All rights reserved.
The information provided herein may not be reproduced and/or published in any form, by print, photo print, microfi lm or any other
means whatsoever (electronically or mechanically) without the prior written authorisation of Sunrise Medical HCM.
The information provided is based on general data concerning the constructions known at the time of the publication of this
manual. Sunrise Medical HCM executes a policy of continuous improvement and reserves the right to changes and modifi cations.
The information provided is valid for the product in its standard version. Sunrise Medical HCM cannot be held liable for possible
damage resulting from specifi cations of the product deviating from the standard confi guration.
The available information has been prepared with all possible diligence, but Sunrise Medical HCM cannot be held liable for
possible errors in the information or the consequences thereof.
Sunrise Medical HCM accepts no liability for loss resulting from work executed by third parties.
Names, trade names, etc. used by Sunrise Medical HCM may not, as per the legislation concerning the protection of trade
names, be considered as being available.
4 Spare parts ......................................................................................................................................................... 12
4.1 Use of the parts lists 12
4.2 Overview exploded views 13
01 Front frame, front fork and front wheel Trophy 20 3W 14
02 Front frame, front suspension and front wheels Trophy 20 4W 15
03 Rear frame, drive unit and rear wheels 16
04 Steering column, mirror and basket 18
05a Console, printed circuit board and throttle control for original electronics (ID-no PBxxxxx only) 20
05b Console, printed circuit board and throttle control for advanced electronics
(ID-no QBxxxxx onwards) 22
06a Wiring, electronics and batteries for original electronics (ID-no PBxxxxx only) 24
06b Wiring, electronics and batteries for advanced electronics (ID-no QBxxxxx onwards) 25
07 Seat and seat post 26
08 Covers Trophy 20 3W 27
09 Covers Trophy 20 4W 29
10 Covers common 31
4.3 Options 32
5 Service instructions ............................................................................................................................................ 33
5.1 Maintenance plan 33
5.2 Batteries 34
5.3 Tyres 35
5.4 Assembly, replacement and adjustment instructions 35
This manual contains the instructions for repairs and general maintenance of the Trophy 20.
Mechanics who do repairs on this scooter 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 specifi cations are important when ordering parts:
• Model
• Year of manufacture
• Colour
• ID-number
• Part number
• Name of the part concerned
This information is provided on the identifi cation plate. See 'Identifi cation of the product'.
Available documentation
The following technical documentation is available / required to service this scooter:
• User manual
• Service manual
Service and technical support
For information concerning specifi c settings, maintenance or repair works please contact the Sunrise Medical HCM Customer
Service department. They are always prepared to help you. Ensure you have at hand:
• Model
• Year of manufacture
• ID-number
1.2 Identifi cation of the product
A
B
TYPE/TYPE/TYP:
YEAR/JAAR/JAHR:
USAGE:
GEBRUIKSGEBIED:
GEBRAUCHSGEBIET:
MAX.LOAD/MAX.BELASTB./ZUL.GESAMTGEW.:
HANDICARE B.V.
VOSSENBEEMD 104
5705 CL HELMOND
THE NETHERLANDS
IDNR.:
DEF
The identifi cation plate contains the following data:
C
A. Model
B. Year of manufacture
C. ID-number
D. Usage: indoor, outdoor or both
E. Maximum load in kg
F. Manufactures address
See for the location of the identifi cation plate ´markings on the scooter´.
Page 8
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
When necessary this service manual refers to other manuals as shown below:
Battery charger: refers to the user manual of the battery charger
Scooter: refers to the general user manual of the Trophy 20
Trophy 208 | Introduction
Page 9
Safety | 9
Trophy 20
Safety | 9
2 Safety
2.1 Personnel qualifi cation
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 fulfi lment 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 Identifi cation on the product
Safety
Safety information is indicated with the warning symbol.
Warning!
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 also provided in this manual
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 infl uence on the scooter.
It cannot be excluded that the scooter will interfere with the electromagnetic fi elds 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.
5. 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.
Page 10
10 | Safety Trophy 20
2.5 Markings on the scooter
Never remove or cover up the markings, symbols and instructions affi xed to the scooter. These safety measures must remain
present and clearly legible throughout the entire lifestam of the scooter.
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:
A. Freewheel handle position
3W
C
4W
C
B
C
A
C
Buran UM 01
B. Identifi cation plate
C. Instruction for transportation
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. Identifi cation plate
A. Model
A
B
TYPE/TYPE/TYP:
YEAR/JAAR/JAHR:
USAGE:
GEBRUIKSGEBIED:
GEBRAUCHSGEBIET:
MAX.LOAD/MAX.BELASTB./ZUL.GESAMTGEW.:
HANDICARE B.V.
VOSSENBEEMD 104
5705 CL HELMOND
THE NETHERLANDS
IDNR.:
DEF
C. Instruction for transportation (
C
Scooter)
B. Year of manufacture
C. ID-number
D. Usage: indoor, outdoor or both
E. Maximum load in kg
F. Manufactures address
Warning!
