Handicare Trophy Service Manual
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Handicare Trophy Service Manual

Mobility scooter
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SERVICE MANUAL
TROPHY

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Summary of Contents for Handicare Trophy

  • Page 1 SERVICE MANUAL TROPHY...
  • 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

    How to order ..............................36     Overview exploded views     (001) Front frame, front fork, and front wheel Trophy 3W ................38     (002) Front frame, frontwheelsuspension and front wheel Trophy 4W ............39     (003) Rear frame, drive unit and rear wheel ....................40  ...

  • Page 4: Preface

    INNERHALB/AUSSERHALB GEBRAUCHSBEBIET: 100 KG MAX.LOAD/MAX.BELASTB./ZUL.GESAMTGEW.: Labels on the scooter Indentification plate data A1 Free wheel Trophy Alpine (and models < 2012) Model A2 Free wheel Trophy (if not A1) Year of manufacture B. Identification plate C. Identification number C. Tyre pressure front wheel(s) D.

  • Page 5: Approval

     Dealer: The person who delivers a Product good maintenance, in which context it also applies obtained from Handicare to customers or third that if the Customer is a Dealer, this Dealer will parties. indemnify Handicare against possible claims from ...

  • Page 6: Statement Of Liability

    Product within a current warranty period does not extend the warranty period. 8. Handicare gives no warranty on repair to or reconditioning of the Product carried out other than under order of and/or at the instructions of Handicare.

  • Page 7: Safety

    Safety speed when driving on a slope, choose a less steep route. Handicare accepts no liability whatsoever for  If you drive on a slope too long, this may damage or injury caused by the failure to result in overheating of the motor.
  • Page 8 Safety When using a mobile telephone in the properly shielded, this may affect sensitive vicinity of a scooter with special adaptations, electrical appliances, such as shop alarms you must first switch off the scooter. and garage openers. The scooter has been ...

  • Page 9: General Description

    The numerous adjustments allow the Trophy to be configured to you needs so that a relaxed position of the hands and shoulders If you use the scooter for other purposes than is assured. The well-organised control panel...

  • Page 10: Steering Column And Dashboard

    General description Steering column and dashboard A. Speed control K. Option: raise B. Throttle handle: reverse L. Hazard lights C. Throttle handle: forward M. Indicator: turn indicator on D. Indicators left/right N. Hazard lights on E. Horn O. Indicator for speed, daily distance, or total F.

  • Page 11: Display Menu

    General description Display menu User km/h Push the I button Daily kilometer counter Push the I button Reset daily counter Push the I button (3 sec.) Kilometer total (user) Push the I button Dealer Hold the hazard light button and press the left horn Kilometer total (user) button briefly Reset total (user)

  • Page 12: Functionality And Connections

    General description Functionality and connections It’s possible to fit the Trophy with either one foot throttle, one hand throttle or two hand throttles. See page 24 and 25 for diagram. A combination of foot throttle and finger control is not possible.

  • Page 13: Forgotten Lock Combination

    General description Forgotten lock combination Changing lock combination If the combination for the lock on the basket is The combination for the lock on the basket can forgotten, it can be recovered in the following be changed in the following manner: manner.

  • Page 14: Main Components

    General description Main components A. Rear wheel B. Lighting H. Mirror C. Seat I. Basket D. Backrest J. Front wheel E. Armrest K. Tilt steering column F. Handlebars with dashboard L. Charging connection for the batteries G. Ignition lock Version 2012v2...

  • Page 15: Maintenance

    Maintenance Maintenance Maintenance table Battery maintenance Refer to the instructions for the batteries. Time Description Daily Load batteries after every use. See 3.2 Weekly Check the tyre pressure and fill if  Make sure that the batteries are always necessary. See 3.4 well charged.

  • Page 16: Troubleshooting

    Troubleshooting Troubleshooting Troubleshooting list If the scooter doesn’t function, while the C. Check whether the neutral handle is in the batteries are fully charged, check the following position. RIVE points. D. Make sure the position of the speed controller has not changed. A.
  • Page 17 Troubleshooting The table below provides explanation for the trip codes that can be indicated by the Egis controller. These trip codes can only be read with the manual programming unit (SP1). LED code Trip code Error type Explanation 2c00 Low battery error Low battery voltage 2c01 Low battery error...

  • Page 18: Technical Specifications

    58Ah batteries Range of travel ISO 7176 60 km Batteries 85Ah batteries Maximum battery dimensions 334x178x253 Dynamic stability on 14° Trophy 3W and 4W slopes Weight scooter without 140 kg (25.6") Climbing capacity for 100 mm batteries obstacles Maximum battery capacity C20 110 Ah...

