1 1015386 S drive controller 90A 12 2 1007078 Hexagon head cap screw M5x16 18 1 1002558 Controller interface 14 1 9006124 Tule 15 2 9004503 Rear light LED 16 4 00000 1501 Hexagon nut M6 I 1 9006105 Horn 18 1 00000 4322 Hexagon bolt M8x12 19 1 9004431 Speed sensor 20 1 9006095 Main harness 21 1 9004419 Charging harness 22 2 9002752 Set battery connection covers 29 1 9006096 Lighting harness 24 1 9006193 Brake switch extension harness 25 1 9005911 Mounting bracket for S drve controller 26 2 00000 4036 Hexagon head cap screwM5x12 Trophy 20 Spare parts 23 060 Wiring electronics and batteries ID no QBxxxxx onwards Buran EV 06b Description Pos Qty Article number 1a 2 9006563 1b 2 9006564 2a 1 9006562 2b 1 9006561 3a 2 9002759 3b 2 9002760 ac 2 9002761 4 5 1012412 4 5 6 1 9002457 7 2 9006080 8 2 00000 3212 9 10 1 1015385 9 10 11 1 1015386 12 2 00000 4036 15 1 9004430 14 1 9006124 15 2 9004503 16 4 00000 1501 qr 1 9004433 18 1 00000 4322 19 1 9004431 20 1 9004429 21 1 9004419 22 2 9002752 Battery harness 60A Battery Har
34. ES User Interface Info 25 E o Cruise Control Em LC Tete Ee B Indicator switch left right LIGHTS SWITCH 23 CLAXON SWITCH RI Viper left vi T gt e e Intermediate 2 Viper Right n r 3 NoT connected 4 Viper left pv 1 D Intermediate fonen 2 e e Meer Ront bur 3 NOT connected 4 Standard finger throttle SpeedSelector acwp vr 1i D E Bpeedsetector Value GN rn 2 h 90 Speeadseiector AGND wT 3 SpeedSetector AVCC BN 4 DREF SD me DRIVE CONTROL SO RD 2 DREF SD 3 mrotte teft SV m 1 ES 3 rotte left Value om RD 2 E e i fhrottie teft AGND wr 3 incl wiring Fx amp e Throttte left SV Jan r D l hrottie left ValuelGWRD 2 frottie tert acnn ur 3 a E 1 VIN eav SD Ro 1 key IN PP elle inicator right 2aV MT BL 3 JOIE Indicator right WT GN 4 L j ov Sp x s izle EE Brake Scan kece pw vr 6 forte coM4es B 7 ste 5 BK 8 e ee Indicator left 24V er 5 Indicator teft ov os 19 9 Light 24V 875n4 BK YL 1 Light ov En 12 Brake Scan ker BN YL 13 Brake switch cnma85 a 14 Broke Scan 1 Broke Scan anwr 2 EM switch GND ME ee EM switch 3 3V BN 2 Emergency Switch Indicator tert 2av far 1 Blink left 24V Indicator left nc 2 Mer
35. Foot throttle information is converted by the MC into a drive signal This signal will be presented here OK 8 Miles hour reset P Set speed and distance calculations to km or miles Km icon on display is shown km km per hour micon on display is shown miles miles per hour Default km Change by pressing the DSS I switch 2 2 seconds 9 Scooter type selection This reflects the diameter of the wheels used t30 Trophy speed algorithm Trophy 30 t20 Trophy speed algorithm Trophy 20 Default t30 Change by pressing the DSS I switch 2 2 seconds 10 This reflects if a beeping sound is enabled 0 no beep when driving backward 1 beeping when driving backward default 1 Change by pressing the DSS I switch 2 2 seconds First one character of the display show b Setting the options Not all options are standard available Some options are only available as ordered at Handicare Not activated values will not be shown in the service menu 11 Cruise Control enable S e 0 disabled 1 enabled Default 0 disabled Can only be changed if Activate CC control option is set to 1 enabled Change by pressing the DSS I switch 2 2 seconds First two characters of the display show CC 12 Manual intelligent throttle switch e 0 off 1 Manual Throttle Switching MTS 2 ntelligent Throttle Switching ITS 3 ITS and MTS active Default O off Can only be change
36. I only Calibration Factor 100 Time foldback speed 96 100 Mkll only Low Battery Alarm Off Enhanced motor compensation up 96 130 MkII only Trucharge Reset Voltage Deci Volts 200 Enhanced motor compensation down 150 Mk Il only Mk II only Enhanced motor compensation up gain 1 Mk II only Inhibit Settings Factory Settings Max Min Inhibit 1 Mode 1 Acceleration 0 1 Seconds 100 11 Inhibit 1 Operation Latching Deceleration 0 1 Seconds 100 11 Inhibit 1 Speed 96 0 Forward Speed 26 100 0 Inhibit 2 Mode 1 Reverse Speed 90 100 0 Inhibit 2 Operation Latching Inhibit 2 Speed 96 0 Throttle Settings Inhibit 3 Mode 1 Throttle Type 1 Inhibit 3 Operation Poe Throttle Deadband 15 atching Inhibit 3 Speed 0 Throttle Gain 140 0 Drive Aux Output Mode 1 Throttle Operated at Power up 2 1 Inhibit 2 Trip Throttle Reference Test On Iso Test Resistor Off General Settings Soft Stop On Brake Time milli seconds 1000 Output Voltage Volts 24 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Diagnostic Flash Sequence 2 Reverse Alarm Off Pulsed Reverse Alarm Off Diagnostic Alarm Off Brake Disconnected Alarm Off Brake Fault Detect On Brake Light Off Push too Fast Threshold 10 Push too Fast Timeout 1 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off 92 Technical product information Trophy 20 7 4 Data sheet Description Remarks Nominal volta
37. Indicator rignt 24V ur m 1 MIN eSV SD RD Bink right 24V indicator right ov 2 Key IN PP 2 7 Key DUT lon 3 n 5 e ce Light ps 1 Front light 24V right av e75ma mem 2 PR 1 Power n off le ER sf PP 24V l Inhibit l Power PCB EK Gin fern ov isa CIE Hom 24V Speed sen OV BK Horn ov pk 2 Speed sensor incl Speed Sensor amp wiring amp magnet Por SN Rearindicator 24V BN 1 WIPER BN 2 Foot Throttle RearLight 24V PP 2 Por wrls BrakeLight 24V us 3 Rear left brake FootThrottie AGND WT 1 Rearindicator OV 4 e ng 6 root throttle Value GN RD 2 RearLight marsi FootThrottle AVCC BN 3 BrakeLight OV ins vr e Rearindicator 24V VT 1 RearLight 24V sk Je BrakeLight 24v RD 3 Rearinalcator OV GN 1 RearLignt ov B 5 Rearindicator 24v JEN 1 rd 07 vw les ReorLight 24v PP 2 VIN 24V Sb RD 1 BrokeLight 24V ns 3 ov SD BK 2 KEY ON OFF Rearinaicator OV pw 4 ee Key DUT GN 3 RearLight OV PP WT 5 Rear right brake se BrakeLight uc vr 6 incl wiring Bot 24V 104 max RD 1 CUN485 A BL7RD Nor cean 2 lee COMABS B LAL 2 COM Not connected 3
38. RAL mode Lever lowest position Motor brake not applied Scooter can be pushed manually A when electronics are off oy Model Year of manufacture ID number Usage indoor outdoor or both Maximum load in kg Manufactures address TYPE TYPE TYP YEAR JAAR JAHR USAGE GEBRUIKSGEBIED GEBRAUCHSGEBIET nmoowx THE NETHERLANDS VOSSENBEEMD 104 5705 CL HELMOND HANDICARE B V MAX LOAD MAX BELASTB NL C Instruction for transportation El Scooter A Warning li The scooter is not intended to be used as seat in motor vehicle 2 6 Technical specifications No changes may be made to the technical specifications 2 7 Modifications Adaptations Modifications not executed by Handicare to components and electronics of this product are not permitted Trophy 20 Tools 9 3 Tools 3 1 Tools The tools below are needed for various mechanical settings and maintenance 1 Screwdriver medium 5 1 Screwdriver crosshead 1 Hammer plastic 1 Chaser 1 Circlip pliers 1 Ring spanner 7 4 9 3 AS E 1 Torque wrench 1 Socket 7 8 10 11 12 13 16 17 1 Socket bit 6 1 Allen key 3 4 5 6 8 1 Loctite 243 1 Shock absorber adjustment key Use only high quality tools for the adjustment s described Make sure that the hexagon of the spanner is attached securely to the hexagon of the fastening article This prevents the rotat
39. ca vor Ave sud J0J28UU0I Bey UIJIM JU 79195 paads