The scooter is not intended to be used as seat in motor vehicle.
2.6 Technical specifi cations
No changes may be made to the technical specifi cations.
2.7 Modifi cations / Adaptations
Modifi cations, not executed by Sunrise Medical HCM, to components and electronics of this product are not permitted.
Page 11
Trophy 20
Tools | 11
3 Tools
3.1 Tools
The tools below are needed for various mechanical settings and maintenance:
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:
QuantityDescriptionFunction
PG - pc programmer
1
B-version
PG - programmer unit
1
SPIB handheld
Adaptation of the drive programs and technical settings.
Reading out the fault history
Alternative device for PC. Adaptation of the drive programs
and technical settings.
Reading out the fault history
PR0210
10237
Page 12
12 | Spare parts Trophy 20
4 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:
• ID-number (see the identifi cation 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 fulfi lment 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.
Page 13
Trophy 20
4.2 Overview exploded views
Spare parts | 13
PosDescriptionPage
01Front frame, front fork and front wheel Trophy 20 3W14
02Front frame, front suspension and front wheels Trophy 20 4W15
03Rear frame, drive unit and rear wheels16
04Steering column, mirror and basket18
05aConsole, printed circuit board and throttle control for original electronics (ID-no PBxxxxx only)20
05bConsole, printed circuit board and throttle control for advanced electronics (ID-no QBxxxxx onwards)22
06aWiring, electronics and batteries for original electronics (ID-no PBxxxxx only)24
06bWiring, electronics and batteries for advanced electronics (ID-no QBxxxxx onwards)25
07Seat and seat post26
08Covers Trophy 20 3W27
09Covers Trophy 20 4W29
10Covers common31
Page 14
14 | Spare parts
01 Front frame, front fork and front wheel Trophy 20 3W
529006079Washer fl at M4x20x1,2
629005928Hexagon bolt M4x12
719003444Mounting bracket front cover
889005689Cable clip
911001796Retaining ring 20mm
1019004153Front fork
11200000.2003Washer fl at M8
12100000.1702Lock nut M8
1319002166Hexagon bolt M8x150 st10.9
14,15,1619004159Front wheel 3W
1511015118Inner tube 12 1/2 x 2 1/4
1611015113Outer tyre 12 1/2 x 2 1/4 black block profi le
1719007273Bracket bumper 3W right
1819007274Bracket bumper 3W left
1949005928Hexagon bolt M4x12
20400000.2106Washer fl at M4 3xD
3019007355Edge protection profi le
Page 15
Trophy 20
02 Front frame, front suspension and front wheels Trophy 20 4W
Spare parts | 15
PosQtyArticle number Description
129002006Cover grey
229004569Hexagon fl ange bolt M8x12 (torque 25Nm, use locktite 247)
3800000.4026Hexagon head cap screwM8x20
4,5,629004511Front wheel 4W
521015118Inner tube 12 1/2 x 2 1/4
621015113Outer tyre 12 1/2 x 2 1/4 black block profi le
729001969Shim ring 1.0mm 16x22mm D988
8a19003408Wheel bracket right (black)
8b19003406Wheel bracket left (black)
921007448PVC black cover M10 DIN912
1041002242Hexagon head cap screwM10x40
11400000.1703Lock nut M10
12,1321012525Assy Shock absorber front 4W
1341002840Skiffy fi xation ring ø10mm
1419003444Mounting bracket front cover
1529006079Washer fl at M4x20x1,2
1629005928Hexagon bolt M4x12
17,1819003392Frame with ball head bearings 4W
1829000493Ball-head bearing 6004 2NSE
1989005689Cable clip
20400000.1702Lock nut M8
2129004459Swing arm lower assy (black)
2229004458Swing arm top assy (black)
23400000.1702Lock nut M8
2449001803Axle suspension parallel bracket
2519001895Mounting plate
2611001796Retaining ring 20mm
2719003403Steer shaft
28400000.1702Lock nut M8
28,2921012524Assy Steering bar
3019007355Edge protection profi le
Page 16
16 | Spare parts
03 Rear frame, drive unit and rear wheels
Trophy 20
PosQtyArticle number Description
129002006Cover grey
221012527Assy Wheel bolt
3800000.4026Hexagon head cap screwM8x20
4a,5,611014662Rear wheel 8", right, black road assy
4b,5,611014661Rear wheel 8", left, black road assy
4c,5,619007436Rear wheel 8" right/left, black outdoor assy
521015117Inner tube 3.00x8
6a29004146Tyre black road
6b21015110Tyre black outdoor
7200001.1463Sticker tire pressure 3,5 Bar
8a19004143Drum brake right
8b19005853Drumbrake left
919000642Speed sensor magnet
1019006080Hexagon head cap screwM5x25
1111012104Motor brake
1211012106Free wheel lever
1311012313Carbon brushes with covers, set of 4
15400000.1703Lock nut M10
1621012124Key for transaxle
1719004564Brake mounting
18200000.4004Hexagon head cap screwM6x45
1919004141Brake left