  • Page 19: Controller Settings Pg Drives Egis 110

    Technical specifications Controller settings PG Drives EGIS 110 Trophy 3 and 4 wheel standard                               Trophy Egis 120 15kmh              Speed Settings  Fast  Slow  Factory Settings  Max  Min        Forward Acceleration (0,1 Seconds)  25  25 ...
  • Page 20 Technical specifications Trophy with foot throttle Egis                               Trophy Egis 120 15kmh foot throttle              Speed Settings  Fast  Slow  Factory Settings  Max  Min        Forward Acceleration (0,1 Seconds)  25  25  Forward Acceleration (0,1 Seconds)  100  1        Forward Deceleration (0,1 Seconds)  13 ...

  • Page 21: Controller Settings Pg Drives S-Drive 120A

    Technical specifications Controller settings PG Drives S-Drive 120A                               Trophy S‐Drive 120 15kmh              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  110        Forward Deceleration (0,1 Seconds)  13  13  Boost Drive Current (Amps) ...
  • Page 22 Technical specifications Trophy with foot throttle S-Drive 120A                            Trophy S‐Drive 120 15kmh foot     throttle              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  110        Forward Deceleration (0,1 Seconds)  13  13 ...

  • Page 23: Controller Settings Pg Drives S-Drive 140A

    Technical specifications Controller settings PG Drives S-Drive 140A                               Trophy S‐Drive 140 15kmh              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130        Forward Deceleration (0,1 Seconds)  13  13  Boost Drive Current (Amps) ...
  • Page 24 Technical specifications Trophy with foot throttle S-Drive 140A                            Trophy S‐Drive 140 15kmh foot     throttle              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130        Forward Deceleration (0,1 Seconds)  13  13 ...
  • Page 25 Technical specifications Controller settings PG Drives S-Drive 140A Alpine                               Trophy S‐Drive 140 Alpine              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130        Forward Deceleration (0,1 Seconds)  13  13 ...
  • Page 26 Technical specifications Trophy with foot throttle S-Drive 140A Alpine                            Trophy S‐Drive 140 Alpine foot     throttle              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130        Forward Deceleration (0,1 Seconds)  13 ...

  • Page 27: Controller Settings Pg Drives S-Drive 140 With Ct Transaxle

    Technical specifications Controller settings PG drives S-Drive 140 with CT transaxle                               Trophy S‐Drive 140 15kmh CT              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130        Forward Deceleration (0,1 Seconds) ...
  • Page 28 Technical specifications Trophy with foot throttle S-Drive 140A met CT transaxle                            Trophy S‐Drive 140 15kmh foot     throttle CT              Speed Settings  Fast  Slow  Motor Settings        Forward Acceleration (0,1 Seconds)  35  35  Current Limit Max (Amps)  130       ...

  • Page 29: Electrical Diagram Trophy Egis

    Technical specifications Electrical diagram Trophy Egis Version 2012v2...
  • Page 30 Technical specifications Electrical diagram Trophy S-Drive fuse 100A Version 2012v2...

  • Page 31: Mounting Instruction Throttle

    Technical specifications Mounting instruction throttle The gas throttle is an important part of the Trophy scooter. Correct dismounting and mounting of the gas throttle is required. The following instructions describe the correct actions to be taken. 1. Unscrewing the gas throttle(s)/cover plate and the console.

  • Page 32: Different Types Of Throttle Controls

    Red throttle control: Never use! Grey throttle control: Never use! Grey throttle control with black lock and warranty seal: Warranty seal Use on an updated product. Black See label near serial number. lock Use on Trophy with S-Drive Version 2012v2...

  • Page 33: Mounting Instructions Throttle Controls

    Mounting instructions throttle controls Safety comes first in the present design of the gas throttle circuit. This means that a build to order Trophy is specifically build to the requested configuration. There is no more ‘loose’ wiring to make rebuild afterwards easier.

  • Page 34: Service Information Transaxles

    5.10 Service information transaxles Summary: End of 2008 Handicare has published the product update "Trophy with S-Drive Controller". Among other things, this update mentioned the new sturdier transaxles for Trophy with Egis controller and for Trophy with S-Drive controller. Since the benefits of these new transaxles remained underexposed in the load of information in the news item, we will explain here the improvements to the transaxle and summarise service instructions for these parts.
  • Page 35 Technical specifications dimensions for CT transaxle Version 2012v2...

  • Page 36: Use Of The Parts Lists

    Parts lists Use of the parts lists How to order This document is meant as a reference book to be used to order parts for the wheelchair that is shown on the front cover. How to order: When ordering parts, please specify: ...

  • Page 37: Overview Exploded Views

    Overview exploded views Drawing Description Page Front frame, front fork, and front wheel Trophy 3W Front frame, frontwheelsuspension and front wheel Trophy 4W Rear frame, drive unit and rear wheel Steering column, mirror and basket Console, printed circuit board and throttle control...

  • Page 38: 001) Front Frame, Front Fork, And Front Wheel Trophy 3W

    Parts lists 7.1 (001) Front frame, front fork, and front wheel Trophy 3W 20 (21/22) Article number Units Description 9000933 Nylon bearing seat post 9004025 Seat post 00001.0008 Spacer block, battery 9005156 Seat post bolt 9000762 Lever freewheel 00000.1701 Lock nut M6...

