Handicare TROPHY 20 Service Manual
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Handicare TROPHY 20 Service Manual

Mobility scooter handicare
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SERVICE MANUAL
TROPHY 20

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Summary of Contents for Handicare TROPHY 20

  • Page 1 SERVICE MANUAL TROPHY 20...
  • Page 2 Handicare executes a policy of continuous improvement and reserves the right to changes and modifi cations. The information provided is valid for the product in its standard version. Handicare cannot be held liable for possible damage resulting from specifi cations of the product deviating from the standard confi guration.

  • Page 3: Table Of Contents

    Trophy 20 Introduction Service manual Trophy 20 ........................ 5 This manual Available documentation Service and technical support Identifi cation of the product Symbols used in this manual  R eference symbol Safety ................................... 7 Personnel qualifi cation Identifi cation on the product...
  • Page 4 Technical product information ..........................82 CE Declaration and standards Technical specifi cations Controller settings PG Drives PGDT S-Drive 90A PGDT S-Drive 120A Data sheet Electrical diagram Trophy 20 Service information transaxles Warranty ................................89 Provisions of warranty Warranty Statement of liability...

  • Page 5: Introduction Service Manual Trophy 20

    1.1 This manual This manual contains the instructions for repairs and general maintenance of the Trophy 20 Mobility Scooter. Mechanics who do repairs on this wheelchair must be well trained and familiar with the repair methods and the maintenance of the Trophy 20 scooter.

  • Page 6: Symbols Used In This Manual

    6 | Introduction Service manual Trophy 20 Trophy 20 1.3 Symbols used in this manual Note! Pointing out possible problems to the user of this manual. Caution! Advice for the user of this manual to prevent damage to the product.

  • Page 7: Safety

    The scooter has been tested for compliance with the applicable requirements regarding electromagnetic radiation (EMC requirements). The Trophy 20’s immunity level is 20 volt/metre. Note! It cannot be excluded that electromagnetic radiation emanating from mobile telephones, medical apparatus and other sources, may have an infl...

  • Page 8: Markings On The Scooter

    8 | Safety Trophy 20 2.5 Markings on the scooter Never remove or cover up the markings, symbols and instructions affi xed to the scooter. These safety measures must remain present and clearly legible throughout the entire lifestam of the scooter.

  • Page 9: Tools

    Trophy 20 Tools | 9 Tools 3.1 Tools The tools below are needed for various mechanical settings and maintenance: Quantity Description Size (mm) Screwdriver, medium Screwdriver, crosshead Hammer (plastic) Chaser Circlip pliers Ring spanner 10 / 11 / 13 / 17...

  • Page 10: Spare Parts

    10 | Spare parts Trophy 20 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: •...

