Handicare TROPHY 20 Service Manual
Handicare Trophy 20 is a mobility scooter designed for both indoor and outdoor use. It features a robust frame, adjustable seat, and a range of safety features. The Trophy 20 is equipped with a powerful electric motor and gel batteries that require no maintenance. It also includes a convenient basket for carrying personal belongings. The scooter is designed for easy maneuverability and can be used by individuals with mobility challenges to explore their surroundings and maintain an active lifestyle.
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SERVICE MANUAL TROPHY 20 2 | Trophy 20 © 2011 Handicare All rights reserved. The information provided herein may not be reproduced and/or published in any form, by print, photo print, microfilm or any other means whatsoever (electronically or mechanically) without the prior written authorisation of Handicare. The information provided is based on general data concerning the constructions known at the time of the publication of this manual. Handicare executes a policy of continuous improvement and reserves the right to changes and modifications. The information provided is valid for the product in its standard version. Handicare cannot be held liable for possible damage resulting from specifications of the product deviating from the standard configuration. The available information has been prepared with all possible diligence, but Handicare cannot be held liable for possible errors in the information or the consequences thereof. Handicare accepts no liability for loss resulting from work executed by third parties. Names, trade names, etc. used by Handicare may not, as per the legislation concerning the protection of trade names, be considered as being available. Trophy 20 | 3 1 Introduction Service manual Trophy 20 ................................................................................................................ 5 1.1 This manual 5 Available documentation 5 Service and technical support 5 1.2 Identification of the product 5 1.3 Symbols used in this manual 6 Reference symbol 6 2 Safety ................................................................................................................................................................... 7 2.1 Personnel qualification 7 2.2 Identification on the product 7 Safety 7 2.3 Temperature 7 2.4 Electromagnetic radiation and interference 7 2.5 Markings on the scooter 8 2.6 Technical specifications 8 2.7 Adaptations 8 3 Tools ..................................................................................................................................................................... 9 3.1 Tools 9 4 Spare parts ......................................................................................................................................................... 10 4.1 Use of the parts lists 10 How to order: 10 4.2 Overview exploded views 11 4.3 Options 27 5 Service instructions ............................................................................................................................................ 28 5.1 Maintenance plan 28 5.2 Batteries 28 5.3 Tyres 29 5.4 Assembly, replacement and adjustment instructions 29 Replacing the front wheel 32 Adjustment shock absorber - front 33 Replacing the shock absorber - front 34 Replacing the swing arms (top and lower assy) 36 Replacing the rear wheel 38 Replacing the mechanical brakes 39 Replacing the carbon brushes 41 Replacing the motor brake 43 Replacing the transaxle 46 Adjustment the shock absorber - rear 48 Replacing the shock absorber - rear 50 Replacing the steering wheel 53 Replacing the gas spring 56 Replacing the throttle 59 Replacing the tiller PCB 61 Replacing the stop switch 63 Replacing the controller 65 Replacing the front tiller cover 66 Replacing the front cover 67 Replacing the rear cover 68 Mount the crutch holder, horizontal 69 Mount the crutch holder, vertical 70 Mount the crutch holder, chassis 71 Mount the anti tip wheels 73 Mount the rear bracket 74 4 | Trophy 20 Mount the walking aid holder Mount the luggage carrier Mount the foot throttle 75 76 77 6 Trouble shooting ................................................................................................................................................. 79 6.1 Mechanical 79 6.2 Electrical 79 6.3 Troubleshooting list 79 7 Technical product information............................................................................................................................. 82 7.1 CE Declaration and standards 82 7.2 Technical specifications 82 7.3 Controller settings PG Drives 84 PGDT S-Drive 90A 84 PGDT S-Drive 120A 85 7.4 Data sheet 86 7.5 Electrical diagram Trophy 20 87 7.6 Service information transaxles 88 8 Warranty ............................................................................................................................................................. 89 8.1 Provisions of warranty 89 Warranty 89 8.2 Statement of liability 90 Trophy 20 1 Introduction Service manual Trophy 20 | 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. Always make sure that the work is carried out safely, particularly with respect to procedures requiring the scooter to be lifted up. We advise that you contact our service department before doing repair work on a scooter that has been involved in an accident. The following specifications are important when ordering parts: • Model • Year of manufacture • Colour • Identification number • Part number • Name of the part concerned This information is provided on the identification plate. See 'Identification of the product'. Available documentation The following technical documentation is available for this scooter: • User manual • Service manual Service and technical support For information concerning specific settings, maintenance or repair works please contact your dealer. He is always prepared to help you. Ensure you have at hand: • Model • Year of manufacture • Identification number This information is provided on the identification plate. See 'Identification of the product'. 1.2 Identification of the product The identification plate contains the following data: A. Model B. Year of manufacture C. Identification number D. Use area indoors or outdoors E. Maximum load in kg 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. 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 The symbol refers to a separate manual. This reference will indicate the specific manual and the section to which is being referred. Pull the charge cord out of the battery charging connection of the electric wheelchair before carrying out any maintenance on the wheelchair. Trophy 20 2 Safety | 7 Safety 2.1 Personnel qualification 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 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. • 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 provided 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 applicable requirements regarding electromagnetic radiation (EMC requirements). The Trophy 20’s immunity level is 20 volt/metre. Note! It cannot be excluded that electromagnetic radiation emanating from mobile telephones, medical apparatus and other sources, may have an influence on the scooter. It cannot be excluded that the scooter will interfere with the electromagnetic fields of, for example, shop doors, burglar alarm systems and/or garage door openers. In the unlikely event that such problems do occur, you are requested to notify your dealer immediately. Powered wheelchairs and scooters can be affected by sources of radio waves, such as radio and TV transmitters, amateur radio stations, lifts, transmitting equipment, stereo radios and mobile telephones If the scooter’s electronics are not well shielded, sensitive electrical devices, such as shop alarm systems and garage door openers, can be affected. The scooter has been tested for such interference. Please report any problems of this nature to your dealer immediately. The following advices are intended to prevent the electric scooter from being driven unintentionally, which could lead to serious injury. 1. Do not turn on any manually controlled equipment for personal communication, such as 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 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. 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: 3W A. Freewheel handle position B. Product ID C. Instruction for transportation C 4W C B C A C A. Freewheel handle position 1. DRIVE mode: Lever fully upper position: Motor brake applied, scooter can not be pushed 2. FREEWHEEL / NEUTRAL mode: Lever lowest position: Motor brake not applied. Scooter can be pushed manually when electronics are off. B. Identification plate A. B. C. D. E. F. Model Date of manufacture Serial number Usage: indoor, outdoor or both Maximum load in kg Manufactures address C. Instruction for transportation (see User manual) Warning! 