2029000689Rubber mounting strip
2119006042Hexagon head cap screwM10x85
22200000.2004Washer fl at M10
23200000.1703Lock nut M10
24a19000603Shock absorber standard
Page 17
Trophy 20
Continued from 03 Rear frame, drive unit and rear wheels
PosQtyArticle number Description
24b19000683Shock absorber heavy duty
2511002242Hexagon head cap screwM10x40
26a19004133Fender mounting bracket right
26b19004132Fender mounting bracket left
27400000.4307Hexagon bolt M6x12
2819003417Rear frame
29200000.2003Washer fl at M8
30200000.1702Lock nut M8
3129002341Button head screw M8x30
3211015292P-clip 6 mm black for advanced electronics (ID-no QBxxxxx onwards)
3319006240Taptite M5x10 hex head fl ange for advanced electronics (ID-no QBxxxxx onwards)
32,3311015554P-clip 6 mm service set (10 pieces) for original electronics (ID-no PBxxxxx only)
3421353Hinge bush M8
Spare parts | 17
Page 18
18 | Spare parts
04 Steering column, mirror and basket
Trophy 20
PosQtyArticle number Description
1a19001135Basket, standard
1b19006137Basket, large (only without locking mechanism)
1c19000703Front Bag, (for std bracket with locking mechanism)
629006129Rubber strip
7a19006128Mounting bracket for std basket & bag (with locking mechanism)
7b19006130Mounting bracket for large basket (without locking mechanism)
8200000.4307Hexagon bolt M6x12
9200000.2202Spring washer M6
1011015387Mounting bracket for mirrors
729006080Hexagon head cap screwM5x25
8200000.3212Recessed buttonhead screw M4x25
9,1011015385Connector cover S-drive 90A
9,10,1111015386S-drive controller 90A
1221007078Hexagon head cap screw M5x16
1311002558Controller interface for original electronics (ID-no PBxxxxx only)
1419006124Tule
1529004503Rear light LED
16400000.1501Hexagon nut M6
1719006105Horn for original electronics (ID-no PBxxxxx only)
18100000.4322Hexagon bolt M8x12
1919004431Speed sensor
2019006095Main harness for original electronics (ID-no PBxxxxx only)
2119004419Charging harness
2229002752Set battery connection covers
2319006096Lighting harness for original electronics (ID-no PBxxxxx only)
2419006193Brake switch extension harness for original electronics (ID-no PBxxxxx only)
2519005911Mounting bracket for S-drve controller for original electronics (ID-no PBxxxxx only)
26200000.4036Hexagon head cap screwM5x12
Page 25
Trophy 20
06b Wiring, electronics and batteries for advanced electronics (ID-no QBxxxxx onwards)
419000042Seat fi xation strip, Master seat
519003907Nylon bearing seat post, Master seat
611012523Assy Seat post std
7100000.3723Button head screw M6x8
8a11008995Captain seat standard
8b11009244Captain seat with high back
9a11008999Armrest right, Captain seat
9b11008998Armrest left, Captain seat
102232103Armrest pad PU, Captain seat
1111008996Seat frame with slider, Captain seat
124229001Thumb screw
1321009001Detent button
1419006157Ring seat post cover
1511012520Assy seat post Captain seat incl. nylon bearing
16100000.3716Button head M5x12 VZ
1719005156Seat post bolt
Page 27
Trophy 20
08 Covers Trophy 20 3W
Spare parts | 27
PosQty Article number Description
129005802Screw EJOT K40x12
219003458Front cover upper part
3a29006094Indicator 12V for original electronics (ID-no PBxxxxx only)
3b29003478Indicator 24V for advanced electronics (ID-no QBxxxxx onwards)
429005802Screw EJOT K40x12
5200000.2106Washer fl at M4 3xD
619003460Front cover rear part
7a19003475Side skirt right 3W
7b19003474Side skirt left 3W
829005928Hexagon bolt M4x12
929006079Washer fl at M4x20
1029005927Hexagon bolt M4x20
11200000.2106Washer fl at M4 3xD
1219003476Floormat 3W
13a19004571Front inner fender right 3W
13b19004570Front inner fender left 3W
1449005928Hexagon bolt M4x12
15a19003473Front fender right 3W
15b19003472Front fender left 3W
20a19004442Front tiller cover Ruby red metallic
20b19004445Front tiller cover Platinum white metallic
20c19004448Front tiller cover Sparkling champagne metallic
20d19004451Front tiller cover Graphite black metallic
20e19004454Front tiller cover Moonstone blue metallic
21200000.3218Recessed buttonhead screw M4x12
Page 28
28 | Spare parts
Continued from 08 Seat and seat post
PosQty Article number Description
22a,27,3211015363Front cover Ruby red metallic
22b,27,3211015364Front cover Platinum white metallic
22c,27,3211015365Front cover Sparkling champagne metallic
22d,27,3211015366Front cover Graphite black metallic
22e,27,3211015367Front cover Moonstone blue metallic
23200000.4060Hexagon head cap screwM4x20
2419004428Head light
25200000.1507Hexagon nut M6
2619003459Front cover bottom
