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Service manual Trophy 20 (English)

Contents

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2. or sat Power PCB SPEED SEN BK Horn ev 150 ei a Speed sen 0V BK Speed sensor incl Console pan v DS Speed Sensor wiring amp magnet M n FUNCTION a O Le Ma EE o por ai aaa F r o WIPER BN 2 Foot Throttle RearLight 24V PP z e ie z gt Rear left brake o BrakeLight 24V os 3 ear left b Reverse drive bel POT WES fFootthrette AGND oT Tr RearIndicator ov mar 4 incl wiring User Interface Info ES e o 0 108688 7N Footihrottie Value GN RD 2 RearLight OV PP WT 5 ee Cruise Controt Bol o FootThrottle avcc N 3 Brakelight DV AR LZ dee pe o fRearindicator 24V JI D Indicator switch left right LIGHTS_SVITCH zg RearLight 24V BK 2 CLAXON SWITCH RI ne O O beet Ve 247 RD F gester 4 Wiper left Gap lRearindicator OV LG gt eo E intermediate 2 RearLight 0V 7 pnzon Rearindicator 24V BN I Ster oV k Wiper Bez bal RearLight 24V pp IS NOT connected 4 CK RD 1 BrakeLight 24V os 3 Winer left Cap ov SD Be fe KEY ON OFF Rearinaicator OV ETag e Internediate onzen 2 Key DUT EI 3 RearLight ov PP WT 5 Rear right brake ee Mere har e e se BrakeLight OV po vr 6 incl wiring INOT connected 4 Standard finger throttle Bat eave 1
3. 62 Service instructions Trophy 20 5 4 5 Console Replacing the throttle Preparation Switch off the scooter with the ignition key Disconnect the batteries 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 e 1008055 Throttle potentiometer Tools used e Screwdriver crosshead Notice e Na 110448 04 001 110448 04 052 Trophy 20 Service instructions 63 Replacing the tiller PCB Preparation Relevant article numbers e Switch off the scooter with the ignition key e 9007265 Tiller PCB for original electronics ID no e Disconnect the batteries PBxxxxx only e 9008789 Tiller PCB Basic for advanced electronics ID Instructions no QBxxxxx onwards The following operations are required to replace the tiller e 9008791 Tiller PCB Dual control for advanced PCB electronics ID no QBxxxxx onwards Note Suitable work area required e 9008790 Tiller PCB Full option for advanced electronics e Remove the basket and the mounting bracket for the ID no QBxxxxx onwards mirrors e Remove the two bolts and remove the front tiller cover Tools used e Remove the tyrap e Socket 10 mm e Remove the nu
4. Standard Definition description Weight test dummy EU guideline 93 42 EEC 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 e 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 EE 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 downward direction S gt 13 gt 13 Static stability in the upward direction z gt 13 gt 13 Lateral static stability 2 gt 13 gt 13 Distance r
5. X X X LK X X lt X gt X lt gt x lt Sign the inspection record table in the user manual 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 War
6. 90 S Drive 180A S Drive II 90 S Drive 180A S Drive II 100 S Drive 180A S Drive Il 190 S Drive II Only 180 S Drive Il Only 90 S Drive II Only 0 Single ended 1 Wig wag 2 Unipolar 0 Drive 1 Inhibit 2 Trip 0 Off 1 Inhibit 2 2 Inhibit 3 90 Technical product information Trophy 20 PGDT S Drive 120A for original electronics ID no PBxxxxx only Speed Settings Fast Slow General Settings Forward Acceleration 0 1 Seconds 35 30 Soft Stop On Forward Deceleration 0 1 Seconds 16 12 Brake Time milli Seconds 1000 Reverse Acceleration 0 1 Seconds 40 40 Output Voltage Volts 24 Reverse Deceleration 0 1 Seconds 35 15 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Max Forward Speed 100 50 Diagnostic Flash Sequence 2 Min Forward Speed 10 30 Reverse Alarm Off Max Reverse Speed 25 30 Min Reverse Speed 5 30 Pulsed Reverse Alarm Off Speed Limit Pot Enabled On Diagnostic Alarm Off Operation Settings Sleep Timer Minutes 0 Brake Disconnected Alarm On Throttle Invert Yes Brake Disconnected Alarm Tone 0 S Drive 120 140 180A S Drive II Brake Fault Detect On Battery Settings Brake Light On Low Battery Flash Level Bars 0 Push too Fast Threshold 100 Cable Resistance milli Ohms 50 Push too Fast Timeout 20 Calibration Factor 100 Freewheel Enable Disable Low Battery Alarm Off Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive Il Trucharge Reset
7. 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 Trophy 20 Technical product information 87 7 Technical product information 7 1 CE Declaration and standards CE bears the CE mark This product complies with the regulations of the Medical Devices Directive and therefore
8. TROPHY 20 V 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 1 Introduction Service manual Trophy 20 1 1 This manual 1 2 Identification of the product 1 3 Symbols used in this manual 2 Safety 2 1 Personnel qualification 2 2 Identification on the product 2 3 Temperature 2 4 Electromagnetic radiation and inte
9. Changed article number 1012456 into 1015401 2012 V3 5 8 Textual 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 e Deleted position 7 stop switch e Changed description of position 12 article number 9004331 e Changed article number of position 27 1012535 into 9007365 e 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 e Changed article numbers 9006562 and 9006561 into 9006097 and 9006101 e Deleted article numbers 9004513 and 9004430 and added article numbers 1015385 1015386 and 1002558 instead e Changed price of article number 9004503 e Changed position of article numbers 1007078 9006096 9006193 9005911 and 00000 4036 e Added article number 9002752 Set battery connection covers 23 06b Added exploded view and spare part list Wiring electronics and batteries according electronics ID no QBxxxxx onwards 24 07
10. 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 e Remove the rear cover e Place the new rear cover Relevant article numbers e 1012537 1012538 1012539 1012540 1012541 Rear cover Tools used e Na Notice e Na 110448 04 001 110448 04 019 Trophy 20 Service instructions 71 5 4 9 Accessories Mount the crutch holder horizontal Preparation e Switch off the scooter with the ignition key Instructions The following operations are required to mount the horizontal crutch holder Note Suitable work area required e 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 72 Service instructions Trophy 20 Mount the crutch holder vertical Preparation Relevant article numbers e Switch off the scooter with the ignition key e 2537 Crutch holder mounted to chair vertical Instructions Tools used The following operations are required to mount the vertical e Allen key 6 mm crutch holder Note Suitable work area required e Remove the armrest from the backrest frame Mount the vertical crutch holder and the armrest with two bolts back on the bac
11. e Lock the freewheel lever e Remove four hexagon bolts and remove the motor cover e Unscrew the carbon brush cover e Pull the carbon brush out of the housing and remove the brush e 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 e Place the carbon brush in the holder this can be done in one way only e Screw the new plastic screw cap onto the carbon brush holder e Rebuild the scooter in the reverse order Relevant article numbers e 1012313 Motor brush set 4 carbon brushes with covers Tools used e Lifting device e Screwdriver short e Allen key 4 mm e Socket 7 mm 10 mm and 16 mm Notice e Some parts need to be replaced the replacement is indicated by a symbol e Make sure the scooter is switched off 110448 04 001 110448 04 002 Trophy 20 Trophy 20 Service instructions 47 Replacing the motor brake Preparation Relevant article numbers e Switch off the scooter with the ignition key e 1012104 Motor brake e Disconnect the batteries e Use a Lifting device to raise the scooter clear of the Tools used ground e Screwdriver e Socket 7mm Instructions e Allen key 4 mm The following operations are required to replace the free wheel lever Notice Note Suitable work area
12. nal evo EFT 6 1d sous paads gt JE as_xvu vr J40 NO p gt u unon esac Ctl tee wre Fr ares LL pu mes VIS Jalas xou yr 440 No e ea vin au aman HIV fe L tze ad Le menu Cp as Ave fale 2 pia DEL y W 1 del xou vor save 308 erp gt u unon ut g 2u paus efo TS ARTS Age W I JE EEEE gt DE Bu as mes Sen se P 1 in rate duo ena vam 240 n0 SES 3 p 32 uu0 gt 30N or Eg as AO a km E bd LA Lens 440 N0 Bum jou qe pases sa Fei KI aon ou une au anug NE am 440 No 1 9 Du UOH 384 ane 440 N0 hei LW no sau on Ve fonts xou vi 8 z ee LA ND ans e E NO vues Ave avaa 7 Ta unon aus anag 1 1 Tan Ag AKI Mai ACL 3465n Aug 2 Nal kvl atin t anal wor are an Tel payDauuo gt 40N 1 af wear w pul DI t e CETE 1 LM vase ave am ani e aaen zeg z pu unoH s paads N wes Ave Dwaal v aolas SIV awae Er ne Ng wot Ave env g Parsons gon Tel gt u arosa asovom 8 DE AO 1 pur wer Ave geil S pause 2 _ ess vol 4 Did Ao wo Te N9 ans ale et ul ky siz Le PAL ao s sey fadl as Ave 9 fA Ao dwor fe L 2 nal A0 21 pu ACL Ye HUNG V 2 Na sam aad EH se P IM EU ST E NO vues Ave 2esgl s Ge Ao 27 pl Ps t un vsv aer a pui Gi pr T Da Fy dada ee ee v VS0 Agr 4 M PUI error a r am rie wre h OO E GE z NDI TT EE l 6 HOLIAS st a TILA vso nar a pur F 8 HOLAS mee eme Joue g Bum Ce e Pal d 2 p
13. operation within the lifetime of the product User Those who use the product e Warranty The rights and obligations set forth in this document e Warranty period The period of time during which the warranty is valid e Warranty provider Handicare B V Vossenbeemd 104 5705 CL Helmond The Netherlands Notwithstanding the rights and obligations of Handicare Client and User set forth in Handicare s general terms and conditions of sale the rights of the Client and or User towards Handicare in case of defects are limited to the provisions set forth in this warranty For the duration of the warranty period Handicare guarantees that the product is without defects In case of any defects the User is required within two weeks after discovery of the defect to contact the dealer He has to complete a return form and return the product or part via the RMA process Handicare will at its sole discretion take the corrective action it seems fit under the given circumstances within a reasonable period of time depends on nature of claim from receipt of the completed return form The warranty period will not be extended after a corrective action 8 2 Warranty period table Power wheelchairs scooters Description Warranty period eee include but are not limited to the parts mentioned Frame 2 years Weldment frame Drive system 1 year Transaxle motor motor brake d Controller controlling mechanism wiring harness electronic