  • Page 39: 002) Front Frame, Frontwheelsuspension And Front Wheel Trophy 4W

    Parts lists 7.2 (002) Front frame, frontwheelsuspension and front wheel Trophy 4W Article number Units Description 1010287 Front frame, incl. ball-head bearings Trophy 4W 00000.1703 Lock nut M10 D985 9002090 Swing arm top assy 00000.3218 Screw M4x12 9000542 Horn 9001641...

  • Page 40: 003) Rear Frame, Drive Unit And Rear Wheel

    9/10 5 / 6 11/12 Article number Units Description 1002646 Carbon brush for Trophy with Egis (8x10mm) 103.00031.000 Carbon brush for Trophy with S-Drive (8x12mm) 1011585 Carbon bruch set for CT transaxle 51035 Carbon brush screw cap for Schmid transaxle...
  • Page 41 Parts lists Article number Units Description 9000642 Speed sensor magnet 00000.4009 Allen bolt M8x35 00000.1703 Lock nut M10 D985 9000603 Rear spring, standard 9000683 Rear spring, heavy duty 1002243 Allen bolt M10x75 00000.4307 Hex bolt M6x12 9000256 Mounting bracket, right mud guard 9000257 Mounting bracket, left mud guard 9000689...

  • Page 42: 004) Steering Column, Mirror And Basket

    Parts lists 7.4 (004) Steering column, mirror and basket Article number Units Description 00000.4041 Allen bolt M8x55 00000.2203 Spring washer M8 9000019 Spacing bush 9000648 Handle, steering adjustment 9000781 Cap, steering adjustment handle 00001.0804 Rolled pin 6x30 9001095 Steering column adjustment tube 1008573 Nylon bushing, steering column 9000610...

  • Page 43: 005) Console, Printed Circuit Board And Throttle Control

    9006111 Ignition lock, > 31-10-2011 9002188 Harness for ignition lock Egis Ignition lock / tiller cover bottom, replacement set, 9006998 Trophy < 01-11-2011 Ignition lock / tiller cover bottom with switch hole, 9006999 replacement set, Trophy < 01-11-2011 Version 2012v2...
  • Page 44 Parts lists Article number Units Description 1008307 Ignition key 1002571 Ignition key (Old type. A126) 9005810 Ignition key > 31-10-2011 9002104 Spacer 3.2x5.5x2.2 9002177 Throttle control dummy 9001230 Cover steering wheel Version 2012v2...

  • Page 45: 006) Electronics, Controller And Batteries

    Parts lists 7.6 (006) Electronics, controller and batteries Article number Units Description 1009814 Replacement Set 2 LED rear lights 00355.4203 Tube light 24V 10W brake light 00355.4203 Tube light 24V 10W indicator 00355.4213 Tube light 24V 5W rear light 00000.3204 Screw M5x25 1008074 Controller, Egis 110A...

  • Page 46: 007) Seat

    Parts lists (007) Seat 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 Version 2012v2...

  • Page 47: 008) Covers Trophy 3W

    Headlight, complete 1010852 Headlight, complete (Version 2, from 11-11-2010) 1009956 Front bumper Trophy 3W 9000485 Front cover, rear portion Trophy 3W 9000460 Foot support, right (not available, See pos 19) 9000461 Foot support, left (not available, See pos 19) 1009941...

  • Page 48: 009) Covers Trophy 4W

    Front cover 9000536 Spherical bulb 24V 21W 9000535 Headlight, complete 1010852 Headlight, complete (Version 2, from 11-11-2010) 9001970 Front bumper Trophy 4W 9001921 Front cover, rear portion Trophy 4W 9001963 Mudgard right hand front 9001964 Mudgard left hand front Version 2012v2...

  • Page 49: 010) Cabling

    Parts lists 7.10 (010) Cabling Article number Units Description 9000783 Power cable complete, Egis 9002449 Power cable complete with quick release clamps, S-Drive 9004029 Power cable complete with ring lugs, S-Drive 9002181 Cable harness, interface/Egis 9002190 Cable harness, interface/Egis for footcontrol 9004431 Speed sensor 9000537...

  • Page 50: 011) Options

    Parts lists 7.11 (011) Options Article number Units Description 9000701 Trolleybag 9000620 Bracket for trolleybag 9000703 Front bag 2537 Cane holder mounted to chair 1001754 Cane holder mounted to chassis 1010833 Mirror right 9000752 Bracket for mirror right 9000436 Anti tip wheel left 9000437 Anti tip wheel right 9000825...

  • Page 51: Version 2012V2

    Parts lists 01-01-2012: Version 2012v1 Page Drawing Position Changes Changed article number and description 1263 Ball-head bearing 6004 ZZE into 9000493 Ball-head bearing 6004 2NSE Deleted article number 1008570, no longer deliverable Changed article number 9002453 into 9006110 14-03-2012: Version 2012v2 Page Drawing Position...

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