  • Page 11: Overview Exploded Views

    Trophy 20 Spare parts | 11 4.2 Overview exploded views Front frame, front fork and front wheel Trophy 20 3W Front frame, front suspension and front wheels Trophy 20 4W Rear frame, drive unit and rear wheels Steering column, mirror and basket...
  • Page 12 12 | Spare parts Trophy 20 01 Front frame, front fork and front wheel Trophy 20 3W Article number Description 9004420 Battery strap 00001.0008 Battery spacer block 9000493 Ball-head bearing 6004 2NSE 9003440 Frame with ball head bearings 3W 9006079 Washer fl...
  • Page 13 Trophy 20 Spare parts | 13 02 Front frame, front suspension and front wheels Trophy 20 4W Article number Description 9002006 Cover grey 9004569 Hexagon fl ange bolt M8x12 (torque 25Nm, use locktite 247) 00000.4026 Hexagon head cap screwM8x20 4,5,6...
  • Page 14 14 | Spare parts Trophy 20 03 Rear frame, drive unit and rear wheels Article number Description 9002006 Cover grey 1012527 Assy Wheel bolt 00000.4026 Hexagon head cap screwM8x20 4a,5,6 1014662 Rear wheel right 4b,5,6 1014661 Rear wheel left 1003249...
  • Page 15 Trophy 20 Spare parts | 15 Continued from 03 Rear frame, drive unit and rear wheels Article number Description 1002242 Hexagon head cap screwM10x40 9004133 Fender mounting bracket right 9004132 Fender mounting bracket left 00000.4307 Hexagon bolt M6x12 9003417 Rear frame 00000.2003...
  • Page 16 16 | Spare parts Trophy 20 04 Steering column, mirror and basket Article number Description 9001135 Basket, standard 9006137 Basket, large (only without locking mechanism) 9000703 Front Bag, (for std bracket with locking mechanism) 00000.3612 Screw M4x10 9000704 Basket holder 00000.4307...
  • Page 17 Trophy 20 Spare parts | 17 Continued from 04 Steering column, mirror and basket Article number Description 9004162 Gas spring 200N 9005802 Screw Ejot K40x12 1012532 Assy Slider Gas-spring 9000610 Gass spring actuator cable 9005607 Spiral pin heavy duty 6x32...
  • Page 18 18 | Spare parts Trophy 20 05 Console, printed circuit board and throttle control Article number Description 9004425 Drum brake actuator cable 9006191 Extension cable for microswitch 00000.3719 Button head screw M5x10 9004330 Brake lever 9004185 Steering wheel 00000.3200 Recessed buttonhead screw M5x12...
  • Page 19 Trophy 20 Spare parts | 19 Continued from 05 Console, printed circuit board and throttle control Article number Description 9000496 Tiller PCB 9004304 Console bottom 9005802 Srew Ejot K40x12 00000.3200 Recessed buttonhead screw M5x12...
  • Page 20 20 | Spare parts Trophy 20 06 Wiring, electronics and batteries Article number Description 9005147 Battery harness 9006097 Power harness S-Drive 90A 9006101 Power harness S-Drive 120A (for Alpine Transaxle) 9002758 Battery (34Ah C5) (40Ah C20) 9002759 Battery (50Ah C5) (60Ah C20)
  • Page 21 Trophy 20 Spare parts | 21 07 Seat and seat post Article number Description 1,2a,2b 1002861 Master seat with armrests 118.00221.000 Armrest right, Master seat 118.00231.000 Armrest left, Master seat 9000034 Seat frame with slider, Master seat 9000042 Seat fi xation strip, Master seat...
  • Page 22 22 | Spare parts Trophy 20 08 Covers Trophy 20 3W Article number Description 9005802 Screw EJOT K40x12 9003458 Front cover upper part 9006094 Indicator 12V 9005802 Screw EJOT K40x12 00000.2106 Washer fl at M4 3xD 9003460 Front cover rear part...
  • Page 23 Trophy 20 Spare parts | 23 Continued from 08 Covers Trophy 20 3W Article number Description 9004446 Front cover Platinum white metalic 9004449 Front cover Sparkling champagne metalic 9004452 Front cover Graphite black metalic 9004455 Front cover Moonstone blue metalic 00000.4060...
  • Page 24 24 | Spare parts Trophy 20 09 Covers Trophy 20 4W Article number Description 9005802 Screw EJOT K40x12 9003458 Front cover upper part 9006094 Indicator 12V 9005802 Screw EJOT K40x12 00000.2106 Washer fl at M4 3xD 9003460 Front cover rear part...
  • Page 25 Trophy 20 Spare parts | 25 Continued from 09 Covers Trophy 20 4W Article number Description 9004428 Head light 00000.1507 Hexagon nut M6 9003459 Front cover bottom 9004652 Push rivet 9005927 Hexagon bolt M4x20 00000.1507 Hexagon nut M6 9003469 Front spoiler...
  • Page 26 Assy Rear fender 00000.3624 Screw M5x8 7,8,9 1012521 Assy Rear bumper 9003480 Refl ector red 1012522 Assy Logo button Handicare 00000.2106 Washer fl at M4 3xD 9005927 Hexagon bolt M4x20 9003462 Frame cover 00000.2106 Washer fl at M4 3xD 9005927...

  • Page 27: Options

    Trophy 20 Spare parts | 27 4.3 Options Article number Description 1a,1b,1c,1d,1e 1012429 Colour exchange set Graphite black metalic (3 covers) 1a,1b,1c,1d,1e 1012430 Colour exchange set Moonstone blue metalic (3 covers) 1a,1b,1c,1d,1e 1012431 Colour exchange set Ruby red metalic (3 covers)

  • Page 28: Service Instructions

    28 | Service instructions 28 | Service instructions Trophy 20 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.