14. 1 9004564 Brake mounting 18 2 00000 4004 Hexagon head cap screwM6x45 19 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 Trophy 20 Spare parts 15 Continued from 03 Rear frame drive unit and rear wheels Pos Qty Article number Description 24b 1 9000683 Shock absorber heavy duty 25 1 1002242 Hexagon head cap screwM10x40 26a 1 9004133 Fender mounting bracket right 26b 1 9004132 Fender mounting bracket left 27 4 00000 4307 Hexagon bolt M6x12 28 1 9003417 Rear frame 29 2 00000 2003 Washer flat M8 30 2 00000 1702 Lock nut M8 s l 2 9002341 Button head screw M8x30 32 1015292 P clip 6 mm black for advanced electronics ID no QBxxxxx onwards 38 1 9006240 Taptite M5x10 hex head flange for advanced electronics ID no QBxxxxx onwards 32 33 1 1015554 P clip 6 mm service set 10 pieces for original electronics ID no PBxxxxx only 34 2 1353 Hinge bush M8 16 Spare parts Trophy 20 04 Steering column mirror and basket J DS C9 G A l ei k Ge RECH Trophy20 EV 04 Pos Qty Article number Description la 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 3 1 9000704 Basket holder 4
15. 1404 RD ee E ew smen saav e o Emorgeney Such e SE GE Indicator left 24V GR 1 AKE SD M mara TA AR Blink left 24V Indicator teft ov Je 2 ma a E BAT 24V 10A mox BK 4 H e S Drive 1 GEES POWER SD POS 30V RD VIN 24V SD RD 1 x Bink right 24V inacator right ov wt GN 2 S TTE o Key IN PP 2 B BATTERY POS 30V 140A RD Key DUT lan 3 J l R e ee BATTERY NEG 30V 1404 Ia CHARGER POS 24V 164 RD Light ov Pap Front light 24V Weer 24v a75na Jean 2 CHARGER OV 16A 3K SI lo INHIBIT CHARGER wT YE S F Y batt pos harness Power La on off Libis 14 rn q batt neg ov harness o o E P os RD e CHARGER Pos eav 16a RD 1 SE CHARGER OV 16A SIS BATTERY NEG 30V 1404 K Charge INHIBIT CHARGER wija 24V connector den H i H Drawing number Geesen Electrical circuit diagra g Trophy 20 S drive 9006194 B 96 Technical product information Trophy 20 7 7 Service information transaxles Regular 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 Part Plan service check Motor brush At least once a year or every 2000 km Clean the collector
16. 2 0 Drive 1 Inhibit 2 Trip Throttle Reference Test On ISO Test Resistor Off Timed Throttle Invert D O0 Off 1 Inhibit 2 2 Inhibit 3 S Drive II Only Technical product information Trophy 20 Speed Settings Forward Acceleration 0 1 Seconds Forward Deceleration 0 1 Seconds Reverse Acceleration 0 1 Seconds Reverse Deceleration 0 1 Seconds Max Forward Speed Min Forward Speed Max Reverse Speed Min Reverse Speed Speed Limit Pot Enabled Operation Settings Sleep Timer Minutes Throttle Invert Battery Settings Low Battery Flash Level Bars Cable Resistance milli Ohms Calibration Factor Low Battery Alarm Trucharge Reset Voltage Deci Volts S Drive 180A S Drive Il Battery Curve Scaler S Drive II Only Inhibit Settings Inhibit 1 Mode Inhibit 1 Operation Inhibit 1 Speed Inhibit 2 Mode Inhibit 2 Operation Inhibit 2 Speed Inihibit 3 Mode Inhibit 3 Operation Inhibit 3 Speed Aux Output Mode Factory Settings Acceleration 0 1 Seconds Deceleration 0 1 Seconds Forward Speed Reverse Speed PGDT S Drive 120A for advanced electronics ID no QBxxxxx onwards Fast Slow General Settings 35 30 Soft Stop 16 12 Brake Time milli Seconds 40 40 Output Voltage Volts 35 15 Status Output Type 100 50 Diagnostic Flash Sequence 10 30 Reverse Alarm 25 30 5 30 Pulsed Reverse Alarm On Diagnostic Alarm 0 Brake Disconnected Alarm Yes B
17. 70 2 8 70 2 8 88 Technical product information Trophy 20 Test data Test weight 160 kg 25 2 stone Operating force Drive lever operation lt 20 IN Resetting the automatic fuse circuit breaker lt 60 N Electronic switches lt 13 5 N Connecting the charger plug lt 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 251803 Tyre pressure 4W rear wheel bar psi 3 5 50 8 Tyre pressure 3W front wheel bar psi 251368 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 7 3 Driving programs The driving programs for Handicare products can be found on our FTP server Log on to the FTP server e Open internet explorer e Go to ftp mobilityftp handicare com e Ente
18. 9004432 Ignition switch for advanced electronics ID no QBxxxxx onwards 16 2 9004303 Cover for indicator switch 17 2 9004435 Indicator switch for advanced electronics ID no QBxxxxx onwards 18 1 9004302 Steering wheel cover bottom 19 1 9004301 Steering wheel cover top 20 1 9005802 Srew Ejot K40x12 21a 1 9007303 Rear cover steering column 21b 1 9006167 Rear cover steering column with hole for switch 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 Al 1 1012535 Assy top for advanced electronics ID no QBxxxxx onwards 28 1 9004438 Speed switch for advanced electronics ID no QBxxxxx onwards Trophy 20 Spare parts 21 Continued from 05b Console printed circuit board and throttle control for advanced electronics ID no QBxxxxx onwards Pos 29 30a Qty NAS ES EH EF Article number 9002792 9008789 9008791 9008790 9007223 9005802 00000 3200 9004641 1015323 9002104 1016535 Description Screw Ejot K30x6 Tiller PCB Basic for advanced electronics ID no QBxxxxx onwards Tiller PCB Dual control for advanced electronics ID no QBxxxxx onwards Tiller PCB Full option for advanced electronics ID no QBxxxxx onwards Console bottom Screw Ejot K40x12 Recessed buttonhead screw M5x12 Throttle harness Cable clips set 25 Spacer 3 2 x 5 5 x 2 2 Full option steering whe
19. DESEN A ES aS ina 033dS e vort A92 sod as ah F Igy as Ave no us 4330 xa vso Ava sua as axvag a vort A92 saN as anin e o gt u as 2 eat Nal STEI SATT s fes as xow vi 2200 m as 380 Ha vort A92 sn as anio gt u AS isa Ams D EE AI ds sta vad 1oou VS2 L Az e424 WA pieren orejs afin ds 3380 YNMS jeeymead Zfolslrlefelt Na fes on sara Se pasojo IEULON DAS xou yt 4a0 NO 5 TA as suvis ES tt TA GS Su E as A NE as Ad NO as aaa JA Essen sg TA SS snivis TA Seene a OS xow et JAD ND A EEE ana n Sd aS ind gas ee 1M ds 3340 g 2 AN9 7 Ad TA pre Na NS as ag Na GS eum Aust K Josu s p ds DES EE a as Ave DA ee qa as Ave Sf DEE EE do e xow vi gem NE as ag A halin ha stakk OT 29 1 ne 7 Ad IL B IA as snivis AD as SITE apivae LA CS AS SAT E CELPA o AW aS Ave TA as 430 TE Ane tard 9 au pajus Na GS TO8iNDO JATA o ca as Ave cla Su pias g T OND 7 mo Li ka DO TET Texas anag DAT tas ou vr 440700 Alas xou vr 22070 Wee 3240 s24nseuy 2 Nal CESI ES as A0 a s xou vi 440 NO L 3240 3820 mal EG TONS 7 AO CORRE caso 6 EI as Ave pe S NE ie wel MO YNMS JOJBAIPU pR A 313144240700 SIS 3u wH D EE 2 GND ag o kl elja unon au anag F a 7 aA GE 18 es pans 2 xa TE 2 AQ aa as Ave T LAI Fea UH TTT aaner bake 6 8 FA paanan ER T AN5 7 Ad ER re e ug o t z 9 s r e e r ores 2 WN N TE al WE El 287 AS wel D DIN
20. Electronics 1 year components New 1 year after invoice SR FER Repaired 90 days after invoice Brakes Consumable parts 40 days after invoice Wheels push handles etc p 8 Mirror mudguards etc ir 2 years Not being service part or consumable part Handicare will only accept shipment costs and corrective costs related to warranty on equipment during the warranty period This warranty will void in case of e The product and or its parts being modified or items having been added by others than Handicare e Changes in cosmetic appearance by use e Failure to observe the instructions for use and maintenance use other than normal use wear and tear negligence collateral damage by neglect of earlier symptoms overloading third party accidents non original parts used and defects not caused by the product e Circumstances beyond our control flood fire etc This warranty does not cover e Tyres and inner tubes e Batteries covered by the battery manufacturer s warranty Clients and or Users have legal statutory rights under applicable national laws relating to the sale of consumer products This warranty does not affect statutory rights you may have nor those rights that cannot be excluded or limited nor rights against the entity from whom the product was purchased Clients may assert any rights they have at their sole discretion 98 Trophy 20 Trophy 20 Version Page Draw Chan
21. Front cover Ruby red metallic 18b 23 31 1 1015364 Front cover Platinum white metallic 1862331 1 1015365 Front cover Sparkling champagne metallic 18d 23 31 1 1015366 Front cover Graphite black metallic 18e 23 31 1 1015367 Front cover Moonstone blue metallic 28 Spare parts Trophy 20 Continued from 09 Covers Trophy 20 4W 27a 32 33 27b 28 29a 29b Qty NNMNM FA ND NNN AN N Article number 00000 4060 9004428 00000 1507 9003459 9004652 9005927 00000 1507 9003469 1015384 9003470 9005802 9004573 9004572 9005928 9004652 9005928 00000 2106 Description Hexagon head cap screwM4x20 Head light Hexagon nut M6 Front cover bottom Push rivet Hexagon bolt M4x20 Hexagon nut M6 Front spoiler Front bumper 4W service set for original electronics ID no PBxxxxx only Front bumper 4W for advanced electronics ID no QBxxxxx onwards Screw EJOT K40x12 Front inner fender right 4W Front inner fender left 4W Hexagon bolt M4x12 Push rivet Hexagon bolt M4x12 Washer flat M4 3xD Trophy 20 Spare parts 29 10 Covers common Trophy20 EV 10 Pos Qty Article number Description la 1 1012537 Assy Rear cover Ruby red metallic 1b 1 1012538 Assy Rear cover Platinum white metallic 1c 1 1012539 Assy Rear cover Sparkling champagne metallic 1d 1 1012540 Assy Rear cover Graphite black metallic 1e 1 1012541 Assy Rear cover Moonstone blue metallic 2 1 9004129 Motor cove
22. Head light Hexagon nut M6 Front cover bottom Push rivet Hexagon bolt M4x20 Hexagon nut M6 Front bumper 3W for original electronics ID no PBxxxxx only Front bumper 3W for advanced electronics ID no QBxxxxx onwards Screw EJOT K40x12 Push rivet Trophy 20 Spare parts 27 09 Covers Trophy 20 4W Ie gt y Le i x 28 Trophy20 EV 09 Pos Qty Article number Description 1 2 9005802 Screw EJOT K40x12 2 1 9003458 Front cover upper part 3a 2 9006094 Indicator 12V for original electronics ID no PBxxxxx only 3b 2 9003478 Indicator 24V for advanced electronics 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 9003467 Side skirt right 4W 7b 1 9003466 Side skirt left 4W 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 4 00000 2106 Washer flat M4 3xD IS A 9005928 Hexagon bolt M4x12 14 1 9003457 Head light cover 15 1 9005802 Screw EJOT K40x12 16a 1 9004442 Front tiller cover Ruby red metallic 16b 1 9004445 Front tiller cover Platinum white metallic 16c 1 9004448 Front tiller cover Sparkling champagne metallic 16d il 9004451 Front tiller cover Graphite black metallic 16e 1 9004454 Front tiller cover Moonstone blue metallic 17 2 00000 3218 Recessed buttonhead screw M4x12 18a 23 31 1 1015363
