Handicare Trophy, Service Manual

Page 1: ...SERVICE MANUAL TROPHY...

Page 2: ...erves 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...

Page 3: ...uit board and throttle control for advanced electronics ID no QT02400 19 06a Wiring electronics and batteries for original electronics ID no QT02400 20 06b Wiring electronics and batteries for advance...

Page 4: ...ettings PG Drives S Drive 140A 81 7 7 Electrical diagram Trophy Egis 89 7 8 Electrical diagram Trophy S Drive 90 7 9 Service information transaxles 92 8 Warranty 93 8 1 Provisions of warranty 93 8 2 S...

Page 5: ...e part concerned This information is provided on the identification plate See Identification of the product Available documentation The following technical documentation is available required to servi...

Page 6: ...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 Refer...

Page 7: ...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...

Page 8: ...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...

Page 9: ...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...

Page 10: ...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...

Page 11: ...nd throttle control for original electronics ID no QT02400 17 05b Console printed circuit board and throttle control for advanced electronics ID no QT02400 19 06a Wiring electronics and batteries for...

Page 12: ...slip mat 13 2 00000 5306 Hinge pin steering adjustment 14 1 00001 0804 Rolled pin 6x30 15 1 1001796 Lock washer 16 1 00000 6008 Ring 20x28x1 17 2 9000632 Bush bearing tiller 18 1 9000542 Horn for orig...

Page 13: ...x40 D931 10 2 9001803 Axle suspension parallel bracket 11 2 9002101 Steer rod 12 1 9001802 Steer shaft 13 8 00000 1702 Lock nut M8 14 1 9001795 Wheel bracket left grey 14 1 9003406 Wheel bracket left...

Page 14: ...04 Rear wheel left side with brake drum grey rim and grey tyre with block profile 5d 1 9007719 Rear wheel left side with brake drum grey rim and black tyre 5e 1 9007723 Rear wheel left side with brake...

Page 15: ...821 Magnet plate speed sensor 14 1 9000642 Speed sensor magnet 15 1 00000 4009 Allen bolt M8x35 16 2 00000 1703 Lock nut M10 D985 17 1 9000603 Rear spring standard 17 1 9000683 Rear spring heavy duty...

Page 16: ...column adjustment tube 8 1 1008573 Nylon bushing steering column 9 1 9000610 Control cable gas spring for steering adjustment 10 2 9000826 Shoulder bolt gas spring 11 2 00000 1701 Lock nut M6 12 1 900...

Page 17: ...e 1 1 9002673 Revision steering wheel with dual throttle S Drive 2 2 1008055 Potentiometer accelerator 3 4 00000 3307 Sheet metal screw 2 9x13 5 1 1001341 Knob speed potentiometer 6 1 1002555 Console...

Page 18: ...rom 05a Console printed circuit board and throttle control for original electronics ID no QT02400 Pos Qty Article number Description 14 2 9005810 Ignition key 31 10 2011 15 4 9002104 Spacer 3 2x5 5x2...

Page 19: ...no QT02400 11 1 9008789 Tiller PCB Basic for advanced electronics ID no QT02400 11 1 9008791 Tiller PCB Dual Control for advanced electronics ID no QT02400 11 1 9008790 Tiller PCB Full Option for adva...

Page 20: ...ube light 24V 10W indicator 4 2 00355 4213 Tube light 24V 5W rear light 5 4 00000 3204 Screw M5x25 6 1 1008074 Controller Egis 110A 6 1 9002457 Controller S Drive 120A from serial number LT03210 6 1 1...

Page 21: ...2504 Controller S Drive 140A 7 1 9008778 Controller interface for advanced electronics ID no QT02400 9 1 9000782 Tulle 32 x 1 6 10 2 9002759 Battery MK 50Ah C5 60Ah C20 10 2 9002761 Battery MK 72Ah C5...

Page 22: ...mber Description 1 1 118 00221 000 Armrest right 2 1 1002861 Master seat with armrests 3 1 1003383 Lumbar knob 4 1 118 00231 000 Armrest left 5 1 9000034 Seat frame with slider right side operation 1...

Page 23: ...6 Side skirt assy not available See 1009940 7 1 1009940 Side skirt assy black set replacement set 8 1 9006856 Rear cover steering column black 31 10 2011 8 1 9006997 Rear cover steering column black w...

Page 24: ...ont cover Platinum white metallic 12e 1 1015782 Front cover Graphite black metallic 13 1 9000536 Spherical bulb 24V 21W 14 1 9000535 Headlight complete 14 1 1010852 Headlight complete Version 2 from 1...

Page 25: ...7 2 1007756 Side skirt assy not available See 1009940 7 1 1009940 Side skirt assy black set replacement set 8 1 9006856 Rear cover steering column black 31 10 2011 8 1 9006997 Rear cover steering col...

Page 26: ...t bumper Trophy 4W 16 1 9001921 Front cover rear portion Trophy 4W 17a 1 9001963 Mudgard right hand front Red metallic 17b 1 1015768 Mudgard right hand front Moonstone blue metallic 17c 1 1015773 Mudg...

