Handicare winner 2004 Service Manual
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Handicare winner 2004 Service Manual

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SERVICEMANUAL
WINNER 2004

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  • Page 1 SERVICEMANUAL WINNER 2004...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents This manual ................................. 4 Product reference ............................... 5 Available documentation ............................7 Service and technical support........................... 7 Identification plate ..............................7 Identification of the product ............................7 Warranty stipulations concerning the scooter ......................8 Liability stipulations concerning the Product ......................9 Used scooters and the environment ........................

  • Page 4: This Manual

    Preface This manual This manual contains the basic instructions for repairs and general maintenance of the Winner electric scooter. Mechanics who do repairs on this scooter must be well trained and familiar with the repair methods and the maintenance of the Winner electric scooter. It is important to see to it that work is always done safely, particularly with respect to activities where the scooter must be lifted up.

  • Page 5: Product Reference

    Preface Product reference XXXXXX-010004000-en.doc 010004000 The product has the following decals and labels. A. Charging connection B. Fuse for lighting C. Automatic fuse D. Driving E. Pushing F. Tire pressure wheels G. Reverse – Forward drive Version 2011v3...
  • Page 6 Preface Charging connection For charging the batteries, see 'charging'. PICPRO-010004210-en.doc Fuse for the lighting Here you find the fuse for the lighting. See 'Product specifications'. Automatic fuse The scooter has a safety fuse feature. See 'automatic fuse' and 'faults'. PICPRO-010004270-en.doc Driving The drive of the motor is switched on: the scooter can be electrically driven.

  • Page 7: Available Documentation

    Preface Available documentation The following technical documentation is available for this scooter: Owner's manual Service manual. XXXXXX-010005000-en.doc Service and technical support For information concerning specific settings, maintenance or repair work please contacts your dealer. He is always prepared to help you. Ensure you have at hand: Model Manufacture year...

  • Page 8: Warranty Stipulations Concerning The Scooter

    Handicare gives no warranty on repair to or reconditioning of the Product carried out other than under order of and/or at the instructions of Handicare. If repairs and/or reconditioning are executed by or on behalf of a Customer, the Customer indemnifies Handicare with respect to the claims of third parties who result, in the broadest sense of the word, from such repairs or reconditioning.

  • Page 9: Liability Stipulations Concerning The Product

    Handicare only accepts liability for loss due to death or physical injury that is the result of a defect in the Product for which Handicare is responsible and for damage to another object that is the private property of the user of the Product, as long as said loss is the direct result of a fault in the Product.

  • Page 10: General Safety Regulations And Instructions

    1 General safety regulations and instructions Handicare accepts no liability whatsoever for damage or injury caused by the failure to (strictly) adhere to the safety guidelines and instructions or else due to carelessness during the use and cleaning of the scooter and possible accessories.
  • Page 11 General safety guidelines and instructions • Never use your scooter to pull a cart: the scooter was not designed for this. Anyway, it is prohibited to do so. You might seriously damage your scooter if you do. • Do not use the footplate as a step. •...

  • Page 12: Adjustment Options

    Adjustment options 2 Adjustment options XXXXXX-010500000-en.doc Seat adjustments The Winner seat offers a number of adjustment options to increase the sitting and driving comfort. The following may be adjusted: A. Seat height and depth B. Backrest C. Lower-back rest D. Arm-rests E.

  • Page 13: Adjusting The Arm-Rest

    Adjustment options 2.1.4 Adjusting the arm-rest See fig. 000000160. • Both armrests can be folded up completely. The height and the angle of the armrest can be adjusted. The adjustment must be done as follows: Turn wheel (A) to adjust the height and the angle of the arm-rest. •...

  • Page 14: Drive Programs

    Drive programs 3 Drive programs A hand held programmer is deliverable for programming the Winner with Solo controller. An user maunal belongs to the delivery of this manual. For the Winner with S-Drive controller there is a software program available but it’s also programmable with the hand held programmer.

  • Page 15: Controller Settings Winner S-Drive 120A

    Drive programs Controller settings Winner S-drive 120A Version 2011v3...