23. Only S Drive Only S Drive 180A S Drive Il S Drive 180A S Drive Il S Drive 180A S Drive Il S Drive II Only S Drive II Only S Drive II Only 0 Single ended 1 Wig wag 2 Unipolar 0 Drive 1 Inhibit 2 Trip 0 Off 1 Inhibit 2 2 Inhibit 3 Trophy 20 Technical product information 93 7 5 Data sheet Description Remarks Nominal voltage 24 V Current main fuse 50 A Max slope percentage 16 K Max slope with a start 9 160kg 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 1272 x 21 4 Type of tyre rear 3 00 8 Tyre pressure maximum front 215 bar Tyre pressure minimum rear 35 bar Maximum dimenstions batteries L262xW173xH211 mm Battery connection type Anderson Maximum allowable charger voltage 30 V Maximum allowable charger current 8 RMS A charger Maximum battery capacity C20 74 Ah Maximum battery capacity C5 63 Ah Forces on levers etc Electronic switches lt 13 5 N Drive lever operation lt 20 N Parking brake lt 60 N Connection of charger lt 60 N Weight 3W 4w 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 Trophy 20 Technical prod
24. Rebuild the scooter in the reverse order Relevant article numbers e 9000603 Shock absorber standard e 9000683 Shock absorber heavy duty Tools used Socket 7mm 17 mm e Allen key 8 mm e 9000825 Suspension adjustment key Notice e Make sure the scooter is switched off 110448 04 001 110448 04 028 Trophy 20 56 Service instructions 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 130 145kg 1 145 160kg 2 standard Position 0 Position 1 Position 2 58 Service instructions Trophy 20 5 4 4 Steering column Replacing the steering wheel Preparation Relevant article numbers e Switch off the scooter with the ignition key e 9004185 Steering wheel e Disconnect the batteries Tools used Instructions e Socket 10 mm The following operations are required to replace the e Screwdriver crosshead steering column e Allen key 6 mm Note Suitable work area required e Remove the basket and the mounting bracket for the Notice mirrors e Make sure the scooter is switched off e Remove the tiller cover front e Disconnect all connectors from the tiller PCB Remove the two Ejot screws and washers to remove the rear cov
25. a dadu ba ta ka ali g a kaa la k a a Dalaman dini a a a Ba gain ka alar a 87 7 1 CE Declaration and standards 87 7 2 Technical specifications 87 7 3 Driving programs 88 7 4 Controller settings PG Drives 89 7 5 Data sheet 93 7 6 Electrical diagram Trophy 20 94 7 7 Service information transaxles 96 8 Waranty ere TE EE Ie 97 8 1 Definitions of terms 97 8 2 Warranty period table 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 Mechanics who do repairs on this scooter 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 e Model e Year of manufacture e Colour ID number e 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 e User manual e Service manual Service and technical support For information
26. 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 e Model e Year of manufacture e _ID 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 nmoomx o Q 2 5 T w x Im z w SS 3 So 26 a wg ua or an no Bae oR gt W i w g 4 a z lt 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 A Caution Advice for the user of this manual to prevent damage to the product A 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 the Trophy 20 Trop
27. harness for original electronics ID no PBxxxxx only 25 1 9005911 Mounting bracket for S drve controller for original electronics ID no PBxxxxx only 26 2 00000 4036 Hexagon head cap screwM5x12 Trophy 20 Spare parts 23 06b Wiring electronics and batteries for advanced electronics ID no QBxxxxx onwards Trophy20 EV 06b Pos Qty Article number Description la 2 9006563 Battery harness 60A 1b 2 9006564 Battery Harness 100A for Alpine transaxle 2a 1 9006562 Power harness S Drive 90A 2b 1 9006561 Power harness S Drive 120A 3a 2 9002759 Battery 50Ah C5 60Ah C20 3b 2 9002760 Battery 63Ah C5 74Ah C20 ae 2 9002761 Battery 72Ah C5 86Ah C20 4 5 1 1012412 Connector cover 4 5 6 1 9002457 S drive controller 120A 2 2 9006080 Hexagon head cap screw M5x25 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 00000 4036 Hexagon head cap screw M5x12 13 1 9008778 Controller interface for advanced electronics ID no QBxxxxx onwards 14 1 9006124 Tule 15 2 9004503 Rear light LED 16 4 00000 1501 Hexagon nut M6 17 1 9004433 Horn for advanced electronics ID no QBxxxxx onwards 18 1 00000 4322 Hexagon bolt M8x12 19 1 9004431 Speed sensor 20 1 9004429 Main harness for advanced electronics ID no QBxxxxx onwards 21 1 9004419 Charging harness 22 2 9002752 Set battery connection covers 24 Spare parts Trophy 2
28. on the anchor of the motor with pressed air from dust Wu 18 biet New brush maximum 18 mm and minimum 8 mm dimensions Trophy 20 Warranty 97 8 Warranty 8 1 Definitions of terms Definitions of terms used in this warranty e Consumable part Part that is subjected to natural wear and tear or natural contamination during normal operation within the lifetime of the product section 9 of Handicare s general terms and conditions of sale e Client Those who purchase the product directly from Handicare e Corrective action Repair replace or refund of the product e Dealer Those who re sell the product to the User e Defect Any circumstance due to which the product is not sound or fit to use caused by a lack of quality of the material used to manufacture the product as well as the quality of the manufacturing process e Option An accessory delivered by Handicare to extend the standard product model e Product Product that is delivered according to brochure or contract e g wheelchair scooter battery charger etc e Part Part of product that can be exchanged or replaced This can be an option accessory service part or consumable part e Returns Product or part that needs to be returned e RMA process Process to return goods contact Handicare s Customer Service e Service part Part that is durable and may be subjected to natural wear and tear or natural contamination during normal
29. parallel bolts e Remove the lock nut at the wheel side of the swing arm and turn the swing arm out of its position e Replace the new swing arm e Rebuild the scooter in the reverse order Relevant article numbers e 9004459 Swing arm lower assy e 9004458 Swing arm top assy Tools used e Torque wrench socket 7 mm 13 mm socket bit 6 mm e Torque wrench socket 17 mm e Allen key 8 mm e Screwdriver e Open ended spanner 10 mm Notice Na 110448 04 001 110448 04 002 Trophy 20 Service instructions 41 42 Service instructions Trophy 20 5 4 3 Rear frame Replacing the rear wheel Preparation e Switch off the scooter with the ignition key e 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 e Remove the cover and four hexagon head cap screws to remove the rear wheel e Mount the new rear wheel in the reverse order Relevant article numbers e 1014662 Rear wheel 8 right black assy e 1014661 Rear wheel 8 left black assy Tools used e Screwdriver e Torque wrench socket bit 6 mm Notice e Na 110448 04 001 110448 04 002 110448 04 014 110448 04 015 Trophy 20 Service instructions 43 Replacing the mechanical brak
30. 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 y 1 DRIVE mode Lever fully upper position Motor brake applied scooter can not be pushed J 2 FREEWHEEL NEUTRAL mo
31. 0 07 Seat and seat post ar Trophy20 EV 07 Pos Qty Article number Description 1 2a 2b 1 1002861 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 9003907 Nylon bearing seat post Master seat 6 1 1012523 Assy Seat post std K 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 18 2 1009001 Detent button 14 1 9006157 Ring seat post cover IS 1 1012520 Assy seat post Captain seat incl nylon bearing 16 1 00000 3716 Button head M5x12 VZ 1174 il 9005156 Seat post bolt Trophy 20 Spare parts 25 08 Covers Trophy 20 3W D GD Nz D 35 8 Ae Go Trophy20 EV 08 Pos Qty Article number Description 1 2 9005802 Screw EJOT K40x12 2 1 9003458 Front cover upper part 3a 2 9006094 Indicator 12V for original electronics ID no PBxxxxx only 3b 2 9003478 Indicator 24V for advanced electronics 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 Si
32. 04 nox RD a CHM48S A BL RD 1 Net connecte lee SpeedSelector AGND WT 1 eee BLL T com Not connected 3 H E T Freedsetector_vatuelcnrn 2 P BAT 24v 104 max BK 4 90 E IBrecasetector t 3 ee SpeedSelector ANE BN 4 DREF SD me P DRIVE CONTROL _SDRD 2 S drive DREF SD Jen 3 fhrottie left SV aw 1 spect DI fihrottie tert Vatuelcuren 2 E e e Eege Kn i Throttle teft aGND wT 3 incl wiring rotte REF SD E 2 ALARM fee Throttie left 5V Tan 1 IS F SW ENT t Tnrottie tert Vauelow rD 2 os Key On Off RE PP R mrottie erreur 3 gt CE kal jot Connecte p REF SD Fer e i a S ne a Ed r d SPEED POT MC GN rD 9 Transaxle incl VIN 24V SD RD Urs STATUS SD BN 10 Key IN PP 2 R Not connected D Indicator right 24V VWTZBL 3 2 RSW Bar le __ DE Indicator right ov WT 6N 4 Vu Late EEE GND x 3 1 baak BK 5 fofa INHIBIT 3 MC bal i 1 Brake Scan KBC2 __ BN wT 6 fafo l COM485 B BUY 7 ET Ge d s S oe Normally closed Indicator teft 24V GR g Indicator teft ov loc 10 9 1 2 3 a s 7 framed EE es Light 24v 875na KVL fair s oholuhehah4 ec Nee ee See ee ee Light ov OUTRE Brake switch Brake Scan KBI oc 13 MOTOR SD POS 26V 1404 BL com485 a BLZRD 14 Broke Scan KI SC 1 e MOTOR SD NEG 26V 1404 RDI Broke Scan KBce n vr 2 BRAKE SD POS 24V osa Tel EM switch GND ME MOTOR SD POS 26V 140A BU BRAKE SD NEG OV asa Te suite MOTOR SD NEG 26V