40. ct for another purpose than the one for which it was intended Parts of the Product are replaced by parts of another origin than those used by Handicare and or parts of the Product are replaced without the permission of Handicare 5 The warranties as mentioned in stipulations 1 through 3 also become null and void if what is involved is re used by a new user within the warranty period and that such re use necessitates adaptations to the product and those adaptations are carried out without the instructions and or at the order of Handicare 6 To retain rights under the warranties delineated above the Customer must in case of damage or other calamities as rapidly as possible contact Handicare and inform them as fully as possible The possibility of taking recourse to the above mentioned warranty conditions becomes null and void for the Customer in any case after 20 workdays after the claim situation or the calamity arises that was the reason for the recourse to the warranty 7 The replacement of a part or the repair or the reconditioning of the Product within a current warranty period does not extend the warranty period 8 Handicare gives no warranty on repair to or reconditioning of the Product carried out other than under order of and or at the instructions of Handicare If repairs and or reconditioning are executed by or on behalf of a Customer the Customer indemnifies Handicare with respect to the claims of third parties who result in the br
41. d direction 2 18 gt 13 Static stability in the upward direction 5 gt 13 gt 13 Lateral static stability gt 13 gt 13 Distance range ISO 7176 4 km miles 45 28 45 28 Dynamic stability max safe slope 9 9 Maximum speed forwards km h mph 12 7 5 Alpine 12 7 5 Alpine Back angle Captain Seat E 0 103 126 0 103 126 Seat depth Captain Seat mm inches 445 17 5 445 17 5 Seat width Captain Seat mm inches 457 18 457 18 Back height excl headrest Captain Seat mm inches 406 16 406 16 Seat height to platform Captain Seat mm inches 350 450 535 350 450 535 13 8 17 7 21 1 13 8 17 7 21 1 Armrest height Captain Seat mm inches 229 273 9 10 7 229 273 9 10 7 Distance between armrests Captain Seat mm inches 457 610 18 24 457 610 18 24 Back angle Master Seat 45 85 180 45 85 180 Seat depth Master Seat mm inches 430 17 430 17 Seat width Master Seat mm inches 500 19 7 500 19 7 Back height excl headrest Master Seat mm inches 550 21 7 550 21 7 Seat height to platform Master Seat mm inches 350 425 535 350 425 535 13 8 16 7 21 1 13 8 16 7 21 1 Armrest height Master Seat mm inches 150 340 5 9 13 4 150 340 5 9 13 4 Distance between armrests Master Seat mm inches 500 19 7 500 19 7 Turning radius ISO 7176 5 mm inches 1030 40 6 1600 63 Reversing width mm inches
42. d if Activate Throttle switch option is set to 1 enabled Change by pressing the DSS I switch 2 2 seconds First two characters of the display show tS 84 Troubleshooting Trophy 20 6 Troubleshooting If the scooter doesn t function while the batteries are fully charged check the following points A Set the scooter off and then on again Check if the problem is solved B Check if all the battery connectors are properly attached and firmly connected C Check whether the freewheel handle is in the DRIVE position D Make sure the position of the speed controller has not changed E If there is a problem the lights of the battery condition meter flash Use the table below to determine the cause of the problem Indication on the display Description of problem Corrective action The complete LED bar flashes rapidly The socket LED is lit continuously after the scooter is switched on The first red LED of the LED bar is lit continuously LED bar left to right chase Two LEDs of the LED bar are lit Three LEDs of the LED bar are lit Seven LEDs of the LED bar are lit Eight LEDs of the LED bar are lit Nine LEDs of the LED bar are lit Ten LEDs of the LED bar are lit The Controller security has found something that causes a problem Short circuit in the potentiometer Cabling from the Tiller PCB to the controller interface is defective Cabling from the Tiller PCB to the touch control i
43. e 1 1012541 Assy Rear cover Moonstone blue metalic 2 1 9004129 Motor cover 9 4 00000 2106 Washer flat M4 3xD 4 4 9005927 Hexagon bolt M4x20 5 2 1012526 Assy Rear fender 6 6 00000 3624 Screw M5x8 7 8 9 1 1012521 Assy Rear bumper 8 2 9003480 Reflector red 9 1 1012522 Assy Logo button Handicare 10 2 00000 2106 Washer flat M4 3xD 11 2 9005927 Hexagon bolt M4x20 12 1 9003462 Frame cover 18 2 00000 2106 Washer flat M4 3xD 14 2 9005927 Hexagon bolt M4x20 15 1 1012516 Assy Battery cover 16 2 9003479 Reflector orange 17 1 1012519 Assy Seat post cover 30 Spare parts Trophy 20 4 3 Options DO Pos Qty Article number Description 1a 1b 1c 1d 1e 1012429 Colour exchange set Graphite black metalic 3 covers 1a 1b 1c 1d 1e 1012430 Colour exchange set Moonstone blue metalic 3 covers 1a 1b 1c 1d 1e 1012431 Colour exchange set Ruby red metalic 3 covers 1a 1b 1c 1d 1e 1012432 Colour exchange set Sparkling champagne metalic 3 covers 1a 1b 1c 1d 1e 1012433 Colour exchange set Platinum white metalic 3 covers 1008572 Assy foot throttle ID no PBxxxxx only 9007499 Assy foot throttle ID no QBxxxxx onwards 2 9000701 Trolleybag 9 4930 Rear Basket 9000620 Mounting bracket rear 4 1001813 Luggage carrier 5 1001814 Walking aid holder 6 9000703 Front bag for std bracket with locking mechanism if 1003095 Cane holder mou
44. e Trophy 20 Trophy 20 Safety 7 2 Safety 2 1 Personnel qualification Repairs may only be carried out by trained and authorised service technicians During the execution of their work they are at all times fully responsible for the fulfilment of locally applicable safety guidelines and standards Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an authorised service technician 2 2 Identification on the product Safety Safety information is indicated with the warning symbol Warning Follow the instructions carefully next to these warning symbols Not paying careful attention to these instructions could result in physical injury or damage to the scooter or the environment Wherever possible safety information is also provided in this manual in the relevant chapter 2 3 Temperature Warning Avoid physical contact with the scooter s motor The motor is continuously in motion during use and can reach high temperatures After use the motor will cool down slowly Physical contact may cause burns Ensure that the scooter is not exposed to direct sunlight for extended periods of time Certain parts of the scooter such as the seat the backrest the armrests and the steering device become hot if exposed to the sun for too long This may cause burns or skin irritation 2 4 Electromagnetic radiation and interference The scooter has been tested for comp
45. er 5 2 Batteries Always follow the instructions related to battery maintenance amp storage as given by the battery manufacturer LL Battery charger The scooter is equipped with gel batteries These batteries are fully encased and sealed and require no maintenance sticker indicates how the batteries are to be connected This sticker is located on the rear cover and on the battery cable Warning Ensure that the batteries are always well charged Do not use the scooter if the batteries are almost flat Doing so may damage the batteries and means you run the risk of coming to an unexpected standstill Ensure that the batteries are never completely flat This can seriously damage the batteries and shorten their lifespan Only use gel batteries Replacing the batteries If battery capacity is so low after fully charging that the scooter can only make short trips or can not be driven at all then the batteries have reached the end of their lifespan Replace the batteries as soon as possible Warning Once the new batteries have been put in place they will need to be charged and run in Battery charger For the correct way to dispose of batteries see A Scooter Used scooters and the environment Trophy 20 Service instructions 33 Cleaning the batteries Gel batteries are maintenance free However attention may be paid to the following matters Note Ensure that the batteries remain clean and dry