  • Page 29: Tyres

    Trophy 20 Service instructions | 29 Service instructions | 29 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. Infl ating the tyres The tyres are equipped with a car tyre valve. You can have the tyres infl ated by your dealer, or at your local petrol station. You can also infl...
  • Page 30 30 | Service instructions 30 | Service instructions Trophy 20 5.4.1 Front frame 3W Replacing the front fork 3W with ball bearings Preparation Notice • Switch off the scooter with the ignition key. • Use a lifting device to raise the drive wheels clear of the •...
  • Page 31 Trophy 20 Service instructions | 31 Service instructions | 31...

  • Page 32: Replacing The Front Wheel

    32 | Service instructions 32 | Service instructions Trophy 20 5.4.2 Front frame 4W Replacing the front wheel Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004511 Front wheel 4W • Use a lifting device to raise the wheels clear of the ground.

  • Page 33: Adjustment Shock Absorber - Front

    Trophy 20 Service instructions | 33 Service instructions | 33 Adjustment shock absorber - front Preparation Tools used • Switch off the scooter with the ignition key. • Special adjustment tool for shock absorbers • 9000825 Suspension adjustment key Instructions...

  • Page 34: Replacing The Shock Absorber - Front

    34 | Service instructions 34 | Service instructions Trophy 20 Replacing the shock absorber - front Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012525 Shock absorber - front • Use a lifting device to raise the wheels clear of the ground.
  • Page 35 Trophy 20 Service instructions | 35 Service instructions | 35 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly!

  • Page 36: Replacing The Swing Arms (Top And Lower Assy)

    36 | Service instructions 36 | Service instructions Trophy 20 Replacing the swing arms (top and lower assy) Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004459 Swing arm lower assy • Use a lifting device to raise the wheels clear of the •...
  • Page 37 Trophy 20 Service instructions | 37 Service instructions | 37 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly!

  • Page 38: Replacing The Rear Wheel

    38 | Service instructions 38 | Service instructions Trophy 20 5.4.3 Rear frame Replacing the rear wheel Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1014662 Rear wheel 8" right, black assy • Use a lifting device to raise the wheels clear of the •...

  • Page 39: Replacing The Mechanical Brakes

    Trophy 20 Service instructions | 39 Service instructions | 39 Replacing the mechanical brakes Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004142 Brake right • Use a lifting device to raise the wheels clear of the •...
  • Page 40 40 | Service instructions 40 | Service instructions Trophy 20...

  • Page 41: Replacing The Carbon Brushes

    Trophy 20 Service instructions | 41 Service instructions | 41 Replacing the carbon brushes Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012313 Motor brush set (4 carbon brushes with covers) • Use a lifting device to raise the wheels clear of the ground.
  • Page 42 42 | Service instructions 42 | Service instructions Trophy 20...

  • Page 43: Replacing The Motor Brake

    Trophy 20 Service instructions | 43 Service instructions | 43 Replacing the motor brake Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012106 Free wheel lever • Use a Lifting device to raise the wheels clear of the ground.
  • Page 44 44 | Service instructions 44 | Service instructions Trophy 20...
  • Page 45 Trophy 20 Service instructions | 45 Service instructions | 45...

  • Page 46: Replacing The Transaxle

    46 | Service instructions 46 | Service instructions Trophy 20 Replacing the transaxle Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012529 Transaxle standard • Use a lifting device to raise the wheels clear of the •...
  • Page 47 Trophy 20 Service instructions | 47 Service instructions | 47 Note! Use Loctite 243 at the indicated locations during assembling the wheelchair.

  • Page 48: Adjustment The Shock Absorber - Rear

    48 | Service instructions 48 | Service instructions Trophy 20 Adjustment the shock absorber - rear Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9000825 Suspension adjustment key Instructions Tools used The following operations are required to adjust the shock •...
  • Page 49 Trophy 20 Service instructions | 49 Service instructions | 49...

  • Page 50: Replacing The Shock Absorber - Rear

    50 | Service instructions 50 | Service instructions Trophy 20 Replacing the shock absorber - rear Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9000603 Shock absorber standard • 9000683 Shock absorber heavy duty...
  • Page 51 Trophy 20 Service instructions | 51 Service instructions | 51...
  • Page 52 52 | Service instructions 52 | Service instructions Trophy 20...