33. 1 Wig wag 2 Unipolar Throttle Deadband 15 Throttle Gain 140 Throttle Operated at Power up 2 _ 0 Drive 1 Inhibit 2 Trip Throttle Reference Test On ISO Test Resistor Off Timed Throttle Invert D 0 Off 1 Inhibit 2 2 Inhibit 3 S Drive II Only Trophy 20 Technical product information 91 PGDT S Drive 90A for advanced electronics ID no QBxxxxx onwards Speed Settings Fast Slow General Settings Forward Acceleration 0 1 Seconds 35 35 Soft Stop On Forward Deceleration 0 1 Seconds 16 16 Brake Time milli Seconds 1500 Reverse Acceleration 0 1 Seconds 40 40 Output Voltage Volts 24 Reverse Deceleration 0 1 Seconds 35 35 Status Output Type 0 0 Trucharge 1 LED 2 Analogue Max Forward Speed 100 100 Diagnostic Flash Sequence 2 Min Forward Speed 10 10 Reverse Alarm Off Max Reverse Speed 25 25 Min Reverse Speed 5 5 Pulsed Reverse Alarm Off Speed Limit Pot Enabled On Diagnostic Alarm Off Operation Settings Sleep Timer Minutes 0 Brake Disconnected Alarm Off Throttle Invert Yes Brake Fault Detect On Battery Settings Brake Light Off Low Battery Flash Level Bars 0 Push too Fast Threshold 100 Cable Resistance milli Ohms 50 Push too Fast Timeout 20 Calibration Factor 100 Freewheel Enable Disable Low Battery Alarm Off Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive Il Trucharge Reset Voltage Deci Volts 250 Motor Settings S Drive 180A S Drive II Curre
34. 2 00000 4307 Hexagon bolt M6x12 5 2 00000 2202 Spring washer M6 6 2 9006129 Rubber strip 7a 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 1015387 Mounting bracket for mirrors 11a 1 1009250 Mirror left 11b 1 1009251 Mirror right i2 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 VK 1 9004169 Cylinder steering column 18 4 9004174 Bush bearing tiller 19 3 9004163 Hinge pin 12x5 2 M8 2il 1 9004181 Bracket steering adjustment 22 1 9004164 Hinge pin 12x8 M8 23a 2 00000 1701 Lock nut M6 for original electronics ID no PBxxxxx only 23b 2 00000 1700 Lock nut M5 for advanced electronics ID no QBxxxxx onwards 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 Qty 1 2 1 1 1 1 1 1 1 1 1 1 1 Article number 9007359 9005802 1012532 9006559 9005607 9004175 00000 2203 00000 4041 9004190 9004191 9004185 9006418 1015387 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 He
35. 20x1 2 6 2 9005928 Hexagon bolt M4x12 7 9003444 Mounting bracket front cover 8 8 9005689 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 Hexagon bolt M8x150 st10 9 14 15 16 1 9004159 Front wheel 3W 15 1 1015118 Inner tube 12 1 2 x 2 1 4 16 1 1015113 Outer tyre 12 1 2 x 2 1 4 black block profile 17 1 9007273 Bracket bumper 3W right 18 1 9007274 Bracket bumper 3W left 19 4 9005928 Hexagon bolt M4x12 20 4 00000 2106 Washer flat M4 3xD 30 1 9007355 Edge protection profile Trophy 20 Spare parts 13 02 Front frame front suspension and front wheels Trophy 20 4W 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 3 8 00000 4026 Hexagon head cap screwM8x20 4 5 6 2 9004511 Front wheel 4W 5 2 1015118 Inner tube 12 1 2 x 2 1 4 6 2 1015113 Outer tyre 12 1 2 x 2 1 4 black block profile 7 2 9001969 Shim ring 1 0mm 16x22mm D988 8a 1 9003408 Wheel bracket right black 8b 1 9003406 Wheel bracket left black 9 2 1007448 PVC black cover M10 DIN912 10 4 1002242 Hexagon head cap screwM10x40 11 4 00000 1703 Lock nut M10 12 13 2 1012525 Assy Shock absorber front 4W 13 4 1002840 Skiffy fixation ring 10mm 14 1 9003444 Mounting bracket front cover 15 2 9006079 Washer flat M4x20x1 2 16 2 9005928 Hexagon bolt M4x12 17 18 1 900
36. 3218 Recessed buttonhead screw M4x12 26 1 1012536 Assy Dashboard speed knob 27 1 9007365 Assy top for original electronics ID no PBxxxxx only 28 1 9006110 Speed switch for original electronics ID no PBxxxxx only 29 3 9002792 Screw Ejot K30x6 Trophy 20 Spare parts 19 Continued from 05a Console printed circuit board and throttle control for original electronics ID no PBxxxxx only Qty NO NN A A Article number 1015179 9007223 9005802 00000 3200 9004641 1015323 9002104 Description Tiller PCB for original electronics ID no PBxxxxx only Console bottom Srew Ejot K40x12 Recessed buttonhead screw M5x12 Throttle harness Cable clips set 25 Spacer 3 2 x 5 5 x 2 2 20 Spare parts Trophy 20 05b Console printed circuit board and throttle control for advanced electronics ID no QBxxxxx onwards drot Buran EV 05b Pos Qty Article number Description 1 1 9007301 Drumbrake actuator cable 2 1 9006191 Extension cable for microswitch S 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 Emergency stop button 8 1 9000904 Emergency stop button dummy 9 2 1008055 Throttle potentiometer 10 1 9007423 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 d 1
37. 3392 Frame with ball head bearings 4W 18 2 9000493 Ball head bearing 6004 2NSE 19 8 9005689 Cable clip 20 4 00000 1702 Lock nut M8 21 2 9004459 Swing arm lower assy black 22 2 9004458 Swing arm top assy black 23 4 00000 1702 Lock nut M8 24 4 9001803 Axle suspension parallel bracket 25 1 9001895 Mounting plate 26 1 1001796 Retaining ring 20mm 27 1 9003403 Steer shaft 28 4 00000 1702 Lock nut M8 28 29 2 1012524 Assy Steering bar 30 1 9007355 Edge protection profile 14 Spare parts Trophy 20 03 Rear frame drive unit and rear wheels CERS Trophy20 EV 03 Pos Qty Article number Description 1 2 9002006 Cover grey 2 2 1012527 Assy Wheel bolt 3 8 00000 4026 Hexagon head cap screwM8x20 4a 5 6 1 1014662 Rear wheel 8 right black road assy 4b 5 6 1 1014661 Rear wheel 8 left black road assy 4c 5 6 1 9007436 Rear wheel 8 right left black outdoor assy 5 2 1015117 Inner tube 3 00x8 6a 2 9004146 Tyre black road 6b 2 1015110 Tyre black outdoor f 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 13 1 1012313 Carbon brushes with covers set of 4 14a 1 1012529 Assy Transaxle Alpine for S Drive 120A 12 km h 14b 1 1012530 Assy Transaxle std 12 km h 15 4 00000 1703 Lock nut M10 16 2 1012124 Key for transaxle r
38. 9 Tiller PCB Basic 9008791 Tiller PCB Dual control 9008790 Tiller PCB Full option 9006138 Emergency stop button 1016535 Full option steering wheel includes 1 5 6 NOaRWN AO Since Full option steering wheel only means to exchange the complete steering wheel this may be advisable to use always as upgrade for Cruise Control on single hand finger control Cruise control will only work together with the Emergency Stop Button If this button doesn t function or isn t present the Scooter will give an error and will not start Safety Trophy 20 Service instructions 83 5 5 Display menu settings K fol ag Starting the service menu for original electronics ID no PBxxxxx only Kilometer total user Reset total user Kilometer total scooter Hours on total scooter Battery voltage O O a 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 for advanced electronics 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 e First information shown after starting the service men
39. Changed position 14 into 9006157 Ring seat post cover e Changed description article number 1012520 into Assy seat post Captain seat incl nylon bearing e 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 e Added position 31 9005802 Screw EJOT K40x12 27 09 Changed position 3 9006094 in 3a and 3b 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 e Added article number 9007499 Assy foot throttle ID no QBxxxxx onwards Article number 9000703 Front bag was mentioned twice delete once e Added article number 1015507 lap strap with roll up for Master Seat 31 32 Added annual inspection table 31 33 Textual changes in chapter 5 100 Trophy 20 Version Page Draw Changes 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 se
40. Instructions e Socket 13 mm The following operations are required to mount the anti tip wheels Note Suitable work area required e Mount with the two bolts on every side on the rear frame an anti tip wheel R 13 110948 03 024 SE 76 Service instructions Trophy 20 Mount the luggage carrier Preparation e Switch off the scooter with the ignition key Instructions The following operations are required to mount the luggage carrier Note Suitable work area required e Remove the armrest from the backrest frame e Mount with the two bolts on every side the luggage carrier on the backrest frame Relevant article numbers 1001813 Luggage carrier Tools used Allen key 6 mm 1948 03 005 iN 110948 03 012 Trophy 20 Service instructions 77 Mount the walking aid holder Preparation Relevant article numbers e Switch off the scooter with the ignition key e 1001814 Walking aid holder Instructions Tools used The following operations are required to mount the walking e Allen key 6 mm aid holder Note Suitable work area required e Remove the armrest on both sides from the backrest frame e Mount with the two bolts on every side the walking aid holder on the backrest frame 110948 03 005 78 Service instructions Trophy 20 Mount the mounting bracket Preparation Relevant
41. Low battery error Low battery voltage 1 2c01 Low battery error Low battery voltage 2 3B01 Motor fault 1 Motor disconnected 3 1400 Bridge fault 1 Motor wiring fault 4 7000 Startup with push selected Parking brake off 4 7001 Push activated in drive mode Parking brake off 6 1e03 Inhibit activated Inhibit active 7 0810 Tiller fault 1 Throttle trip 7 0814 Tiller reference error Throttle trip 7 0815 Tiller lo reference error Throttle trip m 0816 Tiller high reference iso error Throttle trip 7 0817 Tiller lo reference error Throttle trip 7 0300 Speed Limit Potentiometer wiper open Throttle trip 7 1d02 Front end spec change trip Throttle potentiometer trip m 2f01 Tiller displaced error Throttle displaced at power up 8 0002 Eeprom calibration checksum error 2 Possible controller trip 8 0003 Eeprom program checksum error 2 Possible controller trip 8 0100 Running checksum 1 Possible controller trip 8 0203 Eeprom calibration checksum error 1 Possible controller trip 8 0204 Eeprom program checksum error 1 Possible controller trip 8 1501 Brake fault 2 Possible controller trip 8 1705 Relay fault 1 Possible controller trip 8 1802 Watchdog voltage ref error Possible controller trip 86 Troubleshooting Trophy 20 5 Co 0 00 0 Co 00 oo 1805 1b20 2102 2d01 3100 3102 3210 3211 3212 3213 3600 3601 3602 3603 3608 3609 360a 360b 360c 360d 360e 4401 1500 1502 1600 Salty finger ref error