46. eration 0 1 Seconds 95 35 Current Foldback Threshold Amps 80 Max Forward Speed 100 100 Current Foldback Time Seconds 70 Min Forward Speed 10 10 Current Foldback Level 59 Max Reverse Speed 96 25 25 Motor Cooling Time Seconds 660 Min Reverse Speed 96 5 5 Current Foldback Temperature Deg C 50 Speed Limit Pot Enabled On Current Limit Min Amps 10 Motor stall timeout Seconds 0 Mk only Operation Settings Motor Compensation milli Ohms 25 Sleep timer minutes 0 Anti Rollback Level 12 Throttle Invert Yes Pull away Delay centi Seconds 0 Slope Factor 900 Battery Settings Anti Rollback Velocity 0 Low battery Flash Level Bars 0 Bracking current limit Amps 120 MkII only Cable Resistance milli Ohms 50 Time foldback bracking current Amps 120 Mk Il only Calibration Factor 100 Time foldback speed 96 100 Mkll only Low Battery Alarm Off Enhanced motor compensation up 130 MkII only Trucharge Reset Voltage Deci Volts 200 Enhanced motor compensation down 150 Mk II only MK only Enhanced motor compensation up gain 1 Mk II only Inhibit Settings Factory Settings Max Min Inhibit 1 Mode 1 Acceleration 0 1 Seconds 100 11 Inhibit 1 Operation Latching Deceleration 0 1 Seconds 100 11 Inhibit 1 Speed 96 0 Forward Speed 26 100 O Inhibit 2 Mode 1 Reverse Speed 96 100 0 Inhibit 2 Operation Latching Inhibit 2 Speed 96 0 Throttle Settings O Single ended Inhibit 3 Mode 1 Throttle
47. front wheel and fork Preparation Switch off the scooter with the ignition key Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the front fork 3W Remove the front cover and the front cover rear part Remove the retaining ring and spiral pin Remove the complete fork with wheel Remove the hexagon nut washer and bolt to take out the wheel Replace the new front fork 3W Rebuild the scooter in the reverse order Notice Some parts need to be replaced the replacement is indicated by a symbol Some operations have to be carried out by two persons this is indicated by a symbol Relevant article numbers 9004153 Front fork Tools used Torque wrench socket 13 mm Screw driver crosshead Hammer plastic Chaser Circlip pliers Open ended spanner 13 mm 110448 04 001 110448 04 002 110448 04 060 Trophy 20 Service instructions 35 36 Serviceinstructions Trophy 20 5 4 2 Front frame 4W Replacing the front wheel Preparation Switch off the scooter with the ignition key Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the front wheel Remove the cover and the four hexagon screws to remove the front wheel
48. ge 24 V Current main fuse 50 A Max slope percentage 16 Max slope with a start 9 160kg M Motor nominal power 950 Watt Gearing ratio motor gearbox 4100 195 i Wheel diameter front 320x60 mm Wheel diameter rear 360x80 mm Type of tyre front 12 x 2 Type of tyre rear 3 00 8 Tyre pressure maximum front 225 bar Tyre pressure minimum rear 3 5 bar Maximum dimenstions batteries L262xW173xH211 mm Battery connection type Anderson Maximum allowable charger voltage 30 V Maximum allowable charger current 8 RMS charger Maximum battery capacity C20 74 Ah Maximum battery capacity C5 63 Ah Forces on levers etc Electronic switches lt 13 5 Drive lever operation 20 N Parking brake 60 N Connection of charger 60 N Weight 3W AW bat size 40Ah 60Ah 74Ah 40Ah 60Ah 74Ah Frame 70 70 70 80 80 80 Chair 19 19 19 19 19 19 Basket 2 4 2 4 2 4 2 4 2 4 2 4 Batteries 28 8 38 6 48 6 28 8 38 6 48 6 Total 120 130 140 130 140 150 99 Technical product information Trophy 20 7 5 Electrical diagram Trophy 20 ID no PBxxxxx only V 7619006 Jaqunu BuiwpJg wWDJ D finda 3 AG PJDPUDIG SMIP S OZ AUOT D21J1 23 3 Dal vort 93N da vort A0E sus a398vHO LIEIHNI vor AO N3oaeHO T
49. gh the menu shown below f any other button other than the DSS I horn E hazard button G is switched during the service menu the display returns to the user menu and will show actual speed When the batteries of the scooter are removed the service information shall not get lost for at least 1 year The display will blink at a frequency of 1 2HZ indicating this value can be changed 1 Total km 1 S The amount of km the scooter has driven after the last time this value was reset Resettable by pressing the DSS 1 switch 2 2 seconds 2 Total km 2 S The amount of km the scooter has ever driven in its total life 3 Actual battery voltage B The actual battery voltage measured real time 4 Hours ON The amount of hours the scooter has been switched on in its life First one character of the display show H Trophy 20 Service instructions 83 5 Hours Driven The amount of hours the scooter has driven more than 5 of its maximum speed in its life First one character of the display show h 6 Software version First one character of the display show F 7 Signal Actual throttle input Range Actual input of the active throttle available R First characters of the display show C The Icons on the tiller display will indicate the active throttle right hand is lit right hand side throttle is active left hand is lit left hand side throttle is active nohand icons are lit foot throttle is active
50. gnostic Flash Sequence 2 Reverse Alarm Off Pulsed Reverse Alarm Off Diagnostic Alarm Off Brake Disconnected Alarm Off Brake Fault Detect On Brake Light Off Push too Fast Threshold 10 Push too Fast Timeout 1 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off Trophy 20 Technical product information 91 PGDT S Drive 120A ID no QBxxxxx onwards Speed Settings Fast Slow Motor Settings Forward Acceleration 0 1 Seconds 35 35 Current Limit Max Amps 110 Forward Deceleration 0 1 Seconds 16 16 Boost Drive Current Amps 120 Reverse Acceleration 0 1 Seconds 40 40 Boost Drive Time Seconds 10 Reverse Deceleration 0 1 Seconds 35 35 Current Foldback Threshold Amps 80 Max Forward Speed 100 100 Current Foldback Time Seconds 70 Min Forward Speed 10 10 Current Foldback Level 59 Max Reverse Speed 25 25 Motor Cooling Time Seconds 660 Min Reverse Speed 5 5 Current Foldback Temperature Deg C 50 Speed Limit Pot Enabled On Current Limit Min Amps 10 Motor stall timeout Seconds 0 Mk Il only Operation Settings Motor Compensation milli Ohms 25 Sleep timer minutes 0 Anti Rollback Level 12 Throttle Invert Yes Pull away Delay centi Seconds 0 Slope Factor 900 Battery Settings Anti Rollback Velocity 0 Low battery Flash Level Bars 0 Bracking current limit Amps 120 Mk II only Cable Resistance milli Ohms 50 Time foldback bracking current Amps 120 MkI
51. he cover and hexagon flange bolt to remove the rear wheel Remove the two hexagon head cap screws to remove the brake mounting key and brake Remove the hexagon screw and remove the free wheel lever Remove the four lock nuts and remove the transaxle and rubber mounting strips Unscrew the carbon brush cover Pull the carbon brush out of the housing and remove the brush Inspect the collector on the anchor of the motor if the collector is seriously worn replace the entire drive unit Clean the collector on the anchor of the motor from dust with pressed air Place the carbon brush in the holder this can be done in one way only Screw the new plastic screw cap onto the carbon brush holder Rebuild the scooter in the reverse order Relevant article numbers 1012313 Motor brush set 4 carbon brushes with covers Tools used Lifting device Screwdriver Allen key 4 mm Socket 7 mm 10 mm and 16 mm Notice Some parts need to be replaced the replacement is indicated by a symbol Make sure the scooter is switched off 110448 04 001 110448 04 002 Trophy 20 46 Service instructions Trophy 20 48 Serviceinstructions Trophy 20 Replacing the motor brake Preparation Switch off the scooter with the ignition key Disconnect the batteries Use a Lifting device to raise the