  • Page 16: Controller Settings Winner S-Drive 140A Schmid

    Drive programs Controller settings Winner S-drive 140A Schmid. Version 2011v3...

  • Page 17: Controller Settings Winner S-Drive 140A Heavy Duty Schmid

    Drive programs Controller settings Winner S-drive 140A Heavy Duty Schmid. Version 2011v3...

  • Page 18: Controller Settings Winner S-Drive 140A Ct

    Drive programs Controller settings Winner S-drive 140A CT. Version 2011v3...

  • Page 19: Electrical Diagram S-Drive

    Electrical diagrams Electrical Diagram S-Drive Version 2011v3...

  • Page 20: Connections Printed Circuit Board

    Electrical diagrams Connections printed circuit board CN14 CN12 CN13 CN11 CN10 The PCB connections are stated in the table below. Number Connection Number Function Lighting switch Head light Main harness Throttle Key Switch CN14 Horn switch left Speed potentiometer/ Horn switch right / Battery indicator Horn Hazard light switch...

  • Page 21: Technical Specifications

    Technical specification 4 Technical specifications XXXXXX-010900000-nl.doc Product specifications Manufacturer Handicare Nederland b.v. 4.1.1 Winner Model 3 Wheel 4 Wheel Maximum user's weight 159 kg 159 kg Description 3 Wheel 4 Wheel Total length 1410 mm 1410 mm Total width 673 mm...

  • Page 22: Approval

    Technical specifications Batteries 3 Wheel 4 Wheel Maximum dimensions batteries 324 x 175 x 213 mm 324 x 175 x 213 mm Weight scooter without batteries 93 kg 98 kg Battery capacity 80 Ah/20h 80 Ah/20h Maximum permissible charging voltage 13,6 V 13,6 V Maximum charging current...