  • Page 53: Replacing The Steering Wheel

    Trophy 20 Service instructions | 53 Service instructions | 53 5.4.4 Steering column Replacing the steering wheel Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 9004185 Steering wheel Instructions The following operations are required to replace the...
  • Page 54 54 | Service instructions 54 | Service instructions Trophy 20...
  • Page 55 Trophy 20 Service instructions | 55 Service instructions | 55...

  • Page 56: Replacing The Gas Spring

    56 | Service instructions 56 | Service instructions Trophy 20 Replacing the gas spring Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004162 Gas spring 200N Instructions Tools used The following operations are required to replace the gas •...
  • Page 57 Trophy 20 Service instructions | 57 Service instructions | 57 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly!
  • Page 58 58 | Service instructions 58 | Service instructions Trophy 20...

  • Page 59: Replacing The Throttle

    Trophy 20 Service instructions | 59 Service instructions | 59 5.4.5 Console Replacing the throttle Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1008055 Throttle (potentiometer) Instructions Tools used The following operations are required to replace the •...
  • Page 60 60 | Service instructions 60 | Service instructions Trophy 20...

  • Page 61: Replacing The Tiller Pcb

    Trophy 20 Service instructions | 61 Service instructions | 61 Replacing the tiller PCB Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004185 Steering wheel Instructions Tools used The following operations are required to replace the tiller •...
  • Page 62 62 | Service instructions 62 | Service instructions Trophy 20...

  • Page 63: Replacing The Stop Switch

    Trophy 20 Service instructions | 63 Service instructions | 63 Replacing the stop switch Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004185 Steering wheel Instructions Tools used The following operations are required to replace the stop •...
  • Page 64 64 | Service instructions 64 | Service instructions Trophy 20...

  • Page 65: Replacing The Controller

    Trophy 20 Service instructions | 65 Service instructions | 65 5.4.6 Electronics Replacing the controller Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9002457 S-drive controller 120A • 9004513 S-drive controller 90A Instructions The following operations are required to replace the...

  • Page 66: Replacing The Front Tiller Cover

    66 | Service instructions 66 | Service instructions Trophy 20 5.4.7 Covers front Replacing the front tiller cover Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004442/9004445/9004448/9004451/9004454 Front tiller cover Instructions The following operations are required to replace the front...

  • Page 67: Replacing The Front Cover

    Trophy 20 Service instructions | 67 Service instructions | 67 Replacing the front cover Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9004443/9004446/9004449/9004452/9004455 Front cover Instructions The following operations are required to replace the front...

  • Page 68: Replacing The Rear Cover

    68 | Service instructions 68 | Service instructions Trophy 20 5.4.8 Covers rear Replacing the rear cover Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012537/1012538/1012539/1012540/1012541 Rear cover Instructions The following operations are required to replace the rear...

  • Page 69: Mount The Crutch Holder, Horizontal

    Trophy 20 Service instructions | 69 Service instructions | 69 5.4.9 Accessories Mount the crutch holder, horizontal Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1003095 Crutch holder mounted to chair, horizontal Instructions Tools used The following operations are required to mount the •...

  • Page 70: Mount The Crutch Holder, Vertical

    70 | Service instructions 70 | Service instructions Trophy 20 Mount the crutch holder, vertical Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 2537 Crutch holder mounted to chair, vertical Instructions Tools used • Allen key, 6 mm...

  • Page 71: Mount The Crutch Holder, Chassis

    Trophy 20 Service instructions | 71 Service instructions | 71 Mount the crutch holder, chassis Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012515 Crutch holder mounted to chassis Instructions Tools used The following operations are required to mount the crutch •...
  • Page 72 72 | Service instructions 72 | Service instructions Trophy 20 110948-03-015B 110448-04-016...

  • Page 73: Mount The Anti Tip Wheels

    Trophy 20 Service instructions | 73 Service instructions | 73 Mount the anti tip wheels Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1012456 Anti tip set • Use a lifting device to raise the wheels clear of the ground.
  • Page 74 74 | Service instructions 74 | Service instructions Trophy 20 Mount the luggage carrier Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1001813 Luggage carrier Instructions Tools used The following operations are required to mount the luggage •...