52. he swing arm out of its position Replace the new swing arm Rebuild the scooter in the reverse order Relevant article numbers 9004459 Swing arm lower assy 9004458 Swing arm top assy Tools used Torque wrench socket 7 mm 13 mm socket bit 6 mm Torque wrench socket 17 mm Allen key 8 mm Screwdriver Open ended spanner 11 mm Notice Na 110448 04 001 110448 04 002 Service instructions 41 Trophy 20 42 Service instructions Trophy 20 5 4 3 Rear frame Replacing the rear wheel Preparation Switch off the scooter with the ignition key Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the rear wheel Note Suitable work area required Remove the cover and four hexagon head cap screws to remove the rear wheel Mount the new rear wheel in the reverse order Relevant article numbers 1014662 Rear wheel 8 right black assy 1014661 Rear wheel 8 left black assy Tools used Screwdriver Torque wrench socket bit 6 mm Notice Na 110448 04 001 110448 04 002 110448 04 014 110448 04 015 Trophy 20 Service instructions 43 Replacing the mechanical brake Preparation Switch off the scooter with the ignition key
53. head cap screws and remove the controller Mount the new controller Rebuild the scooter in the reverse order Relevant article numbers 9002457 S drive controller 120A 9004513 S drive controller 90A Tools used Allen key 5 mm Notice n case of S drive controller 90A watch out for motor harness and power harness 110448 04 001 110448 04 019 110448 04 020 110448 04 055 Trophy 20 Service instructions 69 5 4 7 Covers front Replacing the front tiller cover Preparation Switch off the scooter with the ignition key Instructions The following operations are required to replace the front tiller cover Note Suitable work area required Remove the basket and the mounting bracket for the mirrors Loosen the two bolts to remove the front tiller cover Mount the new front tiller cover Rebuild the scooter in the reverse order Relevant article numbers 9004442 9004445 9004448 9004451 9004454 Front tiller cover Tools used Socket 10 mm Screwdriver crosshead Notice Make sure the scooter is switched off 110448 04 001 110448 04 006 110448 04 056 70 Service instructions Trophy 20 Replacing the front cover Preparation Switch off the scooter with the ignition key Instructions The following operations are required to replace the front cover Note
54. ics compartment and replace the rear cover Relevant article numbers 9007083 Foot throttle Advanced electronics 1008730 4 8x19 self tapping screw Tools used Allen key 3 mm Metal drill 6 mm Drill e Screwdriver crosshead 110948 03 019 Determine the exact laying of the cables under the frame Note Reposition the cables in case they will be damaged while drilling the two holes Service instructions 81 Trophy 20 82 Service instructions Trophy 20 5 5 Display menu settings Starting the service menu for ID no PBxxxxx only A Kilometer total user R Reset total user DS Kilometer total scooter D Hours on total scooter D Battery voltage Leave dealer menu Hold the hazard light button and press the left horn button briefly Push the button 3 sec Hold the hazard light button and press the left horn button briefly Hold the hazard light button and press the left horn button briefly Hold the hazard light button and press the left horn button briefly Any other button Starting the service menu from ID no QBxxxxx onwards Pushing the hazard button G together with the claxon button E more than 2 seconds the service menu shall be visible First information shown after starting the service menu is the Total km 1 Pushing the hazard button again G allows you to scroll throu
55. ility programmer PG LED code Trip code Errortype 1 2c00 Low battery error 1 2c01 Low battery error 2 3B01 Motor fault 1 3 1400 Bridge fault 1 4 7000 Startup with push selected 4 7001 Push activated in drive mode 6 1e03 Inhibit activated 7 0810 Tiller fault 1 7 0814 Tiller reference error 7 0815 Tiller lo reference error iG 0816 Tiller high reference iso error 0817 Tiller lo reference error iG 0300 Speed Limit Potentiometer wiper open r 1402 Front end spec change trip iG 2101 Tiller displaced error 8 0002 Eeprom calibration checksum error 2 8 0003 Eeprom program checksum error 2 8 0100 Running checksum 1 8 0203 Eeprom calibration checksum error 1 8 0204 Eeprom program checksum error 1 8 1501 Brake fault 2 8 1705 Relay fault 1 8 1802 Watchdog voltage ref error Explanation Low battery voltage Low battery voltage Motor disconnected Motor wiring fault Parking brake off Parking brake off Inhibit active Throttle trip Throttle trip Throttle trip Throttle trip Throttle trip Throttle trip Throttle potentiometer trip Throttle displaced at power up Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Trophy 20 Troubleshooting 85 00000000 CO OO OO OO OO OO OO OO OO OO CO OO OO OO OO OO OO OO 1805 1b20 2102 2404 3100 3102
56. ion of hexagons of fastening articles and spanners that may affect proper adjustment The following tools are needed for various electronic settings PG pc programmer Adaptation of the drive programs and technical settings 1 PR0210 B version Reading out the fault history BG Alternative device for PC Adaptation of the drive programs 1 prog and technical settings 10237 Reading out the fault history 10 Spare parts Trophy 20 4 Spare parts 4 1 Use of the parts lists This document is meant as a reference book to be used to order parts for the scooter that is shown on the front cover How to order When ordering parts please specify D number see the identification plate Group to which the relevant part belongs Article number Number of parts required Description in the relevant language Dimensions if applicable Remark Ifa part does not have a position number it means that the part concerned cannot be purchased separately The part concerned is part of the assembly shown This assembly must be ordered as one piece It has to be replaced in its entirety Boxed position numbers refer to the relevant drawing Order address Please mail or fax your orders to your supplier Service technicians Repairs may only be carried out by trained and authorised service technicians During the execution of their work they are at all times fully responsible for the fulfilment of locall
57. ion 1263 Ball headbearing 6004 ZZE into 9000493 Ball head bearing 6004 2NSE 14 38 03 Changed article numbers 9004144 and 9004145 into 1014661 and 1014662 14 03 Added position 7 00001 1463 Sticker tire pressure 3 5 Bar 18 05 Changed article number 9004438 into 9006110 18 05 Changed article number 9004432 into 9006111 27 Added options position 2 till 13 85 Changed driving program S drive 120A 2012 V2 3 4 Changed table of content Tr 04 Changed article number 9000610 into 9006559 18 05 Changed article number 9004435 into 9006106 19 05 Changed article numbers 9000496 and 9004304 into 1015179 and 9007223 20 06 Changed article number and description 9005147 Battery harness into 9006563 Battery harness fused 60A 20 06 Added position 1b 9006564 Battery harness fused 100A for Alpine transaxle 20 06 Changed article numbers 9006097 9006101 and 9004430 into 9006562 9006561 and 1002558 21 07 Deleted article number 9005628 is no spare part 22 23 08 09 Changed article numbers 9004443 9004446 9004449 9004452 and 9004455 into 1015363 24 1015364 1015365 1015366 and 1015367 27 4 3 Changed price and article number 1012456 into 1015401 46 The article numbers of the standard and heavy duty transaxle were reversed This is corrected 67 Changed article numbers 9004443 9004446 9004449 9004452 and 9004455 into 1015363 1015364 1015365 1015366 and 1015367 18 Changed article number 1012456 into 1015401 2012 V3 5 8 Textua