  • Page 23: Use Of The Parts Lists

    Parts lists Use of the parts lists This document is meant as a reference book to be able to order parts for the scooter as shown on the front. How to order: To order parts please specify: Serial number (see the identification plate). •...
  • Page 24 Parts lists Winner 2004 Winner 2004 001: SCOOTER ASSY (3W) Article number Units Description No spare part 3W Scooter assy 20456.0682 Rubber bellow 9003154 Tiller parallel assy 00000.4134 Screw M8xP1.25x35L 1001675 Arc Washer 00000.1702 Lock nut M8 161.00151.000 Console bottom cover assy 00000.3200...
  • Page 25 Parts lists Winner 2004 Winner 2004 002: SCOOTER ASSY (4W) Article number Units Description No spare part 4W Scooter assy 20456.0682 Rubber bellow 9003154 Tiller parallel assy 00000.4134 Screw M8xP1.25x35L 1001675 Arc Washer 00000.1702 Lock nut M8 161.00151.000 Console bottom cover assy 00000.3200...
  • Page 26 Parts lists Winner 2004 003: CONSOLE TOP COVER ASSY Article number Units Description 1001334 Console top cover 1001335 Head light assy 1001336 Head light seal 264.00121.000 Head light DC24 3W 161.00171.000 Console top cover assy Version 2011v3...
  • Page 27 Parts lists Winner 2004 Winner 2004 004: CONSOLE BOTTOM COVER ASSY Article number Units Description 1001321 Console bottom cover 9003156 Potentionmeter cable assy 1001323 Screw 4,2x12mm 1001208 PCB tiller 1001324 Screw 2,9x8mm 1001325 Horn 1001326 Front indicator assy 1001327 Toggle switch wire assy...
  • Page 28 Parts lists Winner 2004 Winner 2004 005: CONSOLE PANEL ASSY Article number Units Description 1001337 Console panel cover 1001338 Battery indicator + speedswitch (Solo) 9003087 Battery indicator + speedswitch (S-Drive) 1001340 Horn switch cable assy 1001340 Horn switch cable assy...
  • Page 29 Parts lists Winner 2004 Winner 2004 006: WIG-WAG ASSY Article number Units Description No spare part Wig-wag No spare part Finger control (LH) No spare part Finger control (RH) No spare part Screw M4xP0.7x8L black 1001355 Plastic tip finger (LH) (Green)
  • Page 30 Parts lists Winner 2004 Winner 2004 007: TILLER ASSY Article number Units Description 9003091 Handle 125.00031.000 Hand grip (foam) 108.00281.000 Brake handle 00000.9002 Plug for hand grip 22x2 1001313 Pivot bush 1001308 Channel front assy 1001315 Pivot pin 1001316 Spring washer black 1001317 Screw M6xP1.0x10L black...
  • Page 31 Parts lists Winner 2004 008: CHANNEL FRONT ASSY Article number Units Description 1001309 Channel front 1001310 Gas spring 1001311 Pivot pin 00000.1402 Clip E7 1001312 Bush Version 2011v3...
  • Page 32 Parts lists Winner 2004 009: BACK TILLER SHROUD ASSY Article number Units Description 1011153 Back tiller shroud assy (Solo) 1009684 Back tiller shroud assy (S-Drive) 008.00000.391 Label "charger" 00001.1347 Label "CE" 008.00000.371 Label "tiller adjust" 1001361 Charger plug cable assy (Solo)
  • Page 33 Parts lists Winner 2004 010: SCOOTER ASSY (3W) Article number Units Description No spare part 3W Scooter pro assy 108.00291.000 Brake cable assy 00000.7718 P-clip ACC-4 1011153 Back tiller shroud assy (Solo) 1009684 Back tiller shroud assy (S-Drive) 1001365 Screw M4xP0.7x6L black 052.00342.000...
  • Page 34 Parts lists Winner 2004 011: SCOOTER ASSY (4W) Article number Units Description 170.00352.000 Rear wheel assy 1004591 Front wheel assy 1011153 Back tiller shroud assy (Solo) 1009684 Back tiller shroud assy (S-Drive) 1001365 Screw M4*P0.7*6mm 052.00342.000 Tiller cover assy front 1001366 Screw M4*P.07*10mm...
  • Page 35 Parts lists Winner 2004 Winner 2004 012: FRONT TIRE ASSY (3W) Article number Units Description 176.00182.000 Brake hub 172.00062.000 Outer tire 4.10x3.50x6" 176.00191.000 Spacer Bush 00001.1462 Label max 2.7 bar 173.00052.000 Outer Rim 6" 173.00042.000 Inner Rim 6" 171.00021.000 Tube Inner with Cap 015.07030.001...