2729004652Push rivet
2829005927Hexagon bolt M4x20
29200000.1507Hexagon nut M6
30a11015454Front bumper 3W for original electronics (ID-no PBxxxxx only)
30b19007275Front bumper 3W for advanced electronics (ID-no QBxxxxx onwards)
3149005802Screw EJOT K40x12
3229004652Push rivet
Trophy 20
Page 29
Trophy 20
09 Covers Trophy 20 4W
Spare parts | 29
PosQty Article number Description
129005802Screw EJOT K40x12
219003458Front cover upper part
3a29006094Indicator 12V for original electronics (ID-no PBxxxxx only)
3b29003478Indicator 24V for advanced electronics (ID-no QBxxxxx onwards)
429005802Screw EJOT K40x12
5200000.2106Washer fl at M4 3xD
619003460Front cover rear part
7a19003467Side skirt right 4W
7b19003466Side skirt left 4W
8200000.2106Washer fl at M4 3xD
929005927Hexagon bolt M4x20
1019003468Floormat 4W
11a19003465Front fender right 4W
11b19003464Front fender left 4W
911012522Assy Logo button Handicare
10200000.2106Washer fl at M4 3xD
1129005927Hexagon bolt M4x20
1219003462Frame cover
13400000.2106Washer fl at M4 3xD
1449005927Hexagon bolt M4x20
1511012516Assy Battery cover
1629003479Refl ector orange
1711012519Assy Seat post cover
1829007368Sticker Alpine
Page 32
32 | Spare parts
4.3 Options
Trophy 20
8
9
1c1b1a1d 1e
2
5
3
6
4
7
10
11
12
13
14
PosQty Article number Description
1a,1b,1c,1d,1e1012429Colour exchange set Graphite black metallic (3 covers)
1a,1b,1c,1d,1e1012430Colour exchange set Moonstone blue metallic (3 covers)
1a,1b,1c,1d,1e1012431Colour exchange set Ruby red metallic (3 covers)
1a,1b,1c,1d,1e1012432Colour exchange set Sparkling champagne metallic (3 covers)
1a,1b,1c,1d,1e1012433Colour exchange set Platinum white metallic (3 covers)
-1008572Assy foot throttle for original electronics (ID-no PBxxxxx only)
-9000620Mounting bracket rear
41001813Luggage carrier
51001814Walking aid holder
69000703Front bag (for std bracket with locking mechanism)
71003095Cane holder mounted to chair, horizontal
82537 Cane holder mounted to chair, vertical
91015389Cane holder mounted to chassis
101009251Mirror right
111015401Anti tip set
-9000825Adjustmenttool for rear spring
129001135Basket, standard
139006137Basket, large (only without locking mechanism)
141015507Lap strap with roll-up for Master Seat
Page 33
Trophy 20
5 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.
Service instructions | 33
Service instructions | 33
Service instructions | 33
TimeDescription
To be carried out by
UserDealer
DailyCharging the batteries, after each usexWeeklyChecking the tyre pressuresx-
Monthly
Every three
months
Cleaning the scooterxCleaning the upholstery (if necessary)xGrease the seat’s swivel mechanism: the seat needs to be removed for this. See
‘Removing the seat’. Lithium grease is recommended
xx (Annually)
Inspecting the electrical system-x
Checking the batteries-x
Inspecting the drive. (see 7.6)-x
Annually
Inspecting 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 user manual-x
It is recommended that the dealer carries out a service on the scooter at least once a year. If the scooter is used intensively, the
service should be carried out every six months.
Maintenance requirement for re-use
Disinfect surfaces with commercially available disinfectants and clean the surfaces with damp cloths and cleaners tuned.
Warning
Do not use high pressure cleaners or similar to clean the product!
The following work most be carried out before re-use:
Annual inspection
1234567
Electronics
On / off switch
Output connector
Operation
Brake
Programmable settings
Batteries
Level
Connections
Capacity test
Wheels and tyres
Tread depth
Pressure
Bearings
Wheel fi xing nuts
Motors
Cables
Noise
Connections
Brake
Brushes
Page 34
Chassis
Condition
Steering
Seating
Seat
Backrest
Armrests
Electrical
Harnesses
Connections
Lighting system
Test
Forwards
Backwards
Emergency stop
Left turn
Right turn
Uphill / downhill
Obstacle
Brake
List of necessary repairs:
Trophy 20 34 | Service instructions 34 | Service instructions
Annual inspection
1234567
Warning
Pull the charge cable out of the battery charging connection of the scooter before carrying out any maintenance on the scooter.
5.2 Batteries
Always follow the instructions related to battery maintenance & storage as given by the battery manufacturer ( 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 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 almost fl at. 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 fl at. This can seriously damage the batteries and shorten their lifespan.