Page 27: ...e harness interface Egis for footcontrol for original electronics ID no QT02400 3 1 9004431 Speed sensor 4a 1 9000537 Main harness lighting for original electronics ID no QT02400 4b 1 9004653 Main har...

Page 28: ...icle number Description 1 1 9004029 Power cable complete with charge socket and ring lugs S Drive 2 3 1 9004431 Speed sensor 4 1 9004429 Main Harness for advanced electronics ID no QT02400 5 2 99117 F...

Page 29: ...752 Bracket for mirror right 6 1 9000436 Anti tip wheel left 6 1 9000437 Anti tip wheel right 7 1 1015507 Lap strap with roll up for Master Seat 1 9000825 Adjustment tool for rear spring 1 1001809 Foo...

Page 30: ...ting the mechanical parts x Inspecting the bearings x Inspecting the suspension x Checking the tyres x Checking all fastenings and bolts tighten if necessary x Sign the inspection record table in the...

Page 31: ...e batteries are to be connected This sticker is located on the rear cover and on the battery cable Warning Ensure that the batteries are always well charged Do not use the scooter if the batteries are...

Page 32: ...When inflating tyres never exceed the maximum recommended tyre pressure which is stated on the tyres 2 4 bar front and 2 2 bar rear Never forget to replace the valve cap after inflating the tyres The...

Page 33: ...e steer towards the console Guide the harness from the console Make sure the gas throttle connector is positioned inside the steering wheel metalwork The gas throttle can be assembled Assemble the gas...

Page 34: ...Trophy 34 Service instructions 3 5 4 5...

Page 35: ...me you can realize a swift rebuild with little waiting time for the end user and do it in the safest way Loose cables will no longer be available as parts delivery Our advice in converting gas throttl...

Page 36: ...he following operations are required to replace the throttle Note Suitable work area required Remove the two sheet metal screws and the throttle disconnect in between the connector of the throttle Mou...

Page 37: ...ar part Remove the retaining ring and spiral pin Remove the complete fork with wheel Remove the hexagon nut washer and bolt to take out the wheel Replace the new front fork 3W Rebuild the scooter in t...

Page 38: ...Trophy 38 Service instructions 38 Service instructions 5...

Page 39: ...aise the scooter clear of the ground Instructions The following operations are required to replace the front wheel Remove the cover and the four hexagon screws to remove the front wheel Mount the new...

Page 40: ...following operations are required to adjust the shock absorber front Read the table for more information about the adjustment of shock absorbers Use the suspention adjustment key to adjust the shock a...

Page 41: ...ront 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 sh...

Page 42: ...Trophy 42 Service instructions 42 Service instructions 3 4...

Page 43: ...poiler Remove the cover and the hexagon bolt to remove the front wheel Remove the hexagon screw from the lower swing arm Remove the two axle suspension parallel bolts Remove the lock nut at the wheel...

Page 44: ...Trophy 44 Service instructions 44 Service instructions 5 6 7...

Page 45: ...ear wheel white left side with brake drum 9001996 Rear wheel grey left side with brake drum 1015104 Rear wheel grey left side with brake drum and block profile 9001172 Rear wheel white left side stand...

Page 46: ...red 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 rev...

Page 47: ...Service instructions 47 Trophy Service instructions 47 Service instructions 47 5...

Page 48: ...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 Clean the collector on the anchor of the motor from d...

Page 49: ...Service instructions 49 Trophy Service instructions 49 Service instructions 49 3...

Page 50: ...all motor connectors from the S drive controller and the speed sensor cable Lock the freewheel lever Remove the four hexagon bolts and remove the motor cover Remove the hexagon screws and remove the f...

Page 51: ...Service instructions 51 Trophy Service instructions 51 Service instructions 51 3 4 5...

Page 52: ...ble Remove the two hexagon head cap screws to remove the brake mounting key and brake Remove the four lock nuts and remove the transaxle and rubber mounting strips Mount the new the transaxle Rebuild...

Page 53: ...Service instructions 53 Trophy Service instructions 53 Service instructions 53 3 Note Use Loctite 243 at the indicated locations during assembling the scooter 4 5 6...

Page 54: ...rea 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...

Page 55: ...Service instructions 55 Trophy Service instructions 55 Service instructions 55 3 4...

Page 56: ...ry cover Remove the bolts of the rollbar 6x Remove the roll bar Remove the hexagon head cap screw Take out the shock absorber Read the table for more information about the adjustment of shock absorber...

Page 57: ...Service instructions 57 Trophy Service instructions 57 Service instructions 57 3 4 5 6...

Page 58: ...move 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...

Page 59: ...e front tiller cover Remove the nut the four Ejot screws and the dashboard Remove the tyrap Disconnect all connectors from the tiller PCB Remove the three Ejot screws to remove the tiller PCB Disconne...

Page 60: ...Trophy 60 Service instructions 60 Service instructions 3 4 5 6...

Page 61: ...k area required Remove the rear cover Remove the S drive cover Disconnect all connectors from the S drive controller Remove the two hexagon head cap screws and remove the controller Mount the new cont...

Page 62: ...ignition key 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 fra...