  • Page 36 Parts lists Winner 2004 Winner 2004 013: FRONT FORK (3W) Article number Units Description No spare part Fork Weldment No spare part Tube cap No spare part Nylon bearing No spare part Spring stopper No spare part Compression Spring No spare part...
  • Page 37 Parts lists Winner 2004 014: FRONT FORK ASSY (3W) Article number Units Description 170.00342.000 Front wheel assy (3W) 110.00022.000 Front fork assy 00000.2003 Flat washer M8 00000.2203 Spring washer M8 1009325 Bolt M8x25 (10.9) 176.00172.000 Axle for front wheel 176.00251.000 Collar for front wheel 108.00271.000...
  • Page 38 Parts lists Winner 2004 015: FRONT FRAME ASSY (3W) Article number Units Description 110.00072.000 Front frame weldment No spare part Front fork & wheel assy 015.07010.002 Head set 126.00011.000 Front bumper No spare part Snap button 00000.4104 Screw M6xP1.0x55L 00000.2002 Flat washer W6 00000.1701...
  • Page 39 Parts lists Winner 2004 016: FRONT FRAME ASSY (4W) Article number Units Description 1004626 Frontframe 4w weldment 1004581 Steering tube 015.07010.002 Head set 1001261 Insert 1004582 Knuckle RHS 1004583 Knuckle LHS 00000.4110 Bolt M10xP1.5*70mm 00000.1703 Nut M10*P1.5 001.03010.003 Bolt M8*P1.25*125mm 00000.2103...
  • Page 40 Parts lists Winner 2004 016: FRONT FRAME ASSY (4W) Article number Units Description 1004591 Front wheel assy 00000.2005 Washer Ø12*Ø19*1.0 00000.1703 Lock nut M12*P1.75 1004593 Bush Ø16*8mm 00000.4135 Bolt M8*P1.25*25mm 1004594 Brake assy RHS 1004595 Brake assy LHS 00000.1502 Nut M8*P1.25 00000.4311...
  • Page 41 Parts lists Winner 2004 017: KNUCKLE RHS ASSY (4W) Article number Units Description 1004599 Bracket 1004600 Knuckle 1004601 Ball bearing 00000.2003 Washer M8 00000.1702 Nut M8*P1.5 1004602 Bolt M8*P1.5 1004603 Washer 1004582 Knuckle RHS assy (4W) Version 2011v3...
  • Page 42 Parts lists Winner 2004 018: KNUCKLE LHS ASSY (4W) Article number Units Description 1004604 Bracket 1004605 Knuckle 1004601 Ball bearing 00000.2003 Washer M8 00000.1702 Nut M8*P1.5 1004602 Bolt M8*P1.5 1004603 Washer 1004583 Knuckle LHS assy (4W) Version 2011v3...
  • Page 43 Parts lists Winner 2004 019: FLOORPAN ASSY (3W) Article number Units Description No spare part Front cover 3w 1001273 Shroud "J" bracket 00001.1110 Rivet pop 126.00032.000 Bumper trim (LH) 126.00042.000 Bumper trim (RH) 001.15010.002 Snap button 008.00000.401 Label "Winner" 1012256...
  • Page 44 Parts lists Winner 2004 020: SCOOTER ASSY (3W) Article number Units Description No spare part Body frame assy 1012256 Front floorpan assy with floor mat 00000.3304 Screw 4,2x16 257.00001.000 Floor mat 3w 1001276 Holding Elastic Band 00001.1110 Rivet pop 4-4 00000.2108...
  • Page 45 Parts lists Winner 2004 021: FLOORPAN ASSY (4W) Article number Units Description 1004579 Front cover 1001273 Bracket 2t*10*80 00001.1110 Pop rivet 1004580 Side strip 5t*25*380L 1004198 Snap button 008.00000.401 Label "Winner" 1004575 Floorpan assy (4W) Version 2011v3...
  • Page 46 Parts lists Winner 2004 022: SCOOTER ASSY (4W) Article number Units Description No spare part Main frame assy 1004575 Front cover assy 00000.3304 Screw M4*16mm 1004576 Floor mat 3.0t*390*490 1004577 Foot step 3.0t*107*188 1001276 Elastic strap 00001.1110 Pop rivet 00000.2108 Washer M3 138.00011.000...
  • Page 47 Parts lists Winner 2004 023: BODY FRAME ASSY (3W) Article number Units Description No spare part Front frame assy No spare part Rear frame assy 110.00141.000 Axle for rear frame 00000.1402 Clip E7 See 028 and 029 Transaxle assy No spare part 1001266 Screw M10xP1.5x90L...
  • Page 48 Parts lists Winner 2004 024: BODY FRAME ASSY (4W) Article number Units Description No spare part Front frame assy 4w No spare part Rear frame assy (modified) 00000.4105 Bolt M8xP1.25*40mm 00000.1502 Nut M8*P1.25 See 028 and 029 Transaxle assy 1001266 Screw M10xP1.5x90L...