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 Adaptations Adaptations to components of this product are not permitted Trophy 20 3 Tools | 9 Tools 3.1 Tools The tools below are needed for various mechanical settings and maintenance: Quantity 1 1 1 1 1 1 1 1 1 1 1 1 Description Screwdriver, medium Screwdriver, crosshead Hammer (plastic) Chaser Circlip pliers Ring spanner Torque wrench Socket Socket bit Allen key Loctite Shock absorber adjustment key Size (mm) 5 10 / 11 / 13 / 17 7 / 10 / 11 / 12 / 13 / 16 / 17 6 4/5/6/8 243 - 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 hexagons of fastening articles and spanners that may affect proper adjustment. The following tools are needed for various electronic settings: Quantity Description Function 1 PG - pc programmer B-version Adaptation of the drive programs and technical settings. Reading out the fault history 1 PG - programmer unit SPIB handheld Alternative device for PC. Adaptation of the drive programs and technical settings. Reading out the fault history PR0210 10237 10 | Spare parts 4 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: • Serial number (see the identification plate) • Group (to which the relevant part belongs) • Article number • Number of parts required • Description (in the relevant language) • Dimensions (if applicable) Remark: • If a part does not have a position number, it means that the part concerned cannot be purchased separately. The part concerned is part of the assembly shown. This assembly must be ordered as one piece. It has to be replaced in its entirety. • Boxed position numbers refer to the relevant drawing. Order address: Please mail or fax your orders to your supplier. Service technicians: Repairs may only be carried out by trained and authorised service technicians. During the execution of their work they are at all times fully responsible for the fulfilment of 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. Trophy 20 Spare parts | 11 4.2 Overview exploded views 01 02 03 04 05 06 07 08 09 10 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 Console, printed circuit board and throttle control Wiring, electronics and batteries Seat and seat post Covers Trophy 20 3W Covers Trophy 20 4W Covers common Options 12 13 14 16 18 20 21 22 24 26 27 12 | Spare parts Trophy 20 01 Front frame, front fork and front wheel Trophy 20 3W Pos 1 2 3 3,4 5 6 7 8 9 10 11 12 13 14,15,16 15 16 Qty 2 2 2 1 2 2 1 8 1 1 2 1 1 1 1 1 Article number 9004420 00001.0008 9000493 9003440 9006079 9005928 9003444 9005689 1001796 9004153 00000.2003 00000.1702 9002166 9004159 15010.4100 9004161 Description Battery strap Battery spacer block Ball-head bearing 6004 2NSE Frame with ball head bearings 3W Washer flat M4x20x1,2 Haxagon bolt M4x12 Mounting bracket front cover Cable clip Retaining ring 20mm Front fork Washer flat M8 Lock nut M8 haxagon bolt M8x150 st10.9 front wheel 3W Tube Tyre Trophy 20 Spare parts | 13 02 Front frame, front suspension and front wheels Trophy 20 4W Pos 1 2 3 4,5,6 5 6 7 8a 8b 9 10 11 12,13 13 14 15 16 17,18 18 19 20 21 22 23 24 25 26 27 28 28,29 Qty 2 2 8 2 2 2 2 1 1 2 4 4 2 4 1 2 2 1 2 8 4 2 2 4 4 1 1 1 4 2 Article number 9002006 9004569 00000.4026 9004511 15010.4100 9004161 9001969 9003408 9003406 9002054 1002242 00000.1703 1012525 1002840 9003444 9006079 9005928 9003392 9000493 90056891 00000.1702 9004459 9004458 00000.1702 9001803 9001895 1001796 9003403 00000.1702 1012524 Description Cover grey Hexagon flange bolt M8x12 (torque 25Nm, use locktite 247) Hexagon head cap screwM8x20 Front wheel 4W Tube Tyre Shim ring 1.0mm 16x22mm D988 Wheel bracket right Wheel bracket left Cover hexagon head cap screw M10 black Hexagon head cap screwM10x40 Lock nut M10 Assy Shock absorber front 4W Skiffy fixation ring ø10mm Mounting bracket front cover Washer flat M4x20x1,2 Haxagon bolt M4x12 Frame with ball head bearings 4W Ball-head bearing 6004ZZE Cable clip Lock nut M8 Swing arm lower assy Swing arm top assy Lock nut M8 Axle suspension parallel bracket Mounting plate Retaining ring 20mm Steer shaft Lock nut M8 Assy Steering bar 14 | Spare parts Trophy 20 03 Rear frame, drive unit and rear wheels Pos 1 2 3 4a,5,6 4b,5,6 5 6 7 8a 8b 9 10 11 12 13 14a 14b 15 16 17 18 19a 19b 20 21 22 23 24a 24b Qty 2 2 8 1 1 2 2 2 1 1 1 1 1 1 1 1 1 4 2 2 4 1 1 2 1 2 2 1 1 Article number 9002006 1012527 00000.4026 1014662 1014661 1003249 9004146 00001.1463 9004143 9005853 9000642 9006080 1012104 1012106 1012313 1012529 1012530 00000.1703 1012124 9004564 00000.4004 9004142 9004141 9000689 9006042 00000.2004 00000.1703 9000603 9000683 Description Cover grey Assy Wheel bolt Hexagon head cap screwM8x20 Rear wheel right Rear wheel left Tube Tyre Sticker tire pressure 3,5 Bar Drum brake right Drumbrake left Speed sensor magnet Hexagon head cap screwM5x25 Motor brake Free wheel lever Carbon brushes with covers, set of 4 Assy Transaxle Alpine (for S-Drive 120A) Assy Transaxle std Lock nut M10 Key for transaxle Brake mounting Hexagon head cap screwM6x45 Brake right Brake left Rubber mounting strip Hexagon head cap screwM10x85 Washer flat M10 Lock nut M10 Shock absorber standard Shock absorber heavy duty Trophy 20 Spare parts | 15 Continued from 03 Rear frame, drive unit and rear wheels Pos 25 26a 26b 27 28 29 30 31 Qty 1 1 1 4 1 2 2 2 Article number 1002242 9004133 9004132 00000.4307 9003417 00000.2003 00000.1702 9002341 Description Hexagon head cap screwM10x40 Fender mounting bracket right Fender mounting bracket left Hexagon bolt M6x12 Rear frame Washer flat M8 Lock nut M8 Button head screw M8x30 16 | Spare parts Trophy 20 04 Steering column, mirror and basket Pos 1a 1b 1c 2 3 4 5 6 7a 7b 8 9 10 11a 11b 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Qty 1 1 1 2 1 2 2 2 1 1 2 2 1 1 1 2 2 1 2 1 1 4 3 2 1 1 2 2 1 Article number 9001135 9006137 9000703 00000.3612 9000704 00000.4307 00000.2202 9006129 9006128 9006230 00000.4307 00000.2202 9006125 1009250 1009251 00000.2203 00000.1502 9004126 9002792 1012531 9004169 9004174 9004163 00000.1702 9004181 9004164 00000.1701 9004493 9000685 Description Basket, standard Basket, large (only without locking mechanism) Front Bag, (for std bracket with locking mechanism) Screw M4x10 Basket holder Hexagon bolt M6x12 Spring washer M6 Rubber strip Mounting bracket for std basket & bag (with locking mechanism) Mounting bracket for large basket (without locking mechanism) Hexagon bolt M6x12 Spring washer M6 Mounting bracket for mirrors Mirror left Mirror right Spring washer M8 Hexagon nut M8 Cover plate, steering adjustment Screw Ejot K30x6 Assy Tiller bearing Cylinder, steering column Bush bearing tiller Hinge pin 12x5,2 M8 Lock nut M8 Bracket steering adjustment Hinge pin 12x8 M8 Lock nut M6 Hinge pin 8x16 M6 Gas spring operating mechanism Trophy 20 Spare parts | 17 Continued from 04 Steering column, mirror and basket Pos 26 27 28 29 30 31 32 33 34 35 36 Qty 1 2 1 1 1 1 1 1 1 1 1 Article number 9004162 9005802 1012532 9000610 9005607 9004175 00000.2203 00000.4041 9004190 9004191 9004185 Description Gas spring 200N Screw Ejot K40x12 Assy Slider Gas-spring Gass spring actuator cable Spiral pin heavy duty 6x32 Steering column adjustment tube Spring washer M8 Hexagon head cap screwM8x55 Spacer Handle steering adjustment Steering wheel 18 | Spare parts Trophy 20 05 Console, printed circuit board and throttle control Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Qty 1 1 1 1 1 1 1 1 2 2 4 1 1 1 1 2 2 1 1 1 2 2 2 2 2 1 1 1 3 Article number 9004425 9006191 00000.3719 9004330 9004185 00000.3200 9006138 9000904 1008055 9001230 00000.3307 9004331 00000.3719 9005810 9006111 9004303 9004435 9004302 9004301 9005802 9004197 00000.2106 9005802 00000.1662 00000.3218 1012536 1012535 9004438 1001730 Description Drum brake actuator cable Extension cable for microswitch Button head screw M5x10 Brake lever Steering wheel Recessed buttonhead screw M5x12 Stop switch Stop switch dummy Throttle potentiometer Cover steering wheel Sheet-metal screw 2.9x13 Spacer for brake lever Button head screw M5x10 Ignition key Ignition switch Cover for indicator switch Indicator switch Steering wheel cover bottom Steering wheel cover top Srew Ejot K40x12 Rear cover steering column Washer flat M4 3xD Screw Ejot K40x12 Hexagon nut thin M4 Recessed buttonhead screw M4x12 Assy Dashboard speed knob Assy Dashboard top Speed switch Screw Ejot K30x10 Trophy 20 Spare parts | 19 Continued from 05 Console, printed circuit board and throttle control Pos 30 31 32 33 Qty 1 1 4 2 Article number 9000496 9004304 9005802 00000.3200 Description Tiller PCB Console bottom Srew Ejot K40x12 Recessed buttonhead screw M5x12 20 | Spare parts Trophy 20 06 Wiring, electronics and batteries Pos 1 2a 2b 3a 3b 3c 4,5 4,5,6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Qty 2 1 1 2 2 2 1 1 2 2 1 2 1 1 2 1 2 4 1 1 1 1 1 1 1 Article number 9005147 9006097 9006101 9002758 9002759 9002760 1012412 9002457 9006080 00000.3212 9004513 1007078 9004430 9005911 00000.4036 9006124 9004503 00000.1501 9006105 00000.4322 9004431 9006095 9004419 9006096 9006193 Description Battery harness Power harness S-Drive 90A Power harness S-Drive 120A (for Alpine Transaxle) Battery (34Ah C5) (40Ah C20) Battery (50Ah C5) (60Ah C20) Battery (63Ah C5) (74Ah C20) Connector cover S-Drive 120A S-drive controller 120A (for Alpine Transaxle) Hexagon head cap screwM5x25 Recessed buttonhead screw M4x25 S-drive controller 90A Hexagon head cap screwM5x16 Controller interface Mounting bracket for S-drve controller Hexagon head cap screwM5x12 Tule Rear light LED Hexagon nut M6 Horn Hexagon bolt M8x12 Speed sensor Main harness Charging harness Lighting harness