58. ion on the product 7 2 3 Temperature 7 2 4 Electromagnetic radiation and interference 7 2 5 Markings on the scooter 8 2 6 Technical specifications 8 2 7 Modifications Adaptations 8 3 E 9 3 1 Tools 9 4 Spare PAIS jada COR EE dec 10 4 1 Use ofthe parts lists 10 4 2 Overview exploded views 11 01 Front frame front fork and front wheel Trophy 20 3W 12 02 Front frame front suspension and front wheels Trophy 20 4W 13 03 Rear frame drive unit and rear wheels 14 04 Steering column mirror and basket 16 05a Console printed circuit board and throttle control ID no PBxxxxx only 18 05b Console printed circuit board and throttle control ID no QBxxxxx onwards 20 06a Wiring electronics and batteries ID no PBxxxxx only 22 06b Wiring electronics and batteries ID no QBxxxxx onwards 23 07 Seat and seat post 24 08 Covers Trophy 20 3W 25 09 Covers Trophy 20 4W 27 10 Covers common 29 4 3 Options 30 D A 31 5 1 Maintenance plan 31 5 2 Batteries 32 5 3 Tyres 33 5 4 Assembly replacement and adjustment instructions 33 5 4 1 Front frame 3W 34 5 42 Front frame 4W 36 5 4 3 Rear frame 42 5 4 4 Steering column 58 5 4 5 Console 63 5 4 6 Electronics 68 5 4 7 Covers front 69 5 4 8 Covers rear 71 5 4 9 Accessories 72 5 5 Display menu settings 82 6 Troubleshoot ga
59. iul il 9005156 Seat post bolt Trophy 20 Spare parts 25 08 Covers Trophy 20 3W Trophy20 EV 08 Pos Qty Article number Description 1 2 9005802 Screw EJOT K40x12 2 9003458 Front cover upper part 3a 2 9006094 Indicator 12V ID no PBxxxxx only 3b 2 9003478 Indicator 24V ID no QBxxxxx onwards 4 2 9005802 Screw EJOT K40x12 5 2 00000 2106 Washer flat M4 3xD 6 1 9003460 Front cover rear part 7a 1 9003475 Side skirt right 3W 7b 1 9003474 Side skirt left 3W 8 2 9005928 Hexagon bolt M4x12 9 2 9006079 Washer flat M4x20 10 2 9005927 Hexagon bolt M4x20 11 2 00000 2106 Washer flat M4 3xD 12 1 9003476 Floormat 3W 13a 1 9004571 Front inner fender right 3W 13b 1 9004570 Front inner fender left 3W 14 4 9005928 Hexagon bolt M4x12 15a 1 9003473 Front fender right 3W 15b 1 9003472 Front fender left 3W 16 2 00000 2106 Washer flat M4 3xD 17 2 9005928 Hexagon bolt M4x12 18 1 9003457 Head light cover 19 1 9005802 Screw EJOT K40x12 20a 9004442 Front tiller cover Ruby red metalic 20b 1 9004445 Front tiller cover Platinum white metalic 20c 1 9004448 Front tiller cover Sparkling champagne metalic 20d 1 9004451 Front tiller cover Graphite black metalic 20e 1 9004454 Front tiller cover Moonstone blue metalic 21 2 00000 3218 Recessed buttonhead screw M4x12 26 Spare parts Trophy 20 Continued from 08 Seat and seat post Description Front cover Ruby red metalic Front cover Platinum white
60. l changes in Introduction and Safety chapters 11 Updated table of content added drawing number 5b and 6b 13 02 Changed article number 90056891 into 9005689 16 04 Changed article number 9006230 9006125 and 9000685 into 9006130 9006544 and 9007360 17 04 Changed article number and description 9004162 Gas spring 200N into 9007359 Gas spring 300N 18 05a Changed QTY of position 10 and 21 Deleted position 7 stop switch Changed description of position 12 article number 9004331 Changed article number of position 27 1012535 into 9007365 Added position 34 and 35 9004641 Throttle harness and 1015323 Cable clips 20 05b Added exploded view and spare part list Console printed circuit board and throttle control according electronics ID no QBxxxxx onwards 22 06a Changed position 1 90005147 in 1a and 1b 9006563 Battery harness 60A and 9006564 Battery harness 100A Changed article numbers 9006562 and 9006561 into 9006097 and 9006101 Deleted article numbers 9004513 and 9004430 and added article numbers 1015385 1015386 and 1002558 instead Changed price of article number 9004503 Changed position of article numbers 1007078 9006096 9006193 9005911 and 00000 4036 Added article number 9002752 Set battery connection covers 29 06b Added exploded view and spare part list Wiring electronics and batteries according electronics ID no QBxxxxx onwards 24 07 Changed position 14 into 9006157 Ring seat post cover Changed description a
61. lder Note Suitable work area required Mount the horizontal crutch holder with two bolts on the seat frame Relevant article numbers 1003095 Crutch holder mounted to chair horizontal Tools used Open ended spanner 10 mm ad Pa pet PE 110948 03 003 Trophy 20 Service instructions 73 Mount the crutch holder vertical Preparation Relevant article numbers Switch off the scooter with the ignition key 2537 Crutch holder mounted to chair vertical Instructions Tools used The following operations are required to mount the vertical Allen key 6 mm crutch holder Note Suitable work area required Remove the armrest from the backrest frame Mount the vertical crutch holder and the armrest with two bolts back on the backrest frame UE See es M 110948 03 010 MXN 110948 03 011 74 Service instructions Trophy 20 Mount the crutch holder chassis Preparation Relevant article numbers Switch off the scooter with the ignition key 1012515 Crutch holder mounted to chassis Instructions Tools used The following operations are required to mount the crutch Torque wrench socket 7 mm holder on the chassis Metal drill 4 mm Note Suitable work area required Drill Remove the rear cover Remove the two hexagon bolts and washers to remove the rear bumper Mount the c
62. liance with the applicable requirements regarding electromagnetic radiation EMC requirements The Trophy 20 s immunity level is 20 volt metre Note It cannot be excluded that electromagnetic radiation emanating from mobile telephones medical apparatus and other sources may have an influence on the scooter It cannot be excluded that the scooter will interfere with the electromagnetic fields of for example shop doors burglar alarm systems and or garage door openers In the unlikely event that such problems do occur you are requested to notify your dealer immediately Powered wheelchairs and scooters can be affected by sources of radio waves such as radio and TV transmitters amateur radio stations lifts transmitting equipment stereo radios and mobile telephones If the scooter s electronics are not well shielded sensitive electrical devices such as shop alarm systems and garage door openers can be affected The scooter has been tested for such interference Please report any problems of this nature to your dealer immediately The following advices are intended to prevent the electric scooter from being driven unintentionally which could lead to serious injury 1 Do not turn on any manually controlled equipment for personal communication such as 8 radio transmitter or mobile telephone while the electric scooter is switched on 2 Keep at 8 distance from transmitter equipment such as radio and TV stations 3 If the scooter
63. ly Inhibit Settings Factory Settings Max Min Inhibit 1 Mode 1 Acceleration 0 1 Seconds 100 1 Inhibit 1 Operation Latching Deceleration 0 1 Seconds 100 11 Inhibit 1 Speed 96 0 Forward Speed 96 100 10 Inhibit 2 Mode 1 Reverse Speed 96 100 0 Inhibit 2 Operation Latching Inhibit 2 Speed 96 0 Throttle Settings Inhibit 3 Mode il Throttle Type 0 Single ended 1 Wig Wag 2 Unipolar Inhibit 3 Operation Non Throttle Deadband 15 Latching Inhibit 3 Speed 0 Throttle Gain 140 Aux Output Mode 1 Throttle Operated at Power up 2 0 Drive 1 Inhibit 2 Trip Throttle Reference Test On Iso Test Resistor Off General Settings Soft Stop On Brake Time milli seconds 1500 Output Voltage Volts 24 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Diagnostic Flash Sequence 2 Reverse Alarm Off Pulsed Reverse Alarm Off Diagnostic Alarm Off Brake Disconnected Alarm Off Brake Fault Detect On Brake Light On Push too Fast Threshold 10 Push too Fast Timeout 1 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off Trophy 20 Technical product information 89 PGDT S Drive 120A ID no PBxxxxx only Speed Settings Fast Slow Motor Settings Forward Acceleration 0 1 Seconds 95 35 Current Limit Max Amps 110 Forward Deceleration 0 1 Seconds 16 16 Boost Drive Current Amps 120 Reverse Acceleration 0 1 Seconds 40 40 Boost Drive Time Seconds 10 Reverse Decel