  • Page 75: Mount The Walking Aid Holder

    Trophy 20 Service instructions | 75 Service instructions | 75 Mount the walking aid holder Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 1001814 Walking aid holder Instructions Tools used The following operations are required to mount the walking •...
  • Page 76 76 | Service instructions 76 | Service instructions Trophy 20 Mount the mounting bracket Preparation Relevant article numbers • Switch off the scooter with the ignition key. • 9000620 Mounting bracket rear • 4930 Basket Instructions • 9000701 Trolley bag The following operations are required to mount the •...

  • Page 77: Mount The Foot Throttle

    Note! This procedure is intended for the Throphy 20 with • 9007083 Foot throttle Advanced electronics the latest electronics. In case your Trophy 20 has this • 1008730 4,8x19 self tapping screw dashboard, you have the latest version electronics. Contact...
  • Page 78 78 | Service instructions 78 | Service instructions Trophy 20 Ø6 110948-03-020 110948-03-021 110948-03-022 110948-03-013 110948-03-023...

  • Page 79: Trouble Shooting

    Trouble shooting | 79 Trouble shooting If your Trophy 20 is not working even though the batteries are fully charged, the following checks can be carried out before contacting your dealer. Check whether all of the battery clips are fi rmly in place.
  • Page 80 80 | Trophy 20 Indication on the display Description of problem Corrective action Switch off the scooter. Check all connectors. The complete LED bar The Controller security has found something that causes a Check the condition of the batteries. fl ashes rapidly.
  • Page 81 Trophy 20 | 81 The table below provides explanation for the trip codes that can be indicated by the controller. These trip codes can only be read with the manual programming unit (SP1). LED code Trip code Error type Explanation...

  • Page 82: Technical Product Information

    The Alex meets the crash test requirements as described in ISO 7176-19 75 kg 7.2 Technical specifi cations Manufacturer: Handicare ® Model Trophy 20 3 wheels (3W) Trophy 20 4 wheels (4W) Maximum user weight 160 kg Description Total length...
  • Page 83 Trophy 20 Technical product information | 83 Description Ground clearance (max. user weight / loaded) mm (inches) Test data Test weight 160 kg Operating force Drive lever operation < 20 [N] Resetting the automatic fuse (circuit breaker) < 60 [N] Electronic switches <...

  • Page 84: Controller Settings Pg Drives

    84 | Technical product information Trophy 20 7.3 Controller settings PG Drives PGDT S-Drive 90A Speed Settings Fast Slow Motor Settings Forward Acceleration (0,1 Seconds) Current Limit Max (Amps) Forward Deceleration (0,1 Seconds) Boost Drive Current (Amps) Reverse Acceleration (0,1 Seconds)

  • Page 85: Pgdt S-Drive 120A

    Trophy 20 Technical product information | 85 PGDT S-Drive 120A Information is not avaible; contact Handicare for more information Speed Settings Fast Slow Motor Settings Forward Acceleration (0,1 Seconds) Current Limit Max (Amps) Forward Deceleration (0,1 Seconds) Boost Drive Current (Amps)

  • Page 86: Data Sheet

    86 | Technical product information Trophy 20 7.4 Data sheet Description Remarks Nominal voltage Current main fuse Max slope percentage Max slope with a start 9° @ 160kg ° Motor nominal power Watt Gearing ratio (motor gearbox) 4100/195 Wheel diameter front...

  • Page 87: Electrical Diagram Trophy 20

    Trophy 20 Technical product information | 87 7.5 Electrical diagram Trophy 20...

  • Page 88: Service Information Transaxles

    88 | Technical product information Trophy 20 7.6 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.

  • Page 89: Warranty

    • Parts of the Product are replaced by parts of another origin than those used by Handicare and/or parts of the Product are replaced without the permission of Handicare.

  • Page 90: Statement Of Liability

    A. Taking into consideration the following stipulations, Handicare only accepts liability for loss due to death or physical injury that is the result of a defect in the Product for which Handicare is responsible and for damage to another object that is the private property of the user of the Product, as long as said loss is the direct result of a fault in the Product.
  • Page 91 Trophy 20 | 91 Version Page Draw Changes 2011 V1 2012 V1 Changed article number and description 1263 Ball-headbearing 6004 ZZE into 9000493 Ball- head bearing 6004 2NSE 14 / 38 Changed article numbers 9004144 and 9004145 into 1014661 and 1014662 Added position 7, 00001.1463 Sticker tire pressure 3,5 Bar...

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