42. Voltage Deci Volts 250 Motor Settings S Drive 180A S Drive Il Current Limit Max Amps 110 Battery Curve Scaler 0 Boost Drive Current Amps 120 S Drive II Only Boost Drive Time Seconds 10 Inhibit Settings Current Foldback Threshold Amps 60 Inhibit 1 Mode 1 Current Foldback Time Seconds 70 Inhibit 1 Operation Latching Current Foldback Level 59 Inhibit 1 Speed 0 Motor Cooling Time Seconds 660 Inhibit 2 Mode 1 Current Foldback Temperature Deg C 30 Inhibit 2 Operation Latching Current Limit Min Amps 10 Inhibit 2 Speed 0 Motor Stall Timeout Seconds 0 S Drive II Only Inihibit 3 Mode 1 Motor Compensation milli Ohms 25 Inhibit 3 Operation Non Latching AntiRollback Level 12 S Drive Only Inhibit 3 Speed 0 Pull away Delay centi Seconds 0 S Drive Only Aux Output Mode 1 Slope Factor 900 S Drive Only Anti Rollback Velocity 0 S Drive Only Factory Settings Max Min Braking Current Limit Amps 120 S Drive 180A S Drive II Acceleration 0 1 Seconds aA Timed Foldback Braking Current Amps 120 S Drive 180A S Drive II Deceleration 0 1 Seconds 100 1 Timed Foldback Speed 100 S Drive 180A S Drive II Forward Speed 190 H Enhanced Motor Compensation Up 190 S Drive II Only Reverse Speed 100 0 S Drive II Only S Drive II Only Enhanced Motor Compensation Down 180 Enhanced Motor Compensation Up Gain 90 Throttle Settings Throttle Type 1 0 Single ended
43. a Ao wie S aps asinn m A navet Ag uur Jou Josuas peeds oo q g NS dads ojuo ore 9 HILIAS 13834 e smod D fe A 0 crane KG den an 301vn19 EE Dt BEE NADI X0LVNLIY cal DEE L an 19MO 2 HOLIAS Dien r DES amp 9d Jemod GO E HE BEE ajosuo 95 Technical product information no QBxxxxx onwards Advanced electronics ID Trophy 20
44. and 1015113 13 2 Changed article number 15010 4100 9004161 and 9002054 into 1015118 1015113 and 1007448 14 3 ie Changed article number 1003249 into 1015117 e Changed description article numbers 1012529 and 1012530 16 4 Changed article number 9006544 into 1015387 18 5a Changed article number 1001730 into 9002792 20 5b Changed article number 1001730 into 9002792 22 6a Changed description article number 9006564 23 6b Changed description article number 9006564 Sy Updated warranty text Price list Trophy 20 article numbers moved from NetherlandsDesign to EoL related spare part price list V handicare Handicare B V Vossenbeemd 104 5705 CL Helmond The Netherlands T 31 0492 593 888 F 31 0 492 537 931 www handicare com
45. and is lit left hand side throttle is active no hand icons are lit foot throttle is active 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 e Km icon on display is shown km km per hour e micon on display is shown miles miles per hour Default km Change by pressing the DSS 1 switch 2 2 seconds 9 Scooter type selection This reflects the diameter of the wheels used e t30 Trophy speed algorithm Trophy 30 e t20 Trophy speed algorithm Trophy 20 Default t30 Change by pressing the DSS 1 switch 2 2 seconds 10 This reflects if a beeping sound is enabled e 0 no beep when driving backward e 1 beeping when driving backward default 1 Change by pressing the DSS 1 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 Change by pressing the DSS 1 switch 2 2 seconds First two characters of the display show CC 12 Manual intelligent throttle switch e O off e 1 Manual Throttle Switching MTS e 2 Intelligent Throttle Switching ITS 3 ITS and MTS active Defa
46. ange ISO 7176 4 km miles 45 28 45 28 Dynamic stability max safe slope 5 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 2 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 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
47. article numbers e Switch off the scooter with the ignition key e 9000620 Mounting bracket rear e 4930 Basket Instructions e 1015545 Trolley bag The following operations are required to mount the mounting bracket Tools used Note Suitable work area required e Allen key 6 mm Remove the armrest on both sides from the backrest frame e Mount with the two bolts on every side the mounting bracket on the backrest frame Put the basket or trolleybag on the mounting bracket SS 110948 03 005 S e g EL F J y Jj VC SES D gt PA C ss gt v Ii 110948 03 008 Trophy 20 Service instructions 79 Mount the lap strap with roll up to the Master seat Preparation e Switch off the scooter with the ignition key Relevant article numbers e 1015507 Lap strap with roll up for Master Seat Instructions The following operations are required to mount the lap Tools used strap with roll up to the Master Seat e Socket 17 mm Note Suitable work area required e Unzip the cover from the Master seat The frame has a hole on the left and right side Make on both sides at the level of the hole a notch in the cover e Left side The locknut needs to be mounted on the inside of the frame e Right side The plastic bushings and pivot van needs to be used on the right side e When everything is mounted place the black
48. ay Advanced display ae Caucc999 Aommmy Relevant article numbers e 9007083 Foot throttle Advanced electronics e 1008730 4 8x19 self tapping screw i a Je J z Tools used e Allen key 3 mm e Metal drill 6 mm e Drill e Screwdriver crosshead Note This procedure is intended for the Throphy 20 with the latest electronics In case your Trophy 20 has the dashboard as one above you have the latest version electronics Contact Handicare in case you have another dashboard original electronics D no PBxxxxx only 110948 03 018 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 Z 69 Trophy 20 82 Service instructions Trophy 20 Expand controller options for advanced electronics ID no QBxxxxx onwards Upgrade can be done via spare part options see matrix below Right hand z 0 2 2 4 1 4 5 6 or 7 6 Left hand 0 2 2 4 1 4 5 6 or 7 6 Foot 1 1 1 4 2x1 4 5 6 or7 6 Hand foot 0 0 0 1 5 6 or7 6 Dual hand 0 0 2 2 5 6 or 1 7 6 CC only works with 8 standard 0 2 2 1 standard Only remove replay parts 1008055 Throttle potentiometer 9007499 Assy foot throttle 900878
49. cap on the bolts e Turn the flaps of the cover with velcro inside and close the zipper carefully Fold also the zipper back inside 120848 01 04 V 120848 01 05 80 Service instructions Trophy 20 5 4 10 Upgrade instructions controllers Mount the foot throttle for advanced electronics ID no QBxxxxx onwards Preparation The following operations are required to mount the foot e Switch off the scooter with the ignition key throttle e Disconnect the batteries Note Suitable work area required Note Remove always one finger control Replace it with Instructions cover steering wheel 9007423 e 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 e Determine the exact laying of the cables under the frame e Reposition the cables in case they will be damaged while drilling the two holes e Replace the floor mat and position the foot throttle mounting plate on the floor mat e Drill the holes and mount the foot throttle mounting plate e Mount the foot throttle on the mounting plate e Guide the cable trough and under the frame to the electronics compartment on the backside of the scooter e Remove the rear cover e Connect the plug to the socket in the electronics compartment and replace the rear cover Basic displ
50. cover from 90A controller in drawing position 9 10 and 11 24 7 Changed article number position 1 into 9003907 26 8 e Added position numbers 27 and 32 to position 22a 22b 22c 22d and 22e e Changed position 30 in 30a and added position 30b 9007275 e Added position 32 9004652 Push rivet 28 9 e Changed QTY with article numbers 00000 2106 and 9005928 pos 12 and 13 e Added position numbers 23 and 31 to position 18a 18b 18c 18d and 18e e Changed position 27 into 27b and added article number position 27a 32 33 1015384 e Added article number 9004652 9005928 and 00000 2106 29 10 Changed QTY with article numbers 00000 2106 and 9005927 pos 13 and 14 e Added position 18 9007368 Sticker Alpine 30 4 3 Changed article number trolleybag 9000701 into 1015545 e Added Lapstrap with roll up for Master seat to drawing 34 79 Updated several service instructions 83 Added paragraph Expand controller options ID no QBxxxxx onwards 90 91 Changed settings S Drive 90A and 120A 2014 V1 13 2 Changed description of acticle numbers 9003406 9003408 9004458 and 9004459 added black 14 3 Changed article number position 6b 9006940 into 1015110 16 4 Added extra balloons in drawing number 19 and 24 to make it clearer e Added position 34 article number 1353 18 5a Added for original electronics to drawing name and for original electronics ID no PBxxxxx only to the original specific options 21 5b e Added for advanced electronics to draw
51. de 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 QL C Instruction for transportation L3 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 T RV 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 rotation of hexago
52. de 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 1 9004442 Front tiller cover Ruby red metallic 20b 1 9004445 Front tiller cover Platinum white metallic 20c 1 9004448 Front tiller cover Sparkling champagne metallic 20d 1 9004451 Front tiller cover Graphite black metallic 20e 1 9004454 Front tiller cover Moonstone blue metallic 21 2 00000 3218 Recessed buttonhead screw M4x12 26 Spare parts Trophy 20 Continued from 08 Seat and seat post Pos Qty Article number 22a 27 32 1 1015363 22b 27 32 1 1015364 220 PT 932 1 1015365 22d 27 32 1 1015366 22e 27 32 1 1015367 23 2 00000 4060 24 1 9004428 25 2 00000 1507 26 1 9003459 27 2 9004652 28 2 9005927 29 2 00000 1507 30a 1 1015454 30b 1 9007275 31 4 9005802 32 2 9004652 Description Front cover Ruby red metallic Front cover Platinum white metallic Front cover Sparkling champagne metallic Front cover Graphite black metallic Front cover Moonstone blue metallic Hexagon head cap screwM4x20
53. e Preparation e Switch off the scooter with the ignition key e 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 e Remove the cap and hexagon flange bolt to remove the rear wheel Remove the brake cable e Remove the two hexagon head cap screw and remove the brake e Mount the new brake e Rebuild the scooter in the reverse order e Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm Relevant article numbers e 9004141 Brake left Tools used e Screwdriver e Torque wrench socket 16 mm e Allen key 5mm e Loctite 243 Notice e 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 scooter Trophy 20 44 Service instructions 110448 04 018 Trophy 20 Service instructions 45 Replacing the carbon brushes Preparation e Switch off the scooter with the ignition key e Disconnect the batteries e 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 e Remove the rear cover e Disconnect all motor connectors from the S drive controller