64. metalic Front cover Sparkling champagne metalic Front cover Graphite black metalic Front cover Moonstone blue metalic Hexagon head cap screwM4x20 Head light Hexagon nut M6 Front cover bottom Push rivet Hexagon bolt M4x20 Hexagon nut M6 Front bumper 3W Pos Qty Article number 22a 1 1015363 22b 1 1015364 22 1 1015965 22d 1 1015366 22e 1015967 23 2 00000 4060 24 1 9004428 25 2 00000 1507 26 1 9003459 27 2 9004652 28 2 9005927 29 2 00000 1507 30 1 1015454 31 4 9005802 Screw EJOT K40x12 Trophy 20 Spare parts 27 09 Covers Trophy 20 4W Ana 188 Ga 18b I 18d 18d 180 18e fa 18c 7 9 ol o A 8 y em o Q8 Trophy20 EV 09 Pos Qty Article number Description 1 2 9005802 Screw EJOT K40x12 2 9003458 Front cover upper part 3a 2 9006094 Indicator 12V ID no PBxxxxx only 3b 2 9003478 Indicator 24V ID no QBxxxxx onwards 4 2 9005802 Screw EJOT K40x12 5 2 00000 2106 Washer flat M4 3xD 6 1 9003460 Front cover rear part 8 1 9003467 Side skirt right 4W 7b 1 9003466 Side skirt left AW 8 2 00000 2106 Washer flat M4 3xD 9 2 9005927 Hexagon bolt M4x20 10 1 9003468 Floormat 4W 11a 1 9003465 Front fender right 4W 11b 1 9003464 Front fender left 4W 12 2 00000 2106 Washer flat M4 3xD 18 2 9005928 Hexagon bolt M4x12 14 1 9003457 Head light cover 15 1 9005802 Screw EJOT K40x12 16a 1 9004442 Fr
65. n concerning specific settings maintenance or repair works please contact the Handicare Customer Service department They are always prepared to help you Ensure you have at hand Model Year of manufacture D number 1 2 Identification of the product The identification plate contains the following data Model Year of manufacture ID number Usage indoor outdoor or both Maximum load in kg Manufactures address TYPE TYPE TYP YEAR JAAR JAHR USAGE GEBRUIKSGEBIED GEBRAUCHSGEBIET mmoomg A 2 3 T w I lj z m B E a 26 a ug ram or an no 9o oR gt wu 5 ul E a lt zs See for the location of the identification plate markings on the scooter 6 Introduction Service manual Trophy 20 Trophy 20 1 3 Symbols used in this manual Note Pointing out possible problems to the user of this manual Caution Advice for the user of this manual to prevent damage to the product AN Warning Warnings for the user of this manual to prevent personal in jury Not following these instructions may result in physical injury damage to the product or damage to the environment Reference symbol When necessary this service manual refers to other manuals as shown below Battery charger refers to the user manual of the battery charger Scooter refers to the general user manual of th
66. nd the front bumper Remove the Allen hexagon screws and locknut form the shock absorbers on the swing arm top and lower assy Remove shock absorber Adjust the new shock absorber according the specifications Replace the new and adjusted shock absorber Rebuild the scooter in the reverse order Note Be sure you fasten all bolts and nuts with the correct torque Relevant article numbers 1012525 Shock absorber front Tools used Torque wrench socket 17 mm Socket 7 mm Screwdriver crosshead Allen key 8 mm 9000825 Suspension adjustment key Notice Position 0 soft and position 4 hard 110448 04 001 110448 04 002 Service instructions 39 Trophy 20 40 Serviceinstructions Trophy 20 Replacing the swing arms top and lower assy Preparation Switch off the scooter with the ignition key Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the swing arms Note Suitable work area required Remove the front cover and the front spoiler Remove the cover and the hexagon bolt to remove the front wheel Remove the hexagon screw from the lower swing arm Remove shock absorber and the two axle suspension parallel bolts Remove the lock nut at the wheel side of the swing arm and turn t
67. ness 100A Power harness S Drive 90A Power harness S Drive 120A Battery 50Ah C5 60Ah C20 Battery 63Ah C5 74Ah C20 Battery 72Ah C5 86Ah C20 Connector cover S drive controller 120A Hexagon head cap screw M5x25 Recessed buttonhead screw M4x25 Connector cover S drive 90A S drive controller 90A Hexagon head cap screw M5x12 Controller interface Tule Rear light LED Hexagon nut M6 Horn Hexagon bolt M8x12 Speed sensor Main harness Charging harness Set battery connection covers 24 Spareparts Trophy 20 07 Seat and seat post RA Trophy20 EV 07 Pos Qty Article number Description 1 2a 2b 1 100286 1 Master seat with armrests 2a 1 118 00221 000 Armrest right Master seat 2b 1 118 00231 000 Armrest left Master seat 3 4 1 9000034 Seat frame with slider Master seat 4 1 9000042 Seat fixation strip Master seat 5 1 9000933 Nylon bearing seat post Master seat 6 1 1012523 Assy Seat post std 7 1 00000 3723 Button head screw M6x8 8a 1 1008995 Captain seat standard 8b 1 1009244 Captain seat with high back 9a 1 1008999 Armrest right Captain seat 9b 1 1008998 Armrest left Captain seat 10 2 232103 Armrest pad PU Captain seat 11 1 1008996 Seat frame with slider Captain seat 12 4 229001 Thumb screw 13 2 1009001 Detent button 14 1 9006157 Ring seat post cover 5 1 1012520 Assy seat post Captain seat incl nylon bearing 16 1 00000 3716 Button head screw M6x16
68. nted to chair horizontal 8 2537 Cane holder mounted to chair vertical 9 1012515 Cane holder mounted to chassis 10 1009251 Mirror right 11 1015401 Anti tip set 9000825 Adjustmenttool for rear spring 12 9001135 Basket standard 13 9006137 Basket large only without locking mechanism 1015507 Lap strap with roll up for Master Seat Trophy 20 Service instructions 31 5 Service instructions This document is a reference book to be used to order parts for the scooter model shown on the front cover 5 1 Maintenance plan Below we have indicated what needs to be checked how often this should be done and by whom To be carried out by Time Description User Dealer Daily Charging the batteries after each use x Weekly Checking the tyre pressures X Cleaning the scooter X Mon Cleaning the upholstery if necessary x Every three Grease the seat s swivel mechanism the seat needs to be removed for this See months Removing the seat Lithium grease is recommended Annually Inspecting the electrical system Checking the batteries Inspecting the drive see 7 6 Inspecting the mechanical parts Annually Inspecting the bearings Inspecting the suspension Checking the tyres Checking all fastenings and bolts tighten if necessary XX IX X 0X X Sign the inspection record table in the user manual