Brake switch extension harness Trophy 20 Spare parts | 21 07 Seat and seat post Pos 1,2a,2b 2a 2b 3,4 4 5 6 7 8a 8b 9a 9b 10 11 12 13 14 15 16 17 Qty 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 2 1 1 1 1 Article number 1002861 118.00221.000 118.00231.000 9000034 9000042 9000933 1012523 00000.3723 1008995 1009244 1008999 1008998 232103 1008996 229001 1009001 9005628 1012520 00000.3723 9005156 Description Master seat with armrests Armrest right, Master seat Armrest left, Master seat Seat frame with slider, Master seat Seat fixation strip, Master seat Nylon bearing seat post, Master seat Assy Seat post std Button head screw M6x8 Captain seat standard Captain seat with high back Armrest right, Captain seat Armrest left, Captain seat Armrest pad PU, Captain seat Seat frame with slider, Captain seat Thumb screw Detent button Nylon bearing seat post, Captain seat Assy Seat post Captain seat Button head screw M6x8 Seat post bolt 22 | Spare parts Trophy 20 08 Covers Trophy 20 3W Pos 1 2 3 4 5 6 7a 7b 8 9 10 11 12 13a 13b 14 15a 15b 16 17 18 19 20a 20b 20c 20d 20e 21 22a Qty 2 1 2 2 2 1 1 1 2 2 2 2 1 1 1 4 1 1 2 2 1 1 1 1 1 1 1 2 1 Article number 9005802 9003458 9006094 9005802 00000.2106 9003460 9003475 9003474 9005928 9006079 9005927 00000.2106 9003476 9004571 9004570 9005928 9003473 9003472 00000.2106 9005928 9003457 9005802 9004442 9004445 9004448 9004451 9004454 00000.3218 9004443 Description Screw EJOT K40x12 Front cover upper part Indicator 12V Screw EJOT K40x12 Washer flat M4 3xD Front cover rear part Side skirt right 3W Side skirt left 3W Hexagon bolt M4x12 Washer flat M4x20 Hexagon bolt M4x20 Washer flat M4 3xD Floormat 3W Front inner fender right 3W Front inner fender left 3W Hexagon bolt M4x12 Front fender right 3W Front fender left 3W Washer flat M4 3xD Hexagon bolt M4x12 Head light cover Screw EJOT K40x12 Front tiller cover Ruby red metalic Front tiller cover Platinum white metalic Front tiller cover Sparkling champagne metalic Front tiller cover Graphite black metalic Front tiller cover Moonstone blue metalic Recessed buttonhead screw M4x12 Front cover Ruby red metalic Trophy 20 Spare parts | 23 Continued from 08 Covers Trophy 20 3W Pos 22b 22c 22d 22e 23 24 25 26 27 28 29 30 Qty 1 1 1 1 2 1 2 1 2 2 2 1 Article number 9004446 9004449 9004452 9004455 00000.4060 9004428 00000.1507 9003459 9004652 9005927 00000.1507 9004127 Description Front cover Platinum white metalic Front cover Sparkling champagne metalic Front cover Graphite black metalic Front cover Moonstone blue metalic Hexagon head cap screwM4x20 Head light Hexagon nut M6 Front cover bottom Push rivet Hexagon bolt M4x20 Hexagon nut M6 Front bumper 3W 24 | Spare parts Trophy 20 09 Covers Trophy 20 4W Pos 1 2 3 4 5 6 7a 7b 8 9 10 11a 11b 12 13 14 15 16a 16b 16c 16d 16e 17 18a 18b 18c 18d 18e 19 Qty 2 1 2 2 2 1 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 2 Article number 9005802 9003458 9006094 9005802 00000.2106 9003460 9003467 9003466 00000.2106 9005927 9003468 9003465 9003464 00000.2106 9005928 9003457 9005802 9004442 9004445 9004448 9004451 9004454 00000.3218 9004443 9004446 9004449 9004452 9004455 00000.4060 Description Screw EJOT K40x12 Front cover upper part Indicator 12V Screw EJOT K40x12 Washer flat M4 3xD Front cover rear part Side skirt right 4W Side skirt left 4W Washer flat M4 3xD Hexagon bolt M4x20 Floormat 4W Front fender right 4W Front fender left 4W Washer flat M4 3xD Hexagon bolt M4x12 Head light cover Screw EJOT K40x12 Front tiller cover Ruby red metalic Front tiller cover Platinum white metalic Front tiller cover Sparkling champagne metalic Front tiller cover Graphite black metalic Front tiller cover Moonstone blue metalic Recessed buttonhead screw M4x12 Front cover Ruby red metalic Front cover Platinum white metalic Front cover Sparkling champagne metalic Front cover Graphite black metalic Front cover Moonstone blue metalic Hexagon head cap screwM4x20 Trophy 20 Spare parts | 25 Continued from 09 Covers Trophy 20 4W Pos 20 21 22 23 24 25 26 27 28 29a 29b 30 Qty 1 2 1 2 2 2 1 1 2 1 1 4 Article number 9004428 00000.1507 9003459 9004652 9005927 00000.1507 9003469 9003470 9005802 9004573 9004572 9005928 Description Head light Hexagon nut M6 Front cover bottom Push rivet Hexagon bolt M4x20 Hexagon nut M6 Front spoiler Front bumper 4W Screw EJOT K40x12 Front inner fender right 4W Front inner fender left 4W Hexagon bolt M4x12 26 | Spare parts Trophy 20 10 Covers common Pos 1a 1b 1c 1d 1e 2 3 4 5 6 7,8,9 8 9 10 11 12 13 14 15 16 17 Qty 1 1 1 1 1 1 4 4 2 6 1 2 1 2 2 1 2 2 1 2 1 Article number 1012537 1012538 1012539 1012540 1012541 9004129 00000.2106 9005927 1012526 00000.3624 1012521 9003480 1012522 00000.2106 9005927 9003462 00000.2106 9005927 1012516 9003479 1012519 Description Assy Rear cover Ruby red metalic Assy Rear cover Platinum white metalic Assy Rear cover Sparkling champagne metalic Assy Rear cover Graphite black metalic Assy Rear cover Moonstone blue metalic Motor cover Washer flat M4 3xD Hexagon bolt M4x20 Assy Rear fender Screw M5x8 Assy Rear bumper Reflector red Assy Logo button Handicare Washer flat M4 3xD Hexagon bolt M4x20 Frame cover Washer flat M4 3xD Hexagon bolt M4x20 Assy Battery cover Reflector orange Assy Seat post cover Trophy 20 Spare parts | 27 4.3 Options 10 11 1a 1b 1c 1d 1e 2 3 4 5 12 6 7 8 9 13 Pos 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 2 3 4 5 6 7 8 9 10 11 12 13 - Qty Article number 1012429 1012430 1012431 1012432 1012433 1008572 9000701 4930 9000620 1001813 1001814 9000703 1003095 2537 1012515 1009251 1012456 9000825 9001135 9006137 9000703 Description Colour exchange set Graphite black metalic (3 covers) Colour exchange set Moonstone blue metalic (3 covers) Colour exchange set Ruby red metalic (3 covers) Colour exchange set Sparkling champagne metalic (3 covers) Colour exchange set Platinum white metalic (3 covers) Assy foot throttle Trolleybag Rear Basket Mounting bracket rear Luggage carrier Walking aid holder Front bag 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) Front Bag, (for std bracket with locking mechanism) 28 | Service instructions 5 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. Time Description Daily Weekly Charging the batteries, after each use. • Checking the tyre pressures. • Cleaning the wheelchair. • Cleaning the upholstery (if necessary). • Grease the seat’s swivel mechanism: the seat needs to be removed for this. See ‘Removing the seat’. Lithium grease is recommended • Inspecting the electrical system. • Checking the batteries. • Inspecting the drive. (see 7.6) • Inspecting the mechanical parts. • Inspecting the bearings. • Inspecting the suspension. • Checking the tyres. • Checking all fastenings and bolts: tighten if necessary • Sign the inspection record table in the user manual Monthly Every three months Annually To be carried out by User x x x x Dealer - x x (Annually) - x x x x x x x x x It is recommended that your dealer carries out a service on your scooter at least once a year. If the scooter is used intensively, the service should be carried out every six months. In principle, we recommend that you allow your dealer to carry out all required maintenance on your scooter. The maintenance that you will be able to carry out yourself is indicated in the above table. Warning If you should find traces of oil underneath your scooter, you should immediately notify your dealer of this. In such cases do not drive your scooter. 5.2 Batteries Consult the following documentation on battery maintenance: Current regulations relating to batteries The user manual for the battery charger or the instructions on the battery charger (& 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 inside of the battery compartment cover. 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. The use of ‘wet’ batteries is not permitted. If the batteries need to be replaced, then gel batteries must be used. Replacing the batteries If battery capacity is so low 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! Contact your dealer: your dealer will know exactly which batteries are most suitable for your scooter and how to replace the batteries. Once the new batteries have been put in place they will need to be charged and ‘run in’ See user manual ‘Charging the batteries’. See user manual ‘Used scooters and the environment’ for the correct way to dispose of batteries. Cleaning the batteries Gel batteries are maintenance-free. However, attention may be paid to the following matters: 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. Trophy 20 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. Inflating the tyres The tyres are equipped with a car tyre valve. You can have the tyres inflated by your dealer, or at your local petrol station. You can also inflate the tyres yourself using a hand or foot pump. 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. See the ‘product specifications’ for the correct tyre pressure. 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. Contact your dealer to repair tyre punctures. 