Only use gel-batteries
Replacing the batteries
If battery capacity is so low (after fully charging) 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
Once the new batteries have been put in place they will need to be charged and ‘run in’ (
For the correct way to dispose of batteries see (
Scooter) ‘Used scooters and the environment’
Battery charger)
Page 35
Service instructions | 35
Service instructions | 35
Trophy 20
Service instructions | 35
Cleaning the batteries
Gel batteries are maintenance-free. However, attention may be paid to the following matters:
Note!
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.
5.3 Tyres
To ensure that your scooter performs well, it is of great importance for the tyres to be kept at the right pressure.
Infl ating the tyres
The tyres are equipped with a car tyre valve. Remove the caps from the valves before infl ating the tyres. If the tyres are not
adequately infl ated, the range of the scooter may be reduced and the tread may wear more quickly.
Warning
When infl ating 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 infl ating the tyres. The valve cap prevents dirt and sand from getting into the valve.
See the ‘Maintenance table’ regarding tyre checks.
5.4 Assembly, replacement and adjustment instructions
This chapter covers illustrated assembly, replacement and adjustment instructions.
Every separate visual instruction is prefaced with:
• Preparations
• Instructions (suggestions and advice to help you carry out tasks or procedures more easily)
• Notices (extra notes covering information you need when executing the specifi c task)
• Relevant article numbers
• Tools used
The tools for the specifi c task are illustrated in the visual instructions.
Page 36
5.4.1 Front frame 3W
Replacing the front wheel and fork
Trophy 20 36 | Service instructions 36 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the front
fork 3W:
• Remove the front cover and the front cover rear 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 the reverse order.
1
Notice
• 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
2
3
4
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Service instructions | 37
Service instructions | 37
Service instructions | 37
5
6
7
Page 38
5.4.2 Front frame 4W
Replacing the front wheel
Trophy 20 38 | Service instructions 38 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise 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 front wheel in the reverse order.
1
Relevant article numbers
• 9004511 Front wheel 4W
Tools used
• Screwdriver, medium
• Torque wrench, socket bit, 6 mm
Notice
• N.a.
2
3
4
Page 39
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Adjustment shock absorber - front
Service instructions | 39
Service instructions | 39
Service instructions | 39
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 suspention adjustment key to adjust the shock
absorber as desired.
Relevant article numbers
• N.a.
1
Tools used
• 9000825 Suspension adjustment key
Notice
• Position 0 soft and position 4 hard
Page 40
Replacing the shock absorber - front
Trophy 20 40 | Service instructions 40 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the shock
absorber - front:
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.
• 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
specifi cations.
• 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!
Relevant article numbers
• 1012525 Shock absorber - front
Tools used
• Torque wrench, socket,17 mm
• Socket, 7 mm
• Screwdriver, crosshead
• Allen key, 8 mm
• 9000825 Suspension adjustment key
Notice
• Position 0 soft and position 4 hard
1
2
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Service instructions | 41
Service instructions | 41
Service instructions | 41
3
5
4
6
7
8
Page 42
Replacing the swing arms (top and lower assy)
Trophy 20 42 | Service instructions 42 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the swing
arms:
Note! Suitable work area required!
• Remove 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 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.
Relevant article numbers
• 9004459 Swing arm lower assy
• 9004458 Swing arm top assy
Tools used
• Torque wrench, socket, 7 mm-13 mm / socket bit, 6 mm
• Torque wrench, socket, 17 mm
• Allen key, 8 mm
• Screwdriver
• Open ended spanner, 10 mm
Notice
• N.a.
1
2
Page 43
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Service instructions | 43
Service instructions | 43
Service instructions | 43
34
56
7
Page 44
5.4.3 Rear frame
Replacing the rear wheel
Trophy 20 44 | Service instructions 44 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the rear
wheel:
Note! Suitable work area required!
• Remove the cover and four hexagon head cap screws to
remove the rear wheel.
• Mount the new rear wheel in the reverse order.
1
Relevant article numbers
• 1014662 Rear wheel 8" right, black assy
• 1014661 Rear wheel 8" left, black assy
Tools used
• Screwdriver
• Torque wrench, socket bit, 6 mm
Notice
• N.a.
2
3
4
Page 45
Trophy 20
Replacing the mechanical brake
Service instructions | 45
Service instructions | 45
Service instructions | 45
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the
mechanical brake:
Note! Suitable work area required!
• Remove the cap and hexagon fl ange 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 fl ange bolt
with 90 Nm.
1
Relevant article numbers
• 9004141 Brake left
Tools used
• Screwdriver
• Torque wrench, socket, 16 mm
• Allen key, 5 mm
• Loctite 243
Notice
• N.a.
2
3
Note! Use Loctite 243 at the indicated locations during
assembling the scooter.
4
Page 46
Trophy 20 46 | Service instructions 46 | Service instructions
5
Page 47
Trophy 20
Replacing the carbon brushes
Service instructions | 47
Service instructions | 47
Service instructions | 47
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the carbon
brushes:
Note! Suitable work area required!
• Remove the rear cover.
• Disconnect all motor connectors from the S-drive
controller.