69. oadest sense of the word from such repairs or reconditioning Trophy 20 Warranty 97 8 2 Statement of liability Irrespective of what is determined regarding liability in the general conditions applicable to the Product with regard to liability in any case the following applies A Taking into consideration the following stipulations Handicare only accepts liability for loss due to death or physical injury that is the result of a defect in the Product for which Handicare is responsible and for damage to another object that is the private property of the user of the Product as long as said loss is the direct result of a fault in the Product B Handicare accepts no other or further liability than delineated under 1 In particular Handicare accepts no liability for consequential damage in any form whatsoever Used scooters and the environment CA a If your scooter is no longer needed or needs to be replaced it can usually be taken back by your dealer If this is not possible please contact your local authorities for the possibilities of recycling or an environmentally friendly way of disposing of the used materials For the production of the scooter several plastics and metals have been used The scooter also contains electronic components that must go to electronic waste Used batteries belong to chemical waste 98 Trophy 20 Version Page Draw Changes 2011 V1 2012 V1 12 01 Changed article number and descript
70. ont tiller cover Ruby red metalic 16b 1 9004445 Front tiller cover Platinum white metalic 16c 1 9004448 Front tiller cover Sparkling champagne metalic 16d 9004451 Front tiller cover Graphite black metalic 16e 1 9004454 Front tiller cover Moonstone blue metalic VZ 2 00000 3218 Recessed buttonhead screw M4x12 18a 1 1015363 Front cover Ruby red metalic 18b 1 1015364 Front cover Platinum white metalic 18c 1 1015365 Front cover Sparkling champagne metalic 18d 1 1015366 Front cover Graphite black metalic 18e 1 1015367 Front cover Moonstone blue metalic 28 Spare parts Trophy 20 Continued from 09 Covers Trophy 20 4W Pos Qty Article number Description 19 2 00000 4060 Hexagon head cap screwM4x20 20 1 9004428 Head light 24 2 00000 1507 Hexagon nut M6 22 1 9003459 Front cover bottom 23 2 9004652 Push rivet 24 2 9005927 Hexagon bolt M4x20 25 2 00000 1507 Hexagon nut M6 26 9003469 Front spoiler uf il 9003470 Front bumper 4W 28 2 9005802 Screw EJOT K40x12 29a 1 9004573 Front inner fender right 4W 29b 9004572 Front inner fender left 4W 30 4 9005928 Hexagon bolt M4x12 Trophy 20 Spare parts 29 10 Covers common Trophy20 EV 10 Pos Qty Article number Description 18 1 1012537 Assy Rear cover Ruby red metalic 1b 1 1012538 Assy Rear cover Platinum white metalic 1 1012539 Assy Rear cover Sparkling champagne metalic 1d 1012540 Assy Rear cover Graphite black metalic f
71. r preventative service checks are important to verify the condition of the parts and enables to replace them at the right time Therefore see the new service check instructions below Service checks instructions Check if dimensions motor brushes satisfy minimum dimensions as indicated in the illustrations accordingly to the table below Pari Plan service check Motor brush At least once a year or every 2000 km Clean the collector on the anchor of the motor with pressed air from dust 18 New brush maximum 18 mm and minimum 8 mm dimensions 96 Warranty Trophy 20 8 Warranty 8 1 Provisions of warranty Warranty In the warranty and liability provisions the following terms are defined as follows Product The manual or electric wheelchair or scooter manufactured and supplied by Handicare Customer The person who directly obtains a product from Handicare Dealer The person who supplies a product obtained from Handicare to third parties User The person who uses a product manufactured by Handicare Irrespective of what has been determined concerning warranty conditions in the general terms and conditions applicable to the product the following shall in any case apply with regard to the warranty 1 Except insofar as described otherwise in the provisions below Handicare guarantees the product for its suitability for the purpose for which the product is intended all of these points
72. ring 20mm 27 1 9003403 Steer shaft 28 4 00000 1702 Lock nut M8 28 29 2 1012524 Assy Steering bar 14 Spare parts Trophy 20 03 Rear frame drive unit and rear wheels OG Trophy20 EV 03 Pos Qty Article number Description 1 2 9002006 Cover grey 2 2 1012527 Assy Wheel bolt 9 8 00000 4026 Hexagon head cap screwM8x20 4a 5 6 1 1014662 Rear wheel 8 right black assy 4b 5 6 1 1014661 Rear wheel 8 left black assy 5 2 1003249 Tube 6 2 9004146 Tyre Tf 2 00001 1463 Sticker tire pressure 3 5 Bar 8a 1 9004143 Drum brake right 8b 1 9005853 Drumbrake left 9 1 9000642 Speed sensor magnet 10 1 9006080 Hexagon head cap screwM5x25 11 1 1012104 Motor brake 12 1 1012106 Free wheel lever 18 1 1012313 Carbon brushes with covers set of 4 14a 1 1012529 Assy Transaxle Alpine for S Drive 120A 14b 1 1012530 Assy Transaxle std 15 4 00000 1703 Lock nut M10 16 2 1012124 Key for transaxle 17 2 9004564 Brake mounting 18 4 00000 4004 Hexagon head cap screwM6x45 19a 1 9004142 Brake right 19b 1 9004141 Brake left 20 2 9000689 Rubber mounting strip 21 1 9006042 Hexagon head cap screwM10x85 22 2 00000 2004 Washer flat M10 23 2 00000 1703 Lock nut M10 24a 1 9000603 Shock absorber standard 24b 1 9000683 Shock absorber heavy duty Trophy 20 Spare parts 15 Continued from 03 Rear frame drive unit and rear wheels 25 Qty NNN Aaaa Article number 1002242 9004133 9004132 00000 4307
73. rom the backrest frame Mount with the two bolts on every side the luggage carrier on the backrest frame us 9 1 AS 2 I ae Pd AN pv a udi AN 110948 03 012 78 Service instructions Trophy 20 Mount the walking aid holder Preparation Relevant article numbers Switch off the scooter with the ignition key 1001814 Walking aid holder Instructions Tools used The following operations are required to mount the walking Allen key 6 mm aid holder Note Suitable work area required Remove the armrest on both sides from the backrest frame Mount with the two bolts on every side the walking aid holder on the backrest frame FT pt e B V A 110948 03 005 Va DAT ET 110948 03 009 Trophy 20 Service instructions 79 Mount the mounting bracket Preparation Relevant article numbers Switch off the scooter with the ignition key 9000620 Mounting bracket rear 4930 Basket Instructions 9000701 Trolley bag The following operations are required to mount the mounting bracket Note Suitable work area required Tools used Remove the armrest on both sides from the backrest Allen key 6 mm frame Mount with the two bolts on every side the mounting bracket on the backrest frame Putthe basket or knapsack on the mounting bracket LAN 110948 03 005 110
74. rticle number 1012520 into Assy seat post Captain seat incl nylon bearing Changed article number and description 00000 3723 Button head screw M6x8 into 00000 3716 Button head screw M6x16 25 08 Changed position 3 9006094 in 3a and 3b 9006094 Indicator 12V ID no PBxxxxx only and 9003478 Indicator 24V ID no QBxxxxx onwards 26 08 Changed article number 9004127 into 1015454 Added position 31 9005802 Screw EJOT K40x12 217 09 Changed position 3 9006094 in 3a and 30 9006094 Indicator 12V ID no PBxxxxx only and 9003478 Indicator 24V ID no QBxxxxx onwards 30 4 3 Changed description article number 1008572 in Assy foot throttle ID no PBxxxx only Added article number 9007499 Assy foot throttle ID no QBxxxxx onwards Article number 9000703 Front bag was mentioned twice delete once Added article number 1015507 lap strap with roll up for Master Seat Trophy 20 99 Version Page Draw Changes 31 32 Added annual inspection table 31 33 Textual changes in chapter 5 Updated several service instructions 82 5 5 Added paragraph 5 5 Display menu settings 84 Deleted paragraph 6 1 and 6 2 90 91 Added controller settings overview 90A and 120A according new electronics ID no QBxxxxx onwards 94 Added Electrical diagram according new electronics ID no QBxxxxx onwards 2012 v4 86 87 7 2 Updated specifications 88 91 Changed S Drive settings into Mk