54. el for advanced electronics ID no QBxxxxx onwards 22 Spare parts Trophy 20 06a Wiring electronics and batteries for original electronics ID no PBxxxxx only p Ri 3 Trophy20 EV 06a Pos Qty Article number Description la 2 9006563 Battery harness 60A 1b 2 9006564 Battery harness 100A for Alpine transaxle 2a 1 9006097 Power harness S Drive 90A 2b 1 9006101 Power harness S Drive 120A for Alpine Transaxle 3a 2 9002758 Battery 34Ah C5 40Ah C20 3b 2 9002759 Battery 50Ah C5 60Ah C20 86 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 f 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 19 1 1002558 Controller interface for original electronics ID no PBxxxxx only 14 1 9006124 Tule 15 2 9004503 Rear light LED 16 4 00000 1501 Hexagon nut M6 17 1 9006105 Horn for original electronics ID no PBxxxxx only 18 1 00000 4322 Hexagon bolt M8x12 19 1 9004431 Speed sensor 20 1 9006095 Main harness for original electronics ID no PBxxxxx only 2il 1 9004419 Charging harness 22 2 9002752 Set battery connection covers 23 1 9006096 Lighting harness for original electronics ID no PBxxxxx only 24 1 9006193 Brake switch extension
55. enance free However attention may be paid to the following matters Note Ensure that the batteries remain clean and dry 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 e Preparations e 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 e Relevant article numbers Tools used The tools for the specific tas
56. er in the reverse order 110448 04 001 L d 110448 04 006 66 Service instructions Trophy 20 110448 04 054 Trophy 20 Service instructions 67 5 4 6 Electronics Replacing the controller for original electronics ID no PBxxxxx only Preparation e Switch off the scooter with the ignition key e Disconnect the batteries Instructions The following operations are required to replace the controller Note Suitable work area required e Remove the rear cover e Remove the S drive cover e Disconnect all connectors from the S drive controller Remove the two hexagon head cap screws and remove the controller e Mount the new controller e Rebuild the scooter in the reverse order Relevant article numbers e 9002457 S drive controller 120A e 1015386 S drive controller 90A Tools used e Allen key 5 mm Notice e Incase 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 68 Service instructions Trophy 20 5 4 7 Covers front Replacing the front tiller cover Preparation e 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 e Remove the basket a
57. er steering column e Remove the bolt to remove the steering wheel e Mount the new steering wheel e Rebuild the scooter in the reverse order 110448 04 001 d R 110448 04 006 110448 04 041 d 110448 04 045 Trophy 20 Service instructions 59 60 Service instructions Trophy 20 Replacing the gas spring Preparation e Switch off the scooter with the ignition key Instructions The following operations are required to replace the gas spring Note Suitable work area required e Remove the basket the mounting bracket for the mirrors the front cover and the front cover rear part e Pull the handle for steering adjustment upwards and move the steering column downwards e Remove the four hinge pins and the spiral pin e Remove the hinge pin and remove the two bolts from the gas spring slider e Disconnect the gas spring actuator e Remove the gas spring slider and loosen the hinge pin and lock nut e Mount the new gas spring e Rebuild the scooter in the reverse order e Note Be sure you fasten all bolts and nuts with the correct torque Relevant article numbers e 9007359 Gas spring 300N Tools used Socket 8 mm 10 mm 13 mm e Screwdriver crosshead e Hammer plastic Chaser e Loctite 243 Notice e Na 110448 04 001 110448 04 006 Trophy 20
58. ery e Remove the battery e Read the table for more information about the adjustment of shock absorbers e Use the special adjustment tool to adjust the shock absorber as desired e Rebuild the scooter in the reverse order G a NSA 110448 04 001 R p 110448 04 028 110448 04 029 R 110448 04 030 54 Service instructions Trophy 20 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 e Switch off the scooter with the ignition key Instructions The following operations are required to replace the shock absorber rear Note Suitable work area required e Remove the seat e Lift the scooter to raise the wheels clear from the ground e Remove the rear cover e Remove the battery cover e Remove the bolts of the rollbar 6x Remove the roll bar Remove the hexagon head cap screws e 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 e Mount the new correct adjusted shock absorber e
59. et for the mirrors the front cover the front spoiler the front cover rear part the front fender L R the front cover bottom and the front bumper e Remove the Allen hexagon screws and locknut form the shock absorbers on the swing arm top and lower assy e Remove shock absorber e Adjust the new shock absorber according the specifications e Replace the new and adjusted shock absorber e Rebuild the scooter in the reverse order e Note Be sure you fasten all bolts and nuts with the correct torque Relevant article numbers e 1012525 Shock absorber front Tools used e Torque wrench socket 17 mm Socket 7mm e Screwdriver crosshead e Allen key 8 mm e 9000825 Suspension adjustment key Notice e Position 0 soft and position 4 hard 110448 04 001 110448 04 002 Service instructions 39 Trophy 20 40 Service instructions Trophy 20 Replacing the swing arms top and lower assy Preparation e Switch off the scooter with the ignition key e 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 e Remove the front spoiler e Remove the cover and the hexagon bolt to remove the front wheel Remove the hexagon screw from the lower swing arm e Remove the two axle suspension
60. g operations are required to replace the front wheel e Remove the cover and the four hexagon screws to remove the front wheel e Mount the new front wheel in the reverse order Relevant article numbers e 9004511 Front wheel 4W Tools used e Screwdriver medium e Torque wrench socket bit 6 mm Notice e 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 e Switch off the scooter with the ignition key e 9000825 Suspension adjustment key Instructions Notice The following operations are required to adjust the shock e Position 0 soft and position 4 hard absorber front e Read the table for more information about the adjustment of shock absorbers e Use the suspention adjustment key to adjust the shock absorber as desired Relevant article numbers e Na Position 0 standard Position 2 Position 3 Position 4 110448 04 035 38 Service instructions Trophy 20 Replacing the shock absorber front Preparation e Switch off the scooter with the ignition key e 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 brack
61. ges 2011 V1 2012 V1 12 01 Changed article number and description 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 17 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 2il 07 Deleted article number 9005628 is no spare part 22 23 08 09 Changed article numbers 9004443 9004446 9004449 9004452 and 9004455 into 1015363 1015364 124 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 73
62. hy 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 compliance with the a
63. ing name and for advanced electronics ID no QBxxxxx onwards to the advanced specific options e Changed article numbers positions 30 and last position 9007572 9007374 9007373 and 9007372 into 9008789 9008791 9008790 and 1016535 22 6a Added for original electronics to drawing name and for original electronics ID no PBxxxxx only to the original specific options 25 6b e Added for advanced electronics to drawing name and for advanced electronics ID no QBxxxxx onwards to the advanced specific options e Changed article number position 13 9004430 into 9008778 Trophy 20 101 Version Page Draw Changes 24 7 Changed description of article number 00000 3716 29 10 Added postion 18 Sticker Alpine to drawing 30 4 3 e Updated drawing of article number 9000703 front bag e Changed article number position 9 cane holder mounted to chassis 1012515 into 1015389 63 Changed article numbers 9007572 9007374 and 9007373 into 9008789 9008791 and 9008790 82 e Changed article numbers 9007372 9007572 and 9007373 into 1016535 9008789 and 9008791 e Added article number to 4 Tiller PCB Dual control e Updated expand controller options table 88 7 3 Added chapter 7 3 Driving programs Added Tor original advanced electronics to desciptions ID no PBxxxxx only QBxxxxx onwards 89 92 Updated electronic settings 2015 V1 12 1 Changed article numbers 15010 4100 and 9004161 into 1015118
64. k are illustrated in the visual instructions 34 Service instructions Trophy 20 5 4 1 Front frame 3W Replacing the front wheel and fork Preparation e Switch off the scooter with the ignition key e Use a lifting device to raise the scooter clear of the ground Instructions The following operations are required to replace the front fork 3W e Remove the front cover and the front cover rear part e Remove the retaining ring and spiral pin e Remove the complete fork with wheel e Remove the hexagon nut washer and bolt to take out the wheel Replace the new front fork 3W e Rebuild the scooter in the reverse order Notice Some parts need to be replaced the replacement is indicated by a symbol e Some operations have to be carried out by two persons this is indicated by a symbol Relevant article numbers e 9004153 Front fork Tools used e Torque wrench socket 13 mm Screw driver crosshead e Hammer plastic e Chaser e Circlip pliers e Open ended spanner 13 mm 110448 04 001 110448 04 002 110448 04 060 Trophy 20 Service instructions 35 36 Service instructions Trophy 20 5 4 2 Front frame 4W Replacing the front wheel Preparation e Switch off the scooter with the ignition key e Use a lifting device to raise the scooter clear of the ground Instructions The followin