• 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.
• Clean the collector on the anchor of the motor from dust
with pressed air.
• 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.
Relevant article numbers
• 1012313 Motor brush set (4 carbon brushes with covers)
Tools used
• Lifting device
• Screwdriver short
• Allen key, 4 mm
• Socket, 7 mm, 10 mm and 16 mm
Notice
• Some parts need to be replaced; the replacement is
indicated by a
symbol.
• Make sure the scooter is switched off.
1
2
Page 48
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3
5
4
6
7
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Replacing the motor brake
Service instructions | 49
Service instructions | 49
Service instructions | 49
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
• Use a Lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the free
wheel lever:
Note! Suitable work area required!
• Remove the rear cover.
• Disconnect 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 free wheel
lever.
• Mount the new free wheel lever.
• Rebuild the scooter in the reverse order.
Relevant article numbers
• 1012104 Motor brake
Tools used
• Screwdriver
• Socket, 7 mm
• Allen key, 4 mm
Notice
• Some parts need to be replaced; the replacement is
indicated by a
symbol.
• Make sure the scooter is switched off.
1
2
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Trophy 20 50 | Service instructions 50 | Service instructions
3
5
4
6
7
8
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Service instructions | 51
Service instructions | 51
Service instructions | 51
9
Page 52
Replacing the transaxle
Trophy 20 52 | Service instructions 52 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to replace the
transaxle:
Note! Suitable work area required!
• Remove the rear cover.
• Disconnect 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 cover and hexagon fl ange bolt to remove
the rear wheel.
• Remove the brake cable
• 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 the scooter in the reverse order.
• Use Loctite 243 before fastening the hexagon fl ange bolt
with 90 Nm.
Relevant article numbers
• 1012530 Transaxle standard
• 1012529 Transaxle heavy duty
Tools used
• Socket, 7 mm
• Socket, 17 mm
• Torque wrench, socket, 16 mm
• Screwdriver
• Allen key, 5 mm
• Loctite 243
Notice
• Some parts need to be replaced; the replacement is
indicated by a
symbol.
• Make sure the scooter is switched off.
1
2
Page 53
Trophy 20
Service instructions | 53
Service instructions | 53
Service instructions | 53
3
5
4
6
7
Note! Use Loctite 243 at the indicated locations during
assembling the scooter.
8
Page 54
Trophy 20 54 | Service instructions 54 | Service instructions
9
10
Page 55
Trophy 20
Adjustment the shock absorber - rear
Service instructions | 55
Service instructions | 55
Service instructions | 55
Preparation
• Switch off the scooter with the ignition 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.
1
Relevant article numbers
• N.a.
Tools used
• 9000825 Suspension adjustment key
Notice
• Make sure the scooter is switched off.
2
3
4
Page 56
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5
Page 57
Trophy 20
Replacing the shock absorber - rear
Service instructions | 57
Service instructions | 57
Service instructions | 57
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.
• Remove the battery cover.
• Remove the bolts of the rollbar 6x
• Remove the roll-bar
• Remove the hexagon head cap screws
• 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.
Relevant article numbers
• 9000603 Shock absorber standard
• 9000683 Shock absorber heavy duty
Tools used
• Socket, 7 mm / 17 mm
• Allen key, 8 mm
• 9000825 Suspension adjustment key
Notice
• Make sure the scooter is switched off.
1
2
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Trophy 20 58 | Service instructions 58 | Service instructions
3
5
4
6
7
8
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9
Service instructions | 59
Service instructions | 59
Service instructions | 59
Page 60
5.4.4 Steering column
Replacing the steering wheel
Trophy 20 60 | Service instructions 60 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
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 tiller cover front
• Disconnect all connectors from the tiller PCB.
• Remove the two Ejot screws and washers to remove the
rear cover steering column.
• Remove the bolt to remove the steering wheel.
• Mount the new steering wheel.
• Rebuild the scooter in the reverse order.
1
Relevant article numbers
• 9004185 Steering wheel
Tools used
• Socket, 10 mm
• Screwdriver, crosshead
• Allen key, 6 mm
Notice
• Make sure the scooter is switched off.
2
34
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Service instructions | 61
Service instructions | 61
Service instructions | 61
5
Page 62
Replacing the gas spring
Trophy 20 62 | Service instructions 62 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
Instructions
The following operations are required to replace the gas
spring:
Note! Suitable work area required!
• Remove the basket, the mounting bracket for the
mirrors, the front cover and the front cover rear part.
• Pull the handle for steering adjustment upwards and
move the steering column downwards.
• Remove the four hinge pins and the spiral pin.
• Remove the hinge pin and remove the two bolts from the
gas spring slider.
• Disconnect the gas spring actuator
• 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!
Relevant article numbers
• 9007359 Gas spring 300N
Tools used
• Socket, 8 mm / 10 mm / 13 mm
• Screwdriver, crosshead
• Hammer (plastic)
• Chaser
• Loctite 243
Notice
• N.a.