75. rutch holder bracket on the rear frame side of the electronics compartment Drill two holes in the rear bumper drill location is indicated on the inside Replace the rear bumper and mount the crutch holder via the bumper on the bracket 110948 03 014 NS 110948 03 015 110948 03 015A Trophy 20 Service instructions 75 77 5 LATE L a Q A NE A DN EE JP HV 42 110948 03 015B 76 Service instructions Trophy 20 Mount the anti tip wheels Preparation Relevant article numbers Switch off the scooter with the ignition key 1015401 Anti tip set Use a lifting device to raise the scooter clear of the ground Tools used Open ended spanner 13 mm Instructions Socket 13 mm The following operations are required to mount the anti tip wheels Note Suitable work area required Mount with the two bolts on every side on the rear frame an anti tip wheel 110948 03 024 Trophy 20 Service instructions 77 Mount the luggage carrier Preparation Relevant article numbers Switch off the scooter with the ignition key 1001813 Luggage carrier Instructions Tools used The following operations are required to mount the luggage Allen key 6 mm carrier Note Suitable work area required Remove the armrest f
76. s defective Tiller PCB is defective The batteries require charging or there is a poor connection to the batteries The batteries are being charged There is a poor connection to the motor There is a short circuit in the motor The throttle was held in during start up Speed potentiometer fault The controller is malfunctioning The neutral handle is in the neutral position The brake is malfunctioning The battery is malfunctioning Switch off the scooter Check all connectors Check the condition of the batteries Consult the manufacturer if the LED bar continues flashing after the scooter has been switched on Contact the manufacturer Check all connections between the controllers and the batteries If the connections are OK try recharging the batteries Disconnect the battery charger from the scooter Check all connections between the controller and the motor Check the motor cables or replace the motor Restart the scooter without pressing the throttle Check or replace the speed potentiometer Replace the controller Put the neutral handle in the drive position Check the connections between the brake and the controller Replace the brake Check the connections between the batteries and the controller Check the batteries The table below provides explanation for the trip codes that can be indicated by the controller These trip codes can be read with the manual programming unit SP1 or the mob
77. starts making unintended movements or if the brake goes into freewheel neutral mode turn off the powered wheelchair or scooter by removing the ignition key from the lock 4 Be aware of the fact that any accessories components or adaptations installed on the scooter may increase the effect of radio waves Note There is no easy way of testing the effects of radio waves on the general immunity of powered wheelchairs or scooters 5 All cases of unintended movements of the scooter spontaneously going into freewheel neutral mode should be reported to your dealer or to the scooter manufacturer When reporting please indicate whether a source of radio waves was nearby at the time 8 Safety Trophy 20 2 5 Markings on the scooter Never remove or cover up the markings symbols and instructions affixed to the scooter These safety measures must remain present and clearly legible throughout the entire lifestam of the scooter Replace or repair any markings symbols or instructions that have become illegible or damaged immediately Please contact your dealer for assistance Product labels The following sticker label can be found on the product A Freewheel handle position B Identification plate C Instruction for transportation Buran UM 01 A Freewheel handle position 1 DRIVE mode Lever fully upper position Motor brake applied scooter can not be pushed J 2 FREEWHEEL NEUT
78. switched off Remove the battery cover Remove the roll bar Remove the hexagon head cap screw Take out the shock absorber Read the table for more information about the adjustment of shock absorbers Use the special adjustment tool to adjust the shock absorber as desired Mount the new correct adjusted shock absorber Rebuild the scooter in the reverse order 110448 04 001 Q MT p 110448 04 028 56 Service instructions Trophy 20 Trophy 20 Service instructions 57 Standard suspension max 130kg Load User weight Adjust position lt 80kg 0 standard 80 105kg 1 105 130kg 2 Heavy suspension 115 160kg Load User weight Adjust position 115 130kg 0 130 145kg 1 145 160kg 2 standard Position 0 Position 1 Position 2 58 Serviceinstructions Trophy 20 5 4 4 Steering column Replacing the steering wheel Preparation Switch off the scooter with the ignition key Disconnect the batteries Instructions The following operations are required to replace the steering column Note Suitable work area required Remove the basket and the mounting bracket for the mirrors Remove the knob of the speed potentiometer Disconnect all connectors from the tiller PCB Remove the three Ejot screws to remove the tiller PCB Remove the two recessed button head scre
79. ws to remove the console bottom Disconnect the connectors of the console bottom Remove the recessed button head and Ejot screws disconnect the stop switch and remove the top and bottom steering wheel covers Remove the two Ejot screws and washers to remove the rear cover steering column disconnect in between the connectors from the ignition switch Remove the two sheet metal screws and the throttle potentiometer disconnect in between the connector of the throttle Remove the button head screw and the brake lever disconnect in between the connector from the brake lever Remove the bolt to remove the steering wheel Mount the new steering wheel Rebuild the scooter in the reverse order Remove the nut the two Ejot screws and the dashboard Relevant article numbers 9004185 Steering wheel Tools used Socket 10 mm e Screwdriver crosshead Allen key 6 mm Notice Make sure the scooter is switched off 110448 04 001 110448 04 006 Trophy 20 Service instructions 59 60 Service instructions Trophy 20 Trophy 20 Service instructions 61 Replacing the gas spring Preparation Relevant article numbers Switch off the scooter with the ignition key 9007359 Gas spring 300N Instructions Tools used The following operations are required to replace the gas Socket 7 mm 8 mm 10 mm 1
80. y applicable safety guidelines and standards Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an authorised Service technician Trophy 20 Spare parts 11 4 2 Overview exploded views 056 056 05b 050 8 03 8 110348 03_01 02 Pos Description Page 01 Front frame front fork and front wheel Trophy 20 3W 12 02 Front frame front suspension and front wheels Trophy 20 4W 13 03 Rear frame drive unit and rear wheels 14 04 Steering column mirror and basket 16 05a Console printed circuit board and throttle control ID no PBxxxxx only 18 05b Console printed circuit board and throttle control ID no QBxxxxx onwards 20 06a Wiring electronics and batteries ID no PBxxxxx only 22 06b Wiring electronics and batteries ID no QBxxxxx onwards 29 07 Seat and seat post 24 08 Covers Trophy 20 3W 25 09 Covers Trophy 20 4W 27 10 Covers common 29 Options 30 12 Spare parts Trophy 20 01 Front frame front fork and front wheel Trophy 20 3W Trophy20 EV 01 Pos Qty Article number Description 1 2 9004420 Battery strap 2 2 00001 0008 Battery spacer block 3 2 9000493 Ball head bearing 6004 2NSE 9 4 1 9003440 Frame with ball head bearings 3W 5 2 9006079 Washer flat M4x20x1 2 6 2 9005928 Haxagon bolt M4x12 7 9003444 Mounting bracket front cover 8 8 9005

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