5.4 Assembly, replacement and adjustment instructions This chapter covers illustrated assembly, replacement and adjustment instructions. Every separate visual instruction is prefaced with: • Preparation instructions • Relevant article numbers • Tools used • Info (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) In the visual instructions illustrate the tools needed for the specific task. 30 | Service instructions 5.4.1 Trophy 20 Front frame 3W Replacing the front fork 3W with ball bearings Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the drive wheels clear of the ground. Instructions The following operations are required to replace the front fork 3W: • Lift the scooter to raise the wheels clear from the ground. • Remove the front cover, the front cover rear part and the front cover bottom. • Remove the retaining ring and spiral pin. • Remove the complete fork with wheel and the two ballhead bearings 3W. • Remove the hexagon nut, washer and bolt to take out the wheel. • Replace the new front fork 3W. • Rebuild the scooter in the reverse order. Notice • Use a lifting device to raise the drive wheels clear of the ground. • Some parts need to be replaced; the replacement is indicated by a symbol. • Some operations have to be carried out by two persons; this is indicated by a symbol. Relevant article numbers • 9004153 Front fork Tools used • Torque wrench, socket, 13 mm • Screw driver, crosshead • Hammer (plastic) • Chaser • Circlip pliers • Open ended spanner, 13 mm 1 2 3 4 Trophy 20 5 7 Service instructions | 31 6 32 | Service instructions 5.4.2 Trophy 20 Front frame 4W Replacing the front wheel Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Instructions The following operations are required to replace the front wheel: • Lift the scooter to raise the wheels clear from the ground. • Remove the cover and the four hexagon screws to remove the front wheel. • Mount the new front wheel in the reverse order. Relevant article numbers • 9004511 Front wheel 4W Tools used • Lifting device • Torque wrench, socket bit, 6 mm Notice • Use a lifting device to raise the scooter. 1 2 3 4 Trophy 20 Service instructions | 33 Adjustment shock absorber - front Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to adjust the shock absorber - front: • Read the table for more information about the adjustment of shock absorbers. • Use the special adjustment tool to adjust the shock absorber as desired. Relevant article numbers • 9000825 Suspension adjustment key 1 Tools used • Special adjustment tool for shock absorbers • 9000825 Suspension adjustment key Notice • N.a. 34 | Service instructions Trophy 20 Replacing the shock absorber - front Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Instructions The following operations are required to replace the shock absorber - front: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the basket, the front tiller cover, the mounting bracket for the mirrors, the front cover, the front spoiler, the front cover rear part, the front fender L/R, the front cover bottom and the front bumper. • Remove the Allen hexagon screws and locknut form the shock absorbers on the swing arm top and lower assy. • Remove shock absorber • Adjust the new shock absorber according the specifications. • Replace the new and adjusted shock absorber. • Rebuild the scooter in the reverse order. Note! Be sure you fasten all bolts and nuts with the correct torque! 1 Relevant article numbers • 1012525 Shock absorber - front Tools used • Lifting device • Torque wrench, socket,13 mm • Socket, 7 mm • Screwdriver, crosshead • 9000825 Suspension adjustment key Notice • Use a lifting device to raise the scooter. 2 Trophy 20 3 Service instructions | 35 4 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly! 5 7 6 36 | Service instructions Trophy 20 Replacing the swing arms (top and lower assy) Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Instructions The following operations are required to replace the swing arms: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the front cover and the front spoiler. • Remove the cover and the hexagon bolt to remove the front wheel. • Remove the hexagon screw from the lower swing arm. • Remove shock absorber and the two axle suspension parallel bolts. • Remove the lock nut at the wheel side of the swing arm and turn the swing arm out of its position. • Replace the new swing arm. • Rebuild the scooter in the reverse order. 1 Relevant article numbers • 9004459 Swing arm lower assy • 9004458 Swing arm top assy Tools used • Lifting device • Torque wrench, socket, 7 mm-13 mm / socket bit, 6 mm • Allen key, 8 mm • Screwdriver • Ring spanner, 11 mm Notice • Use a lifting device to raise the scooter. 2 Trophy 20 3 Service instructions | 37 4 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly! 5 7 6 38 | Service instructions 5.4.3 Trophy 20 Rear frame Replacing the rear wheel Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Instructions The following operations are required to replace the rear wheel: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the cover and four hexagon head cap screws to remove the rear wheel. • Mount the new rear wheel in the reverse order. Relevant article numbers • 1014662 Rear wheel 8" right, black assy • 1014661 Rear wheel 8" left, black assy Tools used • Lifting device • Screwdriver • Torque wrench, socket bit, 6 mm Notice • Use a lifting device to raise the scooter. 1 2 3 4 Trophy 20 Service instructions | 39 Replacing the mechanical brakes Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Instructions The following operations are required to replace the mechanical brakes: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the cap and hexagon flange bolt to remove the rear wheel. • Remove the brake cable. • Remove the two hexagon head cap screw and remove the brake. • Mount the new brake. • Rebuild the scooter in the reverse order. • Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm. Relevant article numbers • 9004142 Brake right • 9004141 Brake left Tools used • Lifting device • Screwdriver • Torque wrench, socket, 16 mm • Allen key, 6 mm • Loctite 243 Notice • Use a lifting device to raise the scooter. 1 2 3 4 Note! Use Loctite 243 at the indicated locations during assembling the wheelchair. 40 | Service instructions 5 Trophy 20 Trophy 20 Service instructions | 41 Replacing the carbon brushes Relevant article numbers • 1012313 Motor brush set (4 carbon brushes with covers) Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Tools used • Lifting device • Screwdriver • Socket, 7 mm Instructions The following operations are required to replace the carbon brushes: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the rear cover. • Disconnect all connectors from the power module. • Lock the freewheel lever. • Remove four hexagon bolts and remove the motor cover. • Unscrew the carbon brush cover. • Pull the carbon brush out of the housing and remove the brush. • Inspect the collector on the anchor of the motor; if the collector is seriously worn, replace the entire drive unit. • Place the carbon brush in the holder; this can be done in one way only. • Screw the new plastic screw cap onto the carbon brush holder. • Rebuild the scooter in the reverse order. 1 Notice • Use a lifting device to raise the scooter. • Some parts need to be replaced; the replacement is indicated by a symbol. • Make sure the scooter is switched off. 2 42 | Service instructions Trophy 20 3 4 5 6 7 Trophy 20 Service instructions | 43 Replacing the motor brake Relevant article numbers • 1012106 Free wheel lever Preparation • Switch off the scooter with the ignition key. • Use a Lifting device to raise the wheels clear of the ground. Tools used • Lifting device • Screwdriver • Socket, 7 mm • Allen key, 4 mm Instructions The following operations are required to replace the free wheel lever: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the rear cover. • Disconnect all connectors from the power module. • Lock the freewheel lever. • Remove the four hexagon bolts and remove the motor cover. • Remove the hexagon screws and remove the free wheel lever. • Mount the new free wheel lever. • Rebuild the scooter in the reverse order. 1 Notice • Use a lifting device to raise the scooter. • Some parts need to be replaced; the replacement is indicated by a symbol. • Make sure the scooter is switched off. 2 44 | Service instructions Trophy 20 3 4 5 6 7 8 Trophy 20 9 Service instructions | 45 46 | Service instructions Trophy 20 Replacing the transaxle Relevant article numbers • 1012529 Transaxle standard • 1012530 Transaxle heavy duty Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Tools used • Lifting device • Socket, 7 mm • Torque wrench, socket, 16 mm • Screwdriver • Allen key, 4 mm • Ring spanner, 17 mm • Loctite 243 Instructions The following operations are required to replace the transaxle: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Remove the rear cover. • Disconnect all connectors from the power module. • Lock the freewheel lever. • Remove the four hexagon bolts and remove the motor cover. • Remove the cover and hexagon flange bolt to remove the rear wheel. • Remove the two hexagon head cap screws to remove the brake mounting, key and brake. • Remove the hexagon screw and remove the free wheel lever. • Remove the four lock nuts and remove the transaxle and rubber mounting strips. • Mount the new the transaxle. • Rebuild the scooter in the reverse order. • Use Loctite 243 before fastening the hexagon flange bolt with 90 Nm. 1 Notice • Use a lifting device to raise the scooter. • Some parts need to be replaced; the replacement is indicated by a symbol. • Make sure the scooter is switched off. 2 Trophy 20 Service instructions | 47 3 4 5 6 7 8 Note! Use Loctite 243 at the indicated locations during assembling the wheelchair. 