  • Page 49 Parts lists Winner 2004 025: REAR FRAME ASSY Article number Units Description 110.00082.000 Rear Suspension Bridge No spare part Label "serial number" 00001.1110 Rivet pop 1010353 Plastic wheel 00000.2003 Flat washer M8 black 00000.1702 Lock nut M8xP1.25 black 1001232 Screw M8xP1.25x75L black 126.00021.000...
  • Page 50 Parts lists Winner 2004 026: REAR TIRE ASSY Article number Units Description 176.00202.000 172.00051.000 Outer tire 4.10x3.50x6" 176.00191.000 Spacer Bush 00001.1462 Label max 2.7 bar 173.00052.000 Outer Rim 6" 173.00042.000 Inner Rim 6" 171.00021.000 Tube Inner with Cap 00000.4135 Screw M8xP1.25x25L 00000.2203...
  • Page 51 Parts lists Winner 2004 027: TRANSAXLE ASSY Article number Units Description See 028 and 029 Transaxle 1001246 Collar 1001247 Set Screw M8xP1.25x5L 170.00352.000 Rear tire Assy 1001387 Flat washer 12x24x2.5 00000.1703 Lock nut M12xP1.75 1001242 Freewheel lever for Schmid transaxle...
  • Page 52 Parts lists Winner 2004 028: MOTOR TRANSAXLE BRAKE 15 KMPH (AMT SCHMID) Article number Units Description 1002356 Transaxle Schmid 15 kmph (Solo) 1009685 Transaxle Schmid 15 kmph (S-Drive) 1012904 Transaxle CT 15 kmph (S-Drive) No spare part Motor 15 kmph...
  • Page 53 Parts lists Winner 2004 029: MOTOR TRANSAXLE BRAKE 9 KMPH HEAVY DUTY (AMT SCHMID) Article number Units Description 9003239 Transaxle 9 kmph (Solo) 1009686 Transaxle 9 kmph (S-Drive) No spare part Motor 15 kmph 1003267 Brake Assy 1003297 Brake Assy from 09-2008...
  • Page 54 Parts lists Winner 2004 030: SCOOTER ASSY (3W) Article number Units Description No spare part 3W scooter assy No spare part Controller assy 00000.3200 Screw M5xP0.8x12L No spare part Controller cover assy 052.00312.000 Rear motor cover assy 052.00452.000 Battery cover assy...
  • Page 55 Parts lists Winner 2004 031: SCOOTER ASSY (4W) Article number Units Description No spare part 4w scooter por assy No spare part Controller assy 00000.3200 Bolt M5*P0.8*12mm 1001288 Controller cover 052.00312.000 Rear cover assy 052.00452.000 Battery cover assy 1001302 Mud guard 1.2t*168*187 LH 1001303 Bolt M5*P0.8*30mm...
  • Page 56 Parts lists Winner 2004 032: BATTERY COVER ASSY Article number Units Description No spare part Battery cover 008.00000.591 Label circuit diagram 1001284 Window post 00000.2009 Flat washer M3 1001286 Screw M3xP0.5x10L 052.00452.000 Battery cover assy Version 2011v3...
  • Page 57 Parts lists Winner 2004 033: REAR MOTOR COVER ASSY Article number Units Description 052.00392.000 Rear motor cover 264.00101.000 Rear indicator assy (orange) 1014195 Rear light assy (red) 008.00000.411 Label engage/release 008.00000.421 Label circuit breaker 008.00000.401 Label "Winner" 1001268 Velcro-loops 1001269 Velcro-loops 126.00052.000...
  • Page 58 Parts lists Winner 2004 034: CONTROLLER COVER ASSY Article number Units Description 1001288 Cover of controller 1001268 Velcro-loops 1001290 Circuit breaker 60A (Solo) 1001291 Cap of circuit breaker 60A (Solo) Version 2011v3...
  • Page 59 Parts lists Winner 2004 035: CONTROLLER ASSY Article number Units Description 162.00031.000 Controller 110A (not programmed) 9003481 S-Drive controller 120A 9003788 S-Drive controller 140A No spare part Label control panel s/n 1001295 Controller bracket (Solo) 9003089 Controller bracket (S-Drive) No spare part Screw M5xP0.8x20L...
  • Page 60 Parts lists Winner 2004 036: SEAT & SEAT FRAME Article number Units Description 118.00221.000 Armrest, right 1002861 Master seat with armrests 1003383 Lumbar knob 118.00231.000 Armrest, left 9000034 Seat frame with slider (right-side operation) 9000042 Seat fixation strip 1366 Plastic cover for seat fixation strip 9000932 Seat post 9000933...
  • Page 61 Parts lists Version 2011v3...
  • Page 62 Parts lists Version 2011v3...

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