65. krest frame MZ Trophy 20 Service instructions 73 Mount the crutch holder chassis Preparation Switch off the scooter with the ignition key Instructions The following operations are required to mount the crutch holder on the chassis Note Suitable work area required Remove the rear cover Remove the two hexagon bolts and washers to remove the rear bumper Mount the crutch 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 Relevant article numbers e 1012515 Crutch holder mounted to chassis Tools used e Torque wrench socket 7 mm e Metal drill 4 mm e Drill e Allen key 3 mm 110948 03 014 F INS ES 110948 03 015 110948 03 015A Trophy 20 74 Service instructions 110948 03 015B Trophy 20 Service instructions 75 Mount the anti tip wheels Preparation Relevant article numbers e Switch off the scooter with the ignition key e 1015401 Anti tip set e Use a lifting device to raise the scooter clear of the ground Tools used e Open ended spanner 13 mm
66. le 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 4 2 Overview exploded views Ca Ca j Gen 056 gt f gt LR d r sa 03 06b 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 for original electronics ID no PBxxxxx only 18 05b Console printed circuit board and throttle control for advanced electronics ID no QBxxxxx onwards 20 06a Wiring electronics and batteries for original electronics ID no PBxxxxx only 22 06b Wiring electronics and batteries for advanced electronics ID no QBxxxxx onwards 28 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 j Trophy20 EV 01 Pos Qty Article number Description 1 2 9004420 Battery strap 2 2 00001 0008 Battery spacer block 8 2 9000493 Ball head bearing 6004 2NSE 3 4 1 9003440 Frame with ball head bearings 3W 5 2 9006079 Washer flat M4x
67. nd the mounting bracket for the mirrors e Loosen the two bolts to remove the front tiller cover e Mount the new front tiller cover e Rebuild the scooter in the reverse order Relevant article numbers e 9004442 9004445 9004448 9004451 9004454 Front tiller cover Tools used Socket 10 mm e Screwdriver crosshead Notice e Make sure the scooter is switched off 110448 04 001 110448 04 006 110448 04 056 Trophy 20 Service instructions 69 Replacing the front cover Preparation e Switch off the scooter with the ignition key Instructions The following operations are required to replace the front cover Note Suitable work area required e 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 e Put the head light cover back in the new front cover e Rebuild the scooter in the reverse order Relevant article numbers e 1015363 1015364 1015365 1015366 1015367 Front cover Tools used e Screwdriver crosshead Notice e Make sure the scooter is switched off 110448 04 001 1 S 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 70 Service instructions Trophy 20 5 4 8 Covers rear
68. ning Pull the charge cable out of the battery charging connection of the scooter before carrying out any maintenance on the scooter 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 A 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 M 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 maint
69. ns 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 PRO210 B version Reading out the fault history BG et Alternative device for PC Adaptation of the drive programs 1 prog and technical settings 10237 SPIS hema 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 e D number see the identification plate e Group to which the relevant part belongs e Article number e Number of parts required e Description in the relevant language e Dimensions if applicable Remark e 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 e 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 locally applicab
70. nt Limit Max Amps 60 Battery Curve Scaler 0 Boost Drive Current Amps 90 S Drive II Only Boost Drive Time Seconds 10 Inhibit Settings Current Foldback Threshold Amps 60 Inhibit 1 Mode 1 Current Foldback Time Seconds 70 Inhibit 1 Operation Latching Current Foldback Level 59 Inhibit 1 Speed 0 Motor Cooling Time Seconds 660 Inhibit 2 Mode 1 Current Foldback Temperature Deg C 80 Inhibit 2 Operation Latching Current Limit Min Amps 10 Inhibit 2 Speed 0 Motor Stall Timeout Seconds 0 S Drive II Only Inihibit 3 Mode 1 Motor Compensation milli Ohms 25 Inhibit 3 Operation Non Latching AntiRollback Level 12 S Drive Only Inhibit 3 Speed 0 Pull away Delay centi Seconds 0 S Drive Only Aux Output Mode 1 Slope Factor 900 S Drive Only Anti Rollback Velocity 0 S Drive Only Factory Settings Max Min Braking Current Limit Amps 90 S Drive 180A S Drive Il pele NN pena ed Timed Foldback Braking Current Amps 90 S Drive 180A S Drive Il EE Seconds 100 Timed Foldback Speed 100 S Drive 180A S Drive Il Forward Speed 190 0 Enhanced Motor Compensation Up 190 S Drive II Only Reverse Speed 100 0 Enhanced Motor Compensation Down 180 Enhanced Motor Compensation Up Gain 90 S Drive II Only S Drive II Only Throttle Settings Throttle Type 1 0 Single ended 1 Wig wag 2 Unipolar Throttle Deadband 15 Throttle Gain 140 Throttle Operated at Power up
71. ntrollers lit continuously is a poor connection to the batteries and the batteries If the connections are OK try recharging the batteries LED bar left to right chase The batteries are being charged Disconnect the battery charger from the scooter Two LEDs of the LED bar are lit There is a poor connection to the motor Check all connections between the controller and the motor Three LEDs of the LED bar are lit There is a short circuit in the motor Check the motor cables or replace the motor Seven LEDs of the LED bar are lit The throttle was held in during start up Restart the scooter without pressing the throttle Speed potentiometer fault Check or replace the speed potentiometer Eight LEDs of the LED bar are lit The controller is malfunctioning Replace the controller Nine LEDs of the LED bar are lit The neutral handle is in the neutral Put the neutral handle in the drive position position Check the connections between the brake and the The brake is malfunctioning controller Replace the brake Ten LEDs of the LED bar are lit The battery is malfunctioning 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 mobility programmer PG LED code Trip code Error type Explanation 1 2c00
72. o QBxxxxx onwards Trolleybag Rear Basket Mounting bracket rear Luggage carrier Walking aid holder Front bag for std bracket with locking mechanism Cane holder mounted to chair horizontal Cane holder mounted to chair vertical Cane holder mounted to chassis Mirror right Anti tip set Adjustmenttool for rear spring Basket standard Basket large only without locking mechanism 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 xX Cleaning the scooter x Monthly 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 x x Annually Inspecting the electrical system 2 Checking the batteries z 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
73. op Brake Time milli Seconds Output Voltage Volts Status Output Type Diagnostic Flash Sequence Reverse Alarm Pulsed Reverse Alarm Diagnostic Alarm Brake Disconnected Alarm Brake Fault Detect Brake Light Push too Fast Threshold Push too Fast Timeout Freewheel Enable Inhibit 2 Horn Input Enable Motor Settings Current Limit Max Amps Boost Drive Current Amps Boost Drive Time Seconds Current Foldback Threshold Amps Current Foldback Time Seconds Current Foldback Level Motor Cooling Time Seconds Current Foldback Temperature Deg C Current Limit Min Amps Motor Stall Timeout Seconds Motor Compensation milli Ohms AntiRollback Level Pull away Delay centi Seconds Slope Factor Anti Rollback Velocity Braking Current Limit Amps Timed Foldback Braking Current Amps Timed Foldback Speed Enhanced Motor Compensation Up Enhanced Motor Compensation Down Enhanced Motor Compensation Up Gain Throttle Settings Throttle Type 1 Throttle Deadband 15 Throttle Gain 140 Throttle Operated at Power up 2 Throttle Reference Test On ISO Test Resistor Off Timed Throttle Invert 0 S Drive II Only 1500 24 0 0 Trucharge 1 LED 2 Analogue Off Off Off Off On On 100 20 Disable Off S Drive 120 140 180A S Drive II 60 90 10 60 70 59 660 80 10 0 S Drive II Only 25 12 S Drive Only 0 S Drive Only 900 S Drive Only 0 S Drive Only
74. ove the transaxle and rubber mounting strips e Mount the new the transaxle e Rebuild the scooter in the reverse order e Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm Relevant article numbers e 1012530 Transaxle standard e 1012529 Transaxle heavy duty Tools used e Socket 7mm e Socket 17 mm e Torque wrench socket 16 mm e Screwdriver e Allen key 5mm e Loctite 243 Notice e Some parts need to be replaced the replacement is indicated by a symbol e Make sure the scooter is switched off 110448 04 001 110448 04 002 Trophy 20 Service instructions 51 110448 04 021 110448 04 022 110448 04 016 110448 04 017 Note Use Loctite 243 at the indicated locations during assembling the scooter Trophy 20 52 Service instructions 110448 04 025 Replacing the transaxle_9 Trophy 20 Service instructions 53 Adjustment the shock absorber rear Preparation Relevant article numbers e Switch off the scooter with the ignition key e Na Instructions Tools used The following operations are required to adjust the shock e 9000825 Suspension adjustment key absorber rear Note Suitable work area required Notice e Remove the seat Make sure the scooter is switched off e Remove the battery cover e Loosen the battery strap e Disconnect all connectors from the batt
75. pplicable 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 a radio transmitter or mobile telephone while the electric scooter is switched on 2 Keep at a distance from transmitter equipment such as radio and TV stations 3 If the scooter starts making
76. r 3 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 13 4 00000 2106 Washer flat M4 3xD 14 4 9005927 Hexagon bolt M4x20 15 1 1012516 Assy Battery cover 16 2 9003479 Reflector orange 117 1 1012519 Assy Seat post cover 18 2 9007368 Sticker Alpine 30 Spare parts Trophy 20 4 3 Options Pos Qty Article number Description 1a 1b 1c 1d 1e 1a 1b 1c 1d 1e 1a 1b 1c 1d 1e 1a 1b 1c 1d 1e 1a 1b 1c 1d 1e EZE co E cn oe 1012429 1012430 1012431 1012432 1012433 1008572 9007499 1015545 4930 9000620 1001813 1001814 9000703 1003095 2537 1015389 1009251 1015401 9000825 9001135 9006137 1015507 Colour exchange set Graphite black metallic 3 covers Colour exchange set Moonstone blue metallic 3 covers Colour exchange set Ruby red metallic 3 covers Colour exchange set Sparkling champagne metallic 3 covers Colour exchange set Platinum white metallic 3 covers Assy foot throttle for original electronics ID no PBxxxxx only Assy foot throttle for advanced electronics ID n