48 | Service instructions Trophy 20 Adjustment the shock absorber - rear Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 9000825 Suspension adjustment key Instructions The following operations are required to adjust the shock absorber - rear: Note! Suitable work area required! • Remove the seat. • Remove the battery cover. • Loosen the battery strap. • Disconnect all connectors from the battery. • Remove the battery. • Read the table for more information about the adjustment of shock absorbers. • Use the special adjustment tool to adjust the shock absorber as desired. • Rebuild the scooter in the reverse order. Tools used • Special adjustment tool for shock absorbers • 9000825 Suspension adjustment key 1 Notice • Make sure the scooter is switched off. 2 Trophy 20 3 5 Service instructions | 49 4 50 | Service instructions Trophy 20 Replacing the shock absorber - rear Relevant article numbers • 9000603 Shock absorber standard • 9000683 Shock absorber heavy duty Preparation • 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! • Remove the seat. • Lift the scooter to raise the wheels clear from the ground. • Remove the rear cover. • Disconnect all connectors from the power module. • Lock the freewheel lever. • Remove the two hexagon bolts and washers to remove the rear bumper. • Remove the four hexagon bolts and washers to remove the motor cover. • Remove the battery cover. • Remove the hexagon head cap screw • Take out the shock absorber. • Read the table for more information about the adjustment of shock absorbers. • Use the special adjustment tool to adjust the shock absorber as desired. • Mount the new, correct adjusted, shock absorber. • Rebuild the scooter in the reverse order. 1 Tools used • Socket, 7 mm / 13 mm • Allen key, 8 mm • 9000825 Suspension adjustment key Notice • Make sure the scooter is switched off. 2 Trophy 20 Service instructions | 51 3 4 5 6 7 8 52 | Service instructions Trophy 20 9 10 11 12 13 Trophy 20 5.4.4 Service instructions | 53 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 steering column: Note! Suitable work area required! • Remove the basket and the mounting bracket for the mirrors. • Remove the knob of the speed potentiometer. • Remove the nut, the two Ejot screws and the dashboard. • Disconnect all connectors from the tiller PCB. • Remove the three Ejot screws to remove the tiller PCB. • Remove the two recessed button head screws to remove the console bottom. • Disconnect the connectors of the console bottom. • Remove the recessed button head and Ejot screws, disconnect the stop switch and remove the top and bottom steering wheel covers. • Remove the two Ejot screws and washers to remove the rear cover steering column; disconnect in between the connectors from the ignition switch. • Remove the two sheet metal screws and the throttle potentiometer; disconnect in between the connector of the throttle. • Remove the button head screw and the brake lever; disconnect in between the connector from the brake lever. • Remove the bolt to remove the steering wheel. • Mount the new steering wheel. • Rebuild the scooter in the reverse order. 1 Tools used • Socket, 10 mm • Screwdriver, crosshead • Allen key, 6 mm Notice • Make sure the scooter is switched off. 2 54 | Service instructions Trophy 20 3 4 5 6 7 8 Trophy 20 9 Service instructions | 55 56 | Service instructions Trophy 20 Replacing the gas spring Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 9004162 Gas spring 200N Instructions The following operations are required to replace the gas spring: Note! Suitable work area required! • Remove the basket, the front tiller cover, the mounting bracket for the mirrors, the front cover, the front spoiler, the front cover rear part, the front fender L/R, the front cover bottom and the front bumper. • Pull the handle for steering adjustment upwards and move the steering column downwards. • Remove the four hinge pins and the spiral pin. • Disconnect the gas spring actuator, remove the hinge pin and remove the two bolts from the gas spring slider. • Remove the gas spring slider and loosen the hinge pin and lock nut. • Mount the new gas spring. • Rebuild the scooter in the reverse order. • Note! Be sure you fasten all bolts and nuts with the correct torque! Tools used • Socket, 7 mm / 10 mm / 13 mm • Screwdriver, crosshead • Hammer (plastic) • Chaser 1 Notice • N.a. 2 Trophy 20 Service instructions | 57 4 3 Note! See instruction ‘Replacing the front cover, step 2’ for removing the front cover correctly! 5 6 7 8 58 | Service instructions 9 Trophy 20 Trophy 20 5.4.5 Service instructions | 59 Console Replacing the throttle Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 1008055 Throttle (potentiometer) Instructions The following operations are required to replace the throttle: Note! Suitable work area required! • Remove the basket and the mounting bracket for the mirrors. • Remove the knob of the speed potentiometer, the two bolts and remove the front tiller cover. • Remove the nut, the four Ejot screws and the dashboard. • Disconnect all connectors from the tiller PCB. • Remove the three Ejot screws to remove the tiller PCB. • Remove the two recessed button head screws to remove the console bottom. • Disconnect the connectors of the console bottom. • 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. Tools used • Socket, 10 mm • Screwdriver, crosshead 1 Notice • N.a. 2 60 | Service instructions Trophy 20 3 4 5 6 7 Trophy 20 Service instructions | 61 Replacing the tiller PCB Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 9004185 Steering wheel Instructions The following operations are required to replace the tiller PCB: Note! Suitable work area required! • Remove the basket and the mounting bracket for the mirrors. • Remove the knob of the speed potentiometer, the two bolts and remove the front tiller cover. • Remove the nut, the four Ejot screws and the dashboard. • Disconnect all connectors from the tiller PCB. • Remove the three Ejot screws to remove the tiller PCB. • Mount the new tiller PCB. • Rebuild the scooter in the reverse order. Tools used • Socket, 10 mm • Screwdriver, crosshead Notice • Make sure the scooter is switched off. 1 2 3 4 62 | Service instructions 5 Trophy 20 Trophy 20 Service instructions | 63 Replacing the stop switch Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 9004185 Steering wheel Instructions The following operations are required to replace the stop switch: Note! Suitable work area required! • Remove the basket and the mounting bracket for the mirrors. • Remove the knob of the speed potentiometer, the two bolts and remove the front tiller cover. • Remove the nut, the four Ejot screws and the dashboard. • Disconnect all connectors from the tiller PCB. • Remove the three Ejot screws to remove the tiller PCB. • Remove the two recessed button head screws to remove the console bottom. • Disconnect the connectors of the console bottom. • Remove the recessed button head and Ejot screws, disconnect the connectors the stop switch and remove the top and bottom steering wheel covers. • Mount the new stop switch. • Rebuild the scooter in the reverse order. Tools used • Socket, 10 mm • Screwdriver, crosshead 1 Notice • Make sure the scooter is switched off. 2 64 | Service instructions Trophy 20 3 4 5 6 7 Trophy 20 5.4.6 Service instructions | 65 Electronics Replacing the controller Relevant article numbers • 9002457 S-drive controller 120A • 9004513 S-drive controller 90A Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to replace the controller: Note! Suitable work area required! • Remove the rear cover. • Disconnect all connectors from the power module. • Remove the two hexagon head cap screws and remove the controller. • Mount the new controller. • Rebuild the scooter in the reverse order. Tools used • Allen key, 5 mm Notice • N.a. 1 2 3 4 66 | Service instructions 5.4.7 Trophy 20 Covers front Replacing the front tiller cover Relevant article numbers • 9004442/9004445/9004448/9004451/9004454 Front tiller cover Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to replace the front tiller cover: Note! Suitable work area required! • Remove the basket and the mounting bracket for the mirrors. • Loosen the two bolts to remove the front tiller cover. • Mount the new front tiller cover. • Rebuild the scooter in the reverse order. 1 3 Tools used • Socket, 10 mm • Screwdriver, crosshead Notice • Make sure the scooter is switched off. 2 Trophy 20 Service instructions | 67 Replacing the front cover Relevant article numbers • 9004443/9004446/9004449/9004452/9004455 Front cover Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to replace the front cover: Note! Suitable work area required! • Loosen the two bolts to remove the front cover. • Disconnect the connector of the headlight. • Take the head light cover out of the front cover. • Put the head light cover back in the new front cover • Rebuild the scooter in the reverse order. 