12
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3
4
Service instructions | 63Service instructions | 63Service instructions | 63
6
8
7
9
Page 64
5.4.5 Console
Replacing the throttle
Trophy 20 64 | Service instructions 64 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries
Instructions
The 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.
• Mount the new throttle.
• Rebuild the scooter in the reverse order.
1
Relevant article numbers
• 1008055 Throttle (potentiometer)
Tools used
• Screwdriver, crosshead
Notice
• N.a.
2
Page 65
Trophy 20
Replacing the tiller PCB
Service instructions | 65
Service instructions | 65
Service instructions | 65
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
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 two bolts and remove the front tiller cover.
• Remove the tyrap
• 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.
1
Relevant article numbers
• 9007265 Tiller PCB for original electronics (ID-no
PBxxxxx only)
• 9008791 Tiller PCB Dual control for advanced
electronics (ID-no QBxxxxx onwards)
• 9008790 Tiller PCB Full option for advanced electronics
(ID-no QBxxxxx onwards)
Tools used
• Socket, 10 mm
• Screwdriver, crosshead
Notice
• Make sure the scooter is switched off.
2
3
4
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Trophy 20 66 | Service instructions 66 | Service instructions
5
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Trophy 20
Replacing the stop switch
Service instructions | 67
Service instructions | 67
Service instructions | 67
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
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 two bolts and remove the 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.
• 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.
Relevant article numbers
• 9006138 Emergency stop
Tools used
• Socket, 10 mm
• Screwdriver, crosshead
Notice
• Make sure the scooter is switched off.
12
Page 68
34
Trophy 20 68 | Service instructions 68 | Service instructions
5
7
6
Page 69
Trophy 20
5.4.6 Electronics
Replacing the controller for original electronics (ID-no PBxxxxx only)
Service instructions | 69
Service instructions | 69
Service instructions | 69
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
Instructions
The following operations are required to replace the
controller:
Note! Suitable work 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 controller.
• Rebuild the scooter in the reverse order.
1
Relevant article numbers
• 9002457 S-drive controller 120A
• 1015386 S-drive controller 90A
Tools used
• Allen key, 5 mm
Notice
• In case of S-drive controller 90A watch out for motor
harness and power harness.
2
3
4
Page 70
5.4.7 Covers front
Replacing the front tiller cover
Trophy 20 70 | Service instructions 70 | Service instructions
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
Relevant article numbers
• 9004442/9004445/9004448/9004451/9004454
Front tiller cover
Tools used
• Socket, 10 mm
• Screwdriver, crosshead
Notice
• Make sure the scooter is switched off.
2
3
Page 71
Trophy 20
Replacing the front cover
Service instructions | 71
Service instructions | 71
Service instructions | 71
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.
12
Relevant article numbers
• 1015363/1015364/1015365/1015366/1015367
Front cover
Tools used
• Screwdriver, crosshead
Notice
• Make sure the scooter is switched off.
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
Page 72
5.4.8 Covers rear
Replacing the rear cover
Trophy 20 72 | Service instructions 72 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
Instructions
The following operations are required to replace the rear
cover:
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.
1
Relevant article numbers
• 1003095 Crutch holder mounted to chair, horizontal
Tools used
• Open ended spanner, 10 mm
2
10
1
2
110948-03-002
110948-03-003
Page 74
Mount the crutch holder, vertical
Trophy 20 74 | Service instructions 74 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
Instructions
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
Relevant article numbers
• 2537 Crutch holder mounted to chair, vertical
Tools used
• Allen key, 6 mm
2
1
2
3
6
1
110948-03-010
6
110948-03-011
Page 75
Trophy 20
7
Mount the crutch holder, chassis
Service instructions | 75
Service instructions | 75
Service instructions | 75
Preparation
• Switch off the scooter with the ignition key.
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.
1
Relevant article numbers
• 1012515 Crutch holder mounted to chassis
Tools used
• Torque wrench, socket, 7 mm
• Metal drill, 4 mm
• Drill
• Allen key 3 mm
2
1
1
1
7
110948-03-013
3
4
110948-03-014
Ø4
110948-03-015
110948-03-015A
Page 76
Trophy 20 76 | Service instructions 76 | Service instructions
5
1
7
1
1
110948-03-015B
6
3
110448-03-016
Page 77
Trophy 20
Mount the anti tip wheels
Service instructions | 77
Service instructions | 77
Service instructions | 77
Preparation
• Switch off the scooter with the ignition key.
• Use a lifting device to raise the scooter clear of the
ground.
Instructions
The following operations are required to mount the anti tip
wheels:
Note! Suitable work area required!
• Mount with the two bolts on every side on the rear frame
an anti tip wheel.
1
Relevant article numbers
• 1015401 Anti tip set
Tools used
• Open ended spanner, 13 mm
• Socket, 13 mm
13
13
110948-03-024
Page 78
Mount the luggage carrier
Trophy 20 78 | Service instructions 78 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
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.