77. r user name and password User name dealer mobilityftp handicare com Password dealer You will be logged on e Select your wheelchair and the appropriate controller e Click the file to download Trophy 20 Technical product information 89 7 4 Controller settings PG Drives PGDT S Drive 90A for original electronics ID no PBxxxxx only Speed Settings Forward Acceleration 0 1 Seconds Forward Deceleration 0 1 Seconds Reverse Acceleration 0 1 Seconds Reverse Deceleration 0 1 Seconds Max Forward Speed Min Forward Speed Max Reverse Speed Min Reverse Speed Speed Limit Pot Enabled Operation Settings Sleep Timer Minutes Throttle Invert Battery Settings Low Battery Flash Level Bars Cable Resistance milli Ohms Calibration Factor Low Battery Alarm Trucharge Reset Voltage Deci Volts S Drive 180A S Drive II Battery Curve Scaler S Drive II Only Inhibit Settings Inhibit 1 Mode Inhibit 1 Operation Inhibit 1 Speed Inhibit 2 Mode Inhibit 2 Operation Inhibit 2 Speed Inihibit 3 Mode Inhibit 3 Operation Inhibit 3 Speed Aux Output Mode Factory Settings Acceleration 0 1 Seconds Deceleration 0 1 Seconds Forward Speed Reverse Speed Fast Slow 35 35 16 16 40 40 35 35 100 100 10 10 25 25 5 5 100 Off 250 1 Latching 0 1 Latching 0 1 Non Latching 0 1 Max Min 100 1 100 1 100 0 100 0 General Settings Soft St
78. rake Disconnected Alarm Tone Brake Fault Detect Brake Light 0 Push too Fast Threshold so Push too Fast Timeout 100 Freewheel Enable Off Inhibit 2 Horn Input Enable 250 Motor Settings Current Limit Max Amps 0 Boost Drive Current Amps Boost Drive Time Seconds Current Foldback Threshold Amps 1 Current Foldback Time Seconds Latching Current Foldback Level 0 Motor Cooling Time Seconds 1 Current Foldback Temperature Deg C Latching Current Limit Min Amps 0 Motor Stall Timeout Seconds 1 Motor Compensation milli Ohms Non Latching AntiRollback Level 0 Pull away Delay centi Seconds 1 Slope Factor Anti Rollback Velocity Max Min Braking Current Limit Amps 199 1 Timed Foldback Braking Current Amps 1903 2 Timed Foldback Speed a Enhanced Motor Compensation Up Enhanced Motor Compensation Down Enhanced Motor Compensation Up Gain Throttle Settings Throttle Type 1 Throttle Deadband 15 Throttle Gain 140 Throttle Operated at Power up 2 Throttle Reference Test On ISO Test Resistor Off Timed Throttle Invert 0 S Drive II Only 1000 24 0 Off Off Off On On Off 100 20 0 Trucharge 1 LED 2 Analogue S Drive 120 140 180A S Drive Il Disable Off 110 120 10 60 70 59 660 30 10 25 12 900 120 120 100 190 180 90 S Drive 120 140 180A S Drive Il S Drive II Only S Drive Only S Drive Only S Drive
79. required e Some parts need to be replaced the replacement is e Remove the rear cover indicated by a symbol e Disconnect all motor connectors from the S drive e Make sure the scooter is switched off controller and the speed sensor cable e Lock the freewheel lever e Remove the four hexagon bolts and remove the motor cover e Remove the hexagon screws and remove the free wheel lever e Mount the new free wheel lever e Rebuild the scooter in the reverse order 110448 04 001 110448 04 002 Trophy 20 Trophy 20 Service instructions 49 50 Service instructions Trophy 20 Replacing the transaxle Preparation e Switch off the scooter with the ignition key e Disconnect the batteries e 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 e Remove the rear cover e Disconnect all motor connectors from the S drive controller and the speed sensor cable e Lock the freewheel lever e Remove the four hexagon bolts and remove the motor cover e Remove the cover and hexagon flange bolt to remove the rear wheel e Remove the brake cable e Remove the two hexagon head cap screws to remove the brake mounting key and brake e Remove the four lock nuts and rem
80. rference 2 5 Markings on the scooter 2 6 Technical specifications 2 7 Modifications Adaptations 3 Tools 3 1 Tools 4 Spare parts 4 1 Use of the parts lists 4 2 Overview exploded views 4 3 5 Service instructions 5 1 5 2 5 3 5 4 5 5 6 Troubleshooting 01 Front frame front fork and front wheel Trophy 20 3W 02 Front frame front suspension and front wheels Trophy 20 4W 03 Rear frame drive unit and rear wheels 04 Steering column mirror and basket 05a Console printed circuit board and throttle control for original electronics ID no PBxxxxx only oun N ONNNN 18 05b Console printed circuit board and throttle control for advanced electronics ID no QBxxxxx onwards 20 06a Wiring electronics and batteries for original electronics ID no PBxxxxx only 06b Wiring electronics and batteries for advanced electronics ID no QBxxxxx onwards 07 Seat and seat post 08 Covers Trophy 20 3W 09 Covers Trophy 20 4W 10 Covers common Options Maintenance plan Batteries Tyres Assembly replacement and adjustment instructions 5 4 1 Front frame 3W 5 4 2 Front frame 4W 5 4 3 Rear frame 5 4 4 Steering column 5 4 5 Console 5 4 6 Electronics 5 4 7 Covers front 5 4 8 Covers rear 5 4 9 Accessories 5 4 10 Upgrade instructions controllers Display menu settings 22 23 24 25 27 29 30 31 31 32 33 33 34 36 42 58 62 67 68 70 71 80 83 4 Trophy 20 7 Technical product mtormmaton adaa h
81. t the four Ejot screws and the e Screwdriver crosshead dashboard e Disconnect all connectors from the tiller PCB Notice Remove the three Ejot screws to remove the tiller PCB e Make sure the scooter is switched off e Mount the new tiller PCB e Rebuild the scooter in the reverse order 110448 04 001 d R 110448 04 006 110448 04 042 64 Service instructions Trophy 20 110448 04 053 Trophy 20 Service instructions 65 Replacing the stop switch Preparation Relevant article numbers e Switch off the scooter with the ignition key e 9006138 Emergency stop e Disconnect the batteries Tools used Instructions e Socket 10 mm The following operations are required to replace the stop e Screwdriver crosshead switch Note Suitable work area required Notice e Remove the basket and the mounting bracket for the e Make sure the scooter is switched off mirrors Remove the two bolts and remove the front tiller cover e Remove the nut the four Ejot screws and the dashboard e Remove the tyrap e Disconnect all connectors from the tiller PCB e Remove the three Ejot screws to remove the tiller PCB e 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 e Mount the new stop switch e Rebuild the scoot
82. ttings into Mk 2013 V1 12 1 Added position 17 18 19 20 and 30 article number 9007273 9007274 9005928 00000 2106 and 9007355 13 2 e Changed description position 18 article number 1015664 e Added position 30 article number 9007355 14 3 e Changed description of article numbers 1014662 1014661 and 9004146 Added article numbers 9007436 9006940 1015292 9006240 and 1015554 e Changed QTY with article numbers 9004564 and 00000 4004 e Deleted position 19a and changed 19b into 19 16 4 Deleted position 20 00000 1702 Lock nut M8 e Added warning with position 19 and 22 in drawing e Added position 23b 00000 1700 Lock nut M5 QBxxxxx onwards e Added position number 25 to position 26 e Added position 37 9006418 Cover mirror bracket e Added postition 10 37 1015387 Mirror interface and cover ID no PBxxxxx only 18 5a e Changed article number position 1 9004425 into 9007301 e Changed article number and description 9004197 into 21a 9007303 rear cover steering column and 21b 9006167 rear cover steering column with hole for switch e Changed article number position 30 9007265 into 1015179 e Added position 36 9002104 Spacer 3 2 x 5 5 x 2 2 20 5b e Changed article number position 1 9004425 into 9007301 e Changed article number and description 9004197 into 21a 9007303 rear cover steering column and 21b 9006167 rear cover steering column with hole for switch e Added position 36 9002104 Spacer 3 2 x 5 5 x 2 2 22 23 6a 6b Split Connector
83. u is the Total km 1 e Pushing the hazard button again G allows you to scroll through the menu shown below e If 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 84 Service instructions Trophy 20 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 e right hand is lit right hand side throttle is active e left h
84. uct information 94 7 6 Electrical diagram Trophy 20 ID no PBxxxxx only ICS iginal electron Or V 7619006 NS PIDRUDIS SATIP S OZ AYTOT
85. ult 0 off Change by pressing the DSS 1 switch 2 2 seconds First two characters of the display show tS Trophy 20 Troubleshooting 85 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 The Controller security has found Switch off the scooter rapidly something that causes a problem 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 The socket LED is lit continuously Short circuit in the potentiometer Contact the manufacturer after the scooter is switched on Cabling from the Tiller PCB to the controller interface is defective Cabling from the Tiller PCB to the touch control is defective Tiller PCB is defective The first red LED of the LED bar is The batteries require charging or there Check all connections between the co
86. xagon head cap screwM8x55 Spacer Handle steering adjustment Steering wheel see 05a and 05b Cover mirror bracket Mirror interface and cover for original electronics ID no PBxxxxx only 18 Spare parts Trophy 20 05a Console printed circuit board and throttle control for original electronics ID no PBxxxxx only Ee g Q NI A QC KD LOO A a Li UL d 4 Buran EV 05a Pos Qty Article number Description 1 1 9007301 Drumbrake actuator cable 2 1 9006191 Extension cable for microswitch 5 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 9007423 Cover steering wheel 11 4 00000 3307 Sheet metal screw 2 9x13 12 1 9004331 Cover brake position 13 1 00000 3719 Buttonhead screw M5x10 14 1 9005810 Ignition key 18 1 9006111 Ignition switch for original electronics ID no PBxxxxx only 16 2 9004303 Cover for indicator switch 17 2 9006106 Indicator switch for original electronics ID no PBxxxxx only 18 1 9004302 Steering wheel cover bottom 19 1 9004301 Steering wheel cover top 20 1 9005802 Srew Ejot K40x12 21a il 9007303 Rear cover steering column 21b 1 9006167 Rear cover steering column with hole for switch 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

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