1 Tools used • Screwdriver, crosshead Notice • Make sure the scooter is switched off. 2 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. 3 68 | Service instructions 5.4.8 Trophy 20 Covers rear Replacing the rear cover Relevant article numbers • 1012537/1012538/1012539/1012540/1012541 Rear cover Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to replace the rear cover: Note! Suitable work area required! • Remove the rear cover. • Place the new rear cover 1 Tools used • N.a. Notice • N.a. 2 Trophy 20 5.4.9 Service instructions | 69 Accessories Mount the crutch holder, horizontal Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 1003095 Crutch holder mounted to chair, horizontal Instructions The following operations are required to mount the horizontal crutch holder: Note! Suitable work area required! • Mount the horizontal crutch holder with two bolts on the seat frame. Tools used • Open ended spanner, 10 mm 1 2 10 1 2 110948-03-002 110948-03-003 70 | Service instructions Trophy 20 Mount the crutch holder, vertical Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 2537 Crutch holder mounted to chair, vertical Instructions Tools used • Allen key, 6 mm The following operations are required to mount the vertical crutch holder: Note! Suitable work area required! • Remove the armrest from the backrest frame. • Mount the vertical crutch holder and the armrest with two bolts back on the backrest frame. 1 2 1 2 2 3 6 1 6 110948-03-010 110948-03-011 Trophy 20 Service instructions | 71 Mount the crutch holder, chassis Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 1012515 Crutch holder mounted to chassis 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. Tools used • Torque wrench, socket, 7 mm • Metal drill, 4 mm • Drill 1 2 1 1 1 7 110948-03-014 110948-03-013 3 4 Ø4 7 110948-03-015 110948-03-015A 72 | Service instructions Trophy 20 5 1 1 6 1 7 7 110948-03-015B 110448-04-016 Trophy 20 Service instructions | 73 Mount the anti tip wheels Relevant article numbers • 1012456 Anti tip set Preparation • Switch off the scooter with the ignition key. • Use a lifting device to raise the wheels clear of the ground. Tools used • Open ended spanner, 13 mm Instructions The following operations are required to mount the anti tip wheels: Note! Suitable work area required! • Lift the scooter to raise the wheels clear from the ground. • Mount with the two bolts on every side on the rear frame an anti tip wheel. 1 13 110948-03-024 74 | Service instructions Trophy 20 Mount the luggage carrier Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 1001813 Luggage carrier Instructions The following operations are required to mount the luggage carrier: Note! Suitable work area required! • Remove the armrest from the backrest frame. • Mount with the two bolts on every side the luggage carrier on the backrest frame. Tools used • Allen key, 6 mm 1 2 6 2 6 2 1 1 3 110948-03-005 110948-03-012 Trophy 20 Service instructions | 75 Mount the walking aid holder Preparation • Switch off the scooter with the ignition key. Relevant article numbers • 1001814 Walking aid holder Instructions The following operations are required to mount the walking aid holder: Note! Suitable work area required! • Remove the armrest on both sides from the backrest frame. • Mount with the two bolts on every side the walking aid holder on the backrest frame. Tools used • Allen key, 6 mm 1 2 6 6 2 2 1 1 3 110948-03-005 110948-03-009 76 | Service instructions Trophy 20 Mount the mounting bracket Relevant article numbers • 9000620 Mounting bracket rear • 4930 Basket • 9000701 Trolley bag • Preparation • Switch off the scooter with the ignition key. Instructions The following operations are required to mount the mounting bracket: Note! Suitable work area required! • Remove the armrest on both sides from the backrest frame. • Mount with the two bolts on every side the mounting bracket on the backrest frame. • Put the basket or knapsack on the mounting bracket. 1 Tools used • Allen key, 6 mm 2 6 6 2 2 1 1 3 110948-03-005 3 110948-03-006 4 110948-03-007 110948-03-008 Trophy 20 Service instructions | 77 Mount the foot throttle • Determine the exact laying of the cables under the frame. • Reposition the cables in case they will be damaged while drilling the two holes. • Replace the floor mat and position the foot throttle mounting plate on the floor mat. • Drill the holes and mount the foot throttle mounting plate. • Mount the foot throttle on the mounting plate. • Guide the cable trough and under the frame, to the electronics compartment on the backside of the scooter. • Remove the rear cover. • Connect the plug to the socket in the electronics compartment and replace the rear cover. Preparation • Switch off the scooter with the ignition key. Instructions Relevant article numbers • 9007083 Foot throttle Advanced electronics • 1008730 4,8x19 self tapping screw 110948-03_25 Note! This procedure is intended for the Throphy 20 with the latest electronics. In case your Trophy 20 has this dashboard, you have the latest version electronics. Contact you dealer in case you have another dashboard (older version electronics). Tools used • Allen key, 3 mm • Metal drill, 6 mm • Drill • Screwdriver, crosshead The following operations are required to mount the foot throttle: Note! Suitable work area required! • 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! 1 2 110948-03-018 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. 110948-03-019 78 | Service instructions Trophy 20 3 4 3 2 1 2 3X Ø6 3 1 3 110948-03-021 110948-03-020 5 6 110948-03-022 7 110948-03-023 110948-03-013 Trophy 20 6 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 firmly in place. Check whether the freewheel handle is in the drive mode (and not in the freewheel / neutral mode). Troubleshooting table If your scooter is not working, or is not working as it should, go through the following list of possible problems before contacting your dealer. You may be able to solve the problem yourself. 6.1 Mechanical Content not known yet. 6.2 Electrical Problem Possible cause Action Action to be taken by: Scooter cannot be switched ‘on’ Scooter ‘on’ cannot drive The battery clips are not properly attached. The connector cables in the motor compartment are not properly connected to the control mechanism, or are loose. The scooter is in freewheel / neutral mode. Check the battery clips. User Check the connector cables and ensure that they are properly connected to the control mechanism. Dealer Move the freewheel handle to the drive mode and remove the ignition key from the lock. Reinsert the ignition key to restart the scooter. User The manual brake is active The emergency stop button is activated The battery voltage is too low. Release the manual brake De-activate the emergency stop button User User Speed selector switch is in slow (most left) position The motor has overheated. Turn the speed regulator knob to the right. User Remove the ignition key from the lock and allow the scooter to cool down. User Scooter drives very slowly • Check the battery voltage. See ‘Battery indicator’ • Recharge the batteries for eight hours. • Check whether the battery charger is working properly Problems can sometimes be solved by turning the scooter off and then turning it back on again. If you are not able to solve a problem by consulting the above list, then you should contact your dealer. 6.3 Troubleshooting list 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 neutral 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. 80 | Trophy 20 Indication on the display Description of problem The complete LED bar flashes rapidly. The Controller security has found something that causes a problem. The socket LED is lit continuously after the scooter is switched on. Short circuit in the potentiometer. Cabling from the Tiller PCB to the controller interface is defective. Cabling from the Tiller PCB to the touch control is defective. Tiller PCB is defective. Corrective action Switch off the scooter. Check all connectors. Check the condition of the batteries. Consult the manufacturer if the LED bar continues flashing after the scooter has been switched on. Contact the manufacturer. Check all connections between the The first red LED of the The batteries require charging or there is a poor connection to controllers and the batteries. If the connections are OK, try recharging LED bar is lit continuously. the batteries. the batteries. Disconnect the battery charger from LED bar left to right chase. The batteries are being charged. the scooter. Two LEDs of the LED bar Check all connections between the There is a poor connection to the motor. are lit. controller and the motor. Three LEDs of the LED Check the motor cables or replace There is a short circuit in the motor. bar are lit. the motor. Restart the scooter without pressing Seven LEDs of the LED The throttle was held in during start up. the throttle. bar are lit. Speed potentiometer fault. Check or replace the speed potentiometer. Eight LEDs of the LED bar The controller is malfunctioning. Replace the controller. are lit. Put the neutral handle in the drive position. Nine LEDs of the LED bar The neutral handle is in the neutral position. Check the connections between the are lit. The brake is malfunctioning. brake and the controller. Replace the brake. Check the connections between the Ten LEDs of the LED bar The battery is malfunctioning. batteries and the controller. are lit. Check the batteries. 