Page 63: ...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 w...

Page 64: ...ns 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 car...

Page 65: ...ions 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 s...

Page 66: ...t 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 trolley...

Page 67: ...he Master seat The frame has a hole on the left and right side Make on both sides at the level of the hole a notch in the cover Left side The locknut needs to be mounted on the inside of the frame Rig...

Page 68: ...Dismount the basic display and mount the advanced display 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 fram...

Page 69: ...Service instructions 69 Trophy Service instructions 69 Service instructions 69 3 110948 03 022 4 110948 03 023 5...

Page 70: ...t hand 0 2 2 4 1 4 5 7 8 or 9 8 Left hand 0 2 2 4 1 4 5 7 8 or 9 8 Foot 1 1 1 4 2x1 4 5 7 8 or 9 8 Hand foot 0 0 0 1 5 7 8 or 9 8 Dual hand 0 0 2 2 5 7 8 or 9 8 CC only works with 8 standard 0 10 10 1...

Page 71: ...ton briefly Battery voltage Hold the hazard light button and press the left horn button briefly Leave dealer menu Any other button R User km h Push the I button Daily kilometer counter Push the I butt...

Page 72: ...driven after the last time this value was reset Resettable by pressing the DSS I switch 2 seconds 2 Total km 2 S The amount of km the scooter has ever driven in its total life 3 Actual battery voltage...

Page 73: ...enabled 0 no beep when driving backward 1 beeping when driving backward default 1 Change by pressing the DSS I switch 2 seconds First one character of the display show b Setting the options Not all o...

Page 74: ...was held in during start up Speed potentiometer fault Restart the scooter without pressing the throttle Check or replace the speed potentiometer Eight LEDs of the LED bar are lit The controller is mal...

Page 75: ...213 Unknown mux channel Possible controller trip 8 3600 Hardware error Possible controller trip 8 3601 Test trip latch 1 Possible controller trip 8 3602 Test trip latch 2 Possible controller trip 8 36...

Page 76: ...es 1400 55 1 1400 55 1 Total width mm inches 660 26 660 26 Minimum height mm inches 760 29 9 760 29 9 Total weight excluding batteries kg stones 110 17 3 121 19 1 Total weight including batteries 80 A...

Page 77: ...es Maximum dimensions of batteries lxbxh mm inches 334 x 178 x 253 13 1 x 7 x 10 Max battery capacity C20 Ah 86 Max battery capacity C5 Ah 72 Maximum permissible charging voltage Voltage 13 6 Maximum...

Page 78: ...Seconds 60 Bridge Hold Time centi Secs 80 Freewheel Voltage 100 Motor Compensation milli Ohms 45 Freewheel Time out 0 01 Seconds 20 Trophy Egis 120 15 km h foot throttle Speed Settings Fast Slow Facto...

Page 79: ...illi Ohms 50 Current Limit Max Amps 110 Calibration Factor 100 Boost Drive Current Amps 120 Low Battery Alarm Off Boost Drive Time Seconds 10 Current Foldback Threshold Amps 110 Inhibit Settings Curer...

Page 80: ...s 110 Calibration Factor 100 Boost Drive Current Amps 120 Low Battery Alarm Off Boost Drive Time Seconds 10 Current Foldback Threshold Amps 110 Inhibit Settings Curerent Foldback Time Seconds 15 Inhib...

Page 81: ...ed Alarm Off Brake Fault Detect On Brake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Set...

Page 82: ...Brake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Max Amps 130 B...

Page 83: ...Detect On Brake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Max...

Page 84: ...Brake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Max Amps 130 B...

Page 85: ...t Detect On Brake Light Off Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Ma...

Page 86: ...ake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Max Amps 130 Boos...

Page 87: ...Brake Fault Detect On Brake Light On Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current...

Page 88: ...ke Light Off Push too Fast Threshold 35 Push too Fast Timeout 20 Freewheel Enable Disable Inhibit 2 Horn Input Enable Off S Drive 120 140 180A S Drive II Motor Settings Current Limit Max Amps 130 Boos...

Page 89: ...Technical product information 89 Trophy Technical product information 89 7 7 Electrical diagram Trophy Egis...

Page 90: ...Trophy 90 Technical product information 7 8 Electrical diagram Trophy S Drive Original electronics ID no QT02400...

Page 91: ...Technical product information 91 Trophy Technical product information 91 Advanced electronics ID no QT02400...

Page 92: ...but also to some changes that were made to reduce wear of the commutator and brushes This way service costs are reduced The new transaxles are equipped with bigger motor brushes As a consequence the c...

Page 93: ...nctioning 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 war...

Page 94: ...id 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 i...

Page 95: ...ed position 19b article number 9004161 15 3 Added article number 1015444 Motorbrake cover Schmid Changed position and description of article numbers 9000550 9001996 and 1015104 and added position 5d a...

Page 96: ...cle numbers 1015780 1015781 1015782 and 1015763 Graphic black metallic covers Updated drawing 23 26 8 9 Changed naming of the Ruby red covers in Red covers 25 9 Added article numbers 1015775 1015776 1...

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