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 1 1 2 3 4 4 6 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 9 9 10 Trip code 2c00 2c01 3B01 1400 7000 7001 1e03 0810 0814 0815 0816 0817 0300 1d02 2f01 0002 0003 0100 0203 0204 1501 1705 1802 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 Error type Low battery error Low battery error Motor fault 1 Bridge fault 1 Startup with push selected Push activated in drive mode Inhibit activated Tiller fault 1 Tiller reference error Tiller lo reference error Tiller high reference iso error Tiller lo reference error Speed Limit Potentiometer wiper open Front end spec change trip Tiller displaced error Eeprom calibration checksum error 2 Eeprom program checksum error 2 Running checksum 1 Eeprom calibration checksum error 1 Eeprom program checksum error 1 Brake fault 2 Relay fault 1 Watchdog voltage ref error Salty finger ref error Both clamps measuring current Progres counter error Front end spec change trip Battery bridge difference error 1 Temperature settings incorrect No internal timers Internal timer out of range Atod readings not finished before next read Unknown mux channel Hardware error Test trip latch 1 Test trip latch 2 Test trip latch 3 Test trip latch 8 Test trip latch 9 Test trip latch 10 Test trip latch 11 Test trip latch 12 Test trip latch 13 Test trip latch 14 Generic ctrl error Brake fault 1 Brake over current error High battery error Explanation Low battery voltage Low battery voltage Motor disconnected Motor wiring fault Parking brake off Parking brake off Inhibit active Throttle trip Throttle trip Throttle trip Throttle trip Throttle trip Throttle trip Throttle potentiometer trip Throttle displaced at power up Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip Possible controller trip 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 82 | Technical product information 7 Trophy 20 Technical product information 7.1 CE Declaration and standards This product complies with the regulations of the Medical Devices Directive and therefore bears the CE mark. Standard Definition/description EU guideline 93/42 EEC Applicable as mentioned in Appendix 1 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 October 1997 NEN-EN 12184 (2009) Electric wheelchairs, scooters and accompanying battery chargers – Class B Requirements and test methods 2009 Requirements and test methods for impact, static and fatigue strengths July ISO 7176-8 1998 ISO 7176-9 Climate tests for electric wheelchairs Requirements and test methods for control systems for electric wheelchairs ISO 7176-14 1997 ISO 7176-16 Requirements for resistance to ignition of upholstered parts May 1997 ISO 7176-19 The Alex meets the crash test requirements as described in ISO 7176-19 Weight test dummy N/A 160 kg 160 kg 160 kg N/A N/A N/A 75 kg 7.2 Technical specifications Manufacturer: Handicare® Model Maximum user weight Trophy 20 3 wheels (3W) Trophy 20 4 wheels (4W) 160 kg Description Total length Total width Minimum height* Total weight excluding batteries Total weight including batteries (74 Ah C20) Weight of heaviest component Static stability in the downward direction Static stability in the upward direction Lateral static stability Distance range (ISO 7176-4)** Dynamic stability (max. safe slope) Maximum speed forwards Back angle, Captain Seat Seat depth, Captain Seat Seat width, Captain Seat Back height (excl. headrest), Captain Seat Seat height (to platform), Captain Seat Armrest height, Captain Seat Distance between armrests, Captain Seat Back angle, Master Seat Seat depth, Master Seat Seat width, Master Seat Back height (excl. headrest), Master Seat mm (inches) mm (inches) mm (inches) kg (pounds) kg (pounds) kg (pounds) ° ° ° km (miles) ° km/h (mph) ° mm (inches) mm (inches) mm (inches) mm (inches) mm (inches) mm (inches) ° mm (inches) mm (inches) mm (inches) 3W 1265 660 740* 92 140 70 > 13 > 13 > 13 45 9 6 / 12 0 / 103 / 126 445 457 406 350 / 450 / 535** 229 / 273 457 - 610 (18 - 24) 45 / 85 / 180 430 500 550 4W 1265 660 740* 102 150 80 > 13 > 13 > 13 45 9 6 / 12 0 / 103 / 126 445 457 406 350 / 450 / 535** 229 / 273 457 - 610 (18 - 24) 45 / 85 / 180 430 500 550 Seat height (to platform), Master Seat Armrest height, Master Seat Distance between armrests, Master Seat Turning radius (ISO 7176-5) Reversing width Obstacle height (max. user weight) mm (inches) mm (inches) mm (inches) mm (inches) mm (inches) mm (inches) 350 / 425 / 535** 150 / 340 500 (19.7) 1030 1460 80 350 / 425 / 535** 150 / 340 500 (19.7) 1600 1810 80 Trophy 20 Technical product information | 83 Description Ground clearance (max. user weight / loaded) mm (inches) 3W 70 4W 70 Test data Test weight 160 kg Operating force Drive lever operation Resetting the automatic fuse (circuit breaker) Electronic switches Connecting the charger plug < 20 [N] < 60 [N] < 13.5 [N] < 60 [N] Technical specifications for wheels Front wheel diameter (3W) Front wheel diameter (4W) Rear wheel diameter Tyre pressure 4W, front wheel Tyre pressure 4W, rear wheel Tyre pressure 3W, front wheel Tyre pressure 3W, rear wheel mm (inches) mm (inches) mm (inches) bar (psi) bar (psi) bar (psi) bar (psi) 320 x 60 320 x 60 360 x 80 2,5 3,5 2,5 3,5 Batteries Maximum dimensions of batteries (lxbxh) Max. battery capacity C20 Max. battery capacity C5 Maximum permitted charging current mm (inches) Ah Ah Ampère 262 x 173 x 211 74 63 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) 84 | Technical product information Trophy 20 7.3 Controller settings PG Drives PGDT S-Drive 90A 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 Fast 35 16 40 35 100 10 25 5 On Operation Settings Sleep timer (minutes) Throttle Invert 0 Yes Battery Settings Low battery Flash Level (Bars) Cable Resistance (milli-Ohms Calibration Factor Low Battery Alarm 0 50 100 Off Inhibit Settings Inhibit 1: Mode 1 Slow 35 16 40 35 100 10 25 5 Motor Settings Current Limit Max (Amps) Boost Drive Current (Amps) Boost Drive Time (Seconds) Current Foldback Threshold (Amps) Curerent Foldback Time (Seconds) Current Foldback Level (%) Motor Cooling Time (Seconds) Current Foldback Temperature (Deg C) Current Limit Min (Amps) Motor Compensation (milli Ohms) Anti Rollback Level Pull-away Delay (centi-Seconds) Slope Factor Anti Rollback Velocity 60 90 10 60 70 59 660 80 10 25 12 0 750 0 Factory Settings Acceleration (0,1 Seconds) Deceleration (0,1 Seconds) Forward Speed (%) Reverse Speed (%) Max 100 100 100 100 Throttle Settings Inhibit 1: Operation Latching Inhibit 1: Speed (%) Inhibit 2: Mode 0 1 Inhibit 2: Operation Latching Throttle Operated at Power-up Inhibit 2: Speed (%) Inhibit 3: Mode 0 1 Non Latching 0 0 Throttle Reference Test Iso Test Resistor Inhibit 3: Operation Inhibit 3: Speed (%) Aux Output: Mode General Settings Soft Stop 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 Freewheel Speed Limit Freewheel Time Out (0,01 Seconds) Freewheel Enable Inhibit 2 Horn Input Enable Min 1 1 0 0 Throttle Type Throttle Deadband (%) Throttle Gain (%) On 1000 24 0 (0 = Trucharge, 1 = LED, 2 = Analogue) 2 Off Off Off Off On On 0 1 Enable Off 1 0=Single-ended, 1=Wig-Wag, 2=Unipolar 15 140 2 On Off 0 = Drive, 1 = Inhibit, 2 = Trip Trophy 20 Technical product information | 85 PGDT S-Drive 120A Information is not avaible; contact Handicare for more information 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 Fast 35 16 40 35 100 10 25 5 On Operation Settings Sleep timer (minutes) Throttle Invert 0 Yes Battery Settings Low battery Flash Level (Bars) Cable Resistance (milli-Ohms Calibration Factor Low Battery Alarm 0 50 100 Off Inhibit Settings Inhibit 1: Mode 1 Slow 35 16 40 35 100 10 25 5 Motor Settings Current Limit Max (Amps) Boost Drive Current (Amps) Boost Drive Time (Seconds) Current Foldback Threshold (Amps) Curerent Foldback Time (Seconds) Current Foldback Level (%) Motor Cooling Time (Seconds) Current Foldback Temperature (Deg C) Current Limit Min (Amps) Motor Compensation (milli Ohms) Anti Rollback Level Pull-away Delay (centi-Seconds) Slope Factor Anti Rollback Velocity 110 120 10 80 70 59 660 50 10 25 12 0 750 0 Factory Settings Acceleration (0,1 Seconds) Deceleration (0,1 Seconds) Forward Speed (%) Reverse Speed (%) Max 100 100 100 100 Throttle Settings Inhibit 1: Operation Latching Inhibit 1: Speed (%) Inhibit 2: Mode 0 1 Inhibit 2: Operation Latching Throttle Operated at Power-up Inhibit 2: Speed (%) Inhibit 3: Mode Throttle Reference Test Iso Test Resistor Inhibit 3: Speed (%) Aux Output: Mode 0 1 Non Latching 0 0 General Settings Soft Stop 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 Freewheel Speed Limit Freewheel Time Out (0,01 Seconds) Freewheel Enable Inhibit 2 Horn Input Enable On 1000 24 0 (0 = Trucharge, 1 = LED, 2 = Analogue) 2 Off Off Off Off On On 10 1 Disable Off Inhibit 3: Operation Min 1 1 0 0 Throttle Type Throttle Deadband (%) Throttle Gain (%) 1 0=Single-ended, 1=Wig-Wag, 2=Unipolar 15 140 2 On Off 0 = Drive, 1 = Inhibit, 2 = Trip 86 | Technical product information Trophy 20 7.4 Data sheet Description Nominal voltage Current main fuse Max slope percentage Max slope with a start Motor nominal power Gearing ratio (motor gearbox) Wheel diameter front Wheel diameter rear Type of tyre front Type of tyre rear Tyre pressure maximum front Tyre pressure minimum rear Maximum dimenstions batteries Battery connection type Maximum allowable charger voltage Maximum allowable charger current charger Maximum battery capacity C20 Maximum battery capacity C5 Forces on levers etc. Electronic switches Drive lever operation Parking brake Connection of charger Weight bat. size Frame Chair Basket+ Batteries Total Remarks 24 50 16 9° @ 160kg 950 4100/195 320x60 360x80 12½ x 2¼ 3,00-8 2,5 3.5 L262xW173xH211 Anderson 30 V A % ° Watt i mm mm bar bar mm V 8 RMS A 74 63 Ah Ah <13.5 [N] <20 [N] <60 [N] <60 [N] 3W 60Ah 40Ah 70 19 2,4 28,8 120 74Ah 70 19 2,4 38,6 130 4W 60Ah 40Ah 70 19 2,4 48,6 140 80 19 2,4 28,8 130 74Ah 80 19 2,4 38,6 140 80 19 2,4 48,6 150 Trophy 20 7.5 Electrical diagram Trophy 20 Technical product information | 87 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. Service checks instructions: Check if dimensions motor brushes satisfy minimum dimensions as indicated in the illustrations, accordingly to the table below. Part Motor brush Plan service check At least once a year or every 2000 km 18 8 New brush – maximum (18 mm) and minimum (8 mm) dimensions. Trophy 20 8 Warranty | 89 Warranty 8.1 Provisions of warranty Warranty In the warranty and liability provisions the following terms are defined as follows: • Product: The manual or electric wheelchair or scooter manufactured and supplied by Handicare. • Customer: The person who directly obtains a product from Handicare. • Dealer: The person who supplies a product obtained from Handicare to third parties. • User: The person who uses a product manufactured by Handicare. Irrespective of what has been determined concerning warranty conditions in the general terms and conditions applicable to the product, the following shall in any case apply with regard to the warranty: 1. Except insofar as described otherwise in the provisions below, Handicare guarantees the product for its suitability for the purpose for which the product is intended - all of these points as described in this manual - and for the quality of the material of which the product is made and the manner in which the product is manufactured. 2. Repairs or replacement of parts of the product that may be necessary as a result of faults that are based on qualitatively faulty material or manufacturing errors shall be carried out free of charge, as long as such faults occurred within one (1) year of the date of delivery of the product to the Customer. The parts to be replaced must be shipped post-paid to Handicare. Disassembly or assembly of these parts shall be at the expense of the Customer. Therefore, the following cases are not eligible for free repair or replacement as meant above: • The repair or replacement that is necessary in connection with faults that arise after one (1) year after the date of delivery of the Product to the Customer; • The repair or replacement that is required in connection with faults due to improper or careless use of the Product or that are based on the Product being used for another purpose than the one for which it is intended, in which regard it applies that if the Customer is a Dealer, this Dealer will indemnify Handicare against possible claims from Users or other third parties for faults based on an incorrect or careless use of the Product; • Parts that are subject to wear, and the need for repair or replacement of the parts are the actual consequence of normal wear. These can include, but are not limited to, tyres, shrouds, arm-pads, seatings etc. 3. Irrespective of that stipulated under 2, it applies as far as an electric Product is concerned that with regard to the battery that forms part of the Product warranty is only given in case of faults or non-functioning of the battery that are demonstrably the direct consequence of material or manufacturing errors. A fault or non-functioning of the battery as a result of normal wear is not covered by the warranty as meant in these warranty stipulations. Similarly not covered by the warranty are faults or non-functioning that are the consequence of improper or unprofessional use of the Product or the battery that is part of the Product, including the incorrect charging of the battery and the failure to carry out timely and good maintenance, in which context it also applies that if the Customer is a Dealer, this Dealer will indemnify Handicare against possible claims from Users or other third parties that are based on the above mentioned improper or unprofessional use of the Product or the battery that is part of the Product. Handicare does not guarantee batteries provided by dealers or purchased by the customer. 4. The warranty conditions as mentioned in above stipulations in any case become null and void if: • The guidelines of Handicare for the maintenance of the Product are not, or insufficiently, followed; • A necessary repair or replacement of parts is based on neglect, damage or abuse of the Product or a use of the Product for another purpose than the one for which it was intended; • Parts of the Product are replaced by parts of another origin than those used by Handicare and/or parts of the Product are replaced without the permission of Handicare. 5. The warranties as mentioned in stipulations 1 through 3 also become null and void if what is involved is re-used by a new user within the warranty period and that such re-use necessitates adaptations to the product and those adaptations are carried out without the instructions and/or at the order of Handicare. 6. To retain rights under the warranties delineated above, the Customer must, in case of damage or other calamities, as rapidly as possible contact Handicare and inform them as fully as possible. The possibility of taking recourse to the above-mentioned warranty conditions becomes null and void for the Customer in any case after 20 workdays after the claim situation or the calamity arises that was the reason for the recourse to the warranty. 7. The replacement of a part or the repair or the reconditioning of the Product within a current warranty period does not extend the warranty period. 8. Handicare gives no warranty on repair to or reconditioning of the Product carried out other than under order of and/or at the instructions of Handicare. If repairs and/or reconditioning are executed by or on behalf of a Customer, the Customer indemnifies Handicare with respect to the claims of third parties who result, in the broadest sense of the word, from such repairs or reconditioning. 90 | Warranty Trophy 20 8.2 Statement of liability Irrespective of what is determined regarding liability in the general conditions applicable to the Product, with regard to liability in any case the following applies: A. Taking into consideration the following stipulations, Handicare only accepts liability for loss due to death or physical injury that is the result of a defect in the Product for which Handicare is responsible and for damage to another object that is the private property of the user of the Product, as long as said loss is the direct result of a fault in the Product. B. Handicare accepts no other or further liability than delineated under 1. In particular Handicare accepts no liability for consequential damage, in any form whatsoever. Used scooters and the environment If your scooter is no longer needed or needs to be replaced, it can usually be taken back by your dealer. If this is not possible, please contact your local authorities for the possibilities of recycling or an environmentally friendly way of disposing of the used materials. For the production of the scooter several plastics and metals have been used. The scooter also contains electronic components that must go to electronic waste. Used batteries belong to chemical waste. Trophy 20 | 91 Version Page 2011 V1 2012 V1 12 14 / 38 14 18 18 27 85 Draw 01 03 03 05 05 Changes Changed article number and description 1263 Ball-headbearing 6004 ZZE into 9000493 Ballhead bearing 6004 2NSE Changed article numbers 9004144 and 9004145 into 1014661 and 1014662 Added position 7, 00001.1463 Sticker tire pressure 3,5 Bar Changed article number 9004438 into 9006110 Changed article number 9004432 into 9006111 Added options, position 2 till 13 Changed driving program S-drive 120A ">

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Key features
- Robust frame
- Adjustable seat
- Powerful electric motor
- Gel batteries (maintenance-free)
- Basket
- Safety features
- Indoor and outdoor use
Frequently asked questions
The Trophy 20 scooter is equipped with gel batteries, which are fully encased and require no maintenance. You can find more information on battery maintenance in the User Manual for the battery charger or instructions on the battery charger itself.
The Trophy 20 scooter can have different battery sizes. You can find the specific type of battery installed in your scooter on the identification plate. The available battery types are: 34Ah C5 (40Ah C20), 50Ah C5 (60Ah C20), and 63Ah C5 (74Ah C20).
It is recommended to have your scooter serviced by a dealer at least once a year. However, if the scooter is used intensively, it's best to have it serviced every six months.