1
6
Relevant article numbers
• 1001813 Luggage carrier
Tools used
• Allen key, 6 mm
2
6
2
1
110948-03-005
2
1
3
110948-03-012
Page 79
Trophy 20
Mount the walking aid holder
Service instructions | 79
Service instructions | 79
Service instructions | 79
Preparation
• Switch off the scooter with the ignition key.
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.
1
6
Relevant article numbers
• 1001814 Walking aid holder
Tools used
• Allen key, 6 mm
2
6
2
2
1
3
110948-03-005
1
110948-03-009
Page 80
Mount the mounting bracket
Trophy 20 80 | Service instructions 80 | Service instructions
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 trolleybag on the mounting bracket.
1
6
Relevant article numbers
• 9000620 Mounting bracket rear
• 4930 Basket
• 1015545 Trolley bag
Tools used
• Allen key, 6 mm
2
6
2
2
1
110948-03-005
3
4
3
1
110948-03-006
-
-
-
-
Page 81
Trophy 20
Mount the lap strap with roll-up to the Master seat
Preparation
• Switch off the scooter with the ignition key.
Instructions
The following operations are required to mount the lap
strap with roll-up to the Master Seat:
Note! Suitable work area required!
• Unzip the cover from the 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.
• Right side: The plastic bushings and pivot van needs to
be used on the right side.
• When everything is mounted, place the black cap on the
bolts.
• Turn the fl aps of the cover with velcro inside and close
the zipper carefully. Fold also the zipper back inside.
Service instructions | 81
Service instructions | 81
Service instructions | 81
Relevant article numbers
• 1015507 Lap strap with roll-up for Master Seat
Tools used
• Socket, 17 mm
1
2
Page 82
5.4.10 Upgrade instructions controllers
Mount the foot throttle for advanced electronics (ID-no QBxxxxx onwards)
Trophy 20 82 | Service instructions 82 | Service instructions
Preparation
• Switch off the scooter with the ignition key.
• Disconnect the batteries.
Instructions
Basic display
Advanced display
The following operations are required to mount the foot
throttle:
Note! Suitable work area required!
Note! Remove always one fi nger-control! Replace it with
cover steering wheel 9007423.
• Loosen the fl oor mat from the frame.
Note! For mounting the foot throttle on the fl oor mat you
have to drill two holes in the fl oor mat and frame. Be
sure you will not damage any cables mounted under the
frame!
• 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 fl oor mat and position the foot throttle
mounting plate on the fl oor 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.
Relevant article numbers
• 9007083 Foot throttle Advanced electronics
• 1008730 4,8x19 self tapping screw
Note! This procedure is intended for the Throphy 20 with
the latest electronics. In case your Trophy 20 has the
dashboard as one above, you have the latest version
electronics. Contact Sunrise Medical HCM in case you
have another dashboard (original electronics ID-no
PBxxxxx only).
1
Tools used
• Allen key, 3 mm
• Metal drill, 6 mm
• Drill
• Screwdriver, crosshead
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
Page 83
Trophy 20
3
1
2
3X
3
Service instructions | 83
Service instructions | 83
Service instructions | 83
3
4
1
2
Ø6
3
110948-03-020
5
6
110948-03-021
110948-03-022
7
8
110948-03-013
110948-03-023
Page 84
Expand controller options for advanced electronics (ID-no QBxxxxx onwards)
Upgrade can be done via spare part options (see matrix below):
Trophy 20 84 | Service instructions 84 | Service instructions
from
to
Right handLeft handFootHand/footDual handCC
Emergency
stop
Right hand-022+41+45+6 (or 7)6
Left hand0-22+41+45+6 (or 7)6
Foot11-1+42x1+45+6 (or 7)6
Hand/foot000-15+6 (or 7)6
Dual hand0022-5+6 (or 1+7)6
CC (only works with 8)standard0221-standard
0. Only remove/replay parts
1. 1008055 Throttle potentiometer
2. 9007499 Assy foot throttle
3. 9008789 Tiller PCB Basic
4. 9008791 Tiller PCB Dual control
5. 9008790 Tiller PCB Full option
6. 9006138 Emergency stop button
7. 1016535 Full option steering wheel (includes 1+5+6)
Since Full option steering wheel only means to exchange the complete steering wheel, this may be advisable to use always as
upgrade for Cruise Control on single hand/fi nger control.
Cruise control will only work together with the Emergency Stop Button. If this button doesn’t function or isn’t present, the Scooter
will give an error and will not start. (Safety!)
Page 85
Trophy 20
5.5 Display menu settings
PBSRR
Service instructions | 85
Service instructions | 85
Service instructions | 85
E
G
C
I
E
Starting the service menu for original electronics (ID-no PBxxxxx only)
Kilometer total (user) Hold the hazard light button and press the left horn button briefl y
Reset total (user Push the I button (3 sec.)
R
Kilometer total (scooter) Hold the hazard light button and press the left horn button briefl y
Hours-on total (scooter) Hold the hazard light button and press the left horn button briefl y
Battery voltage Hold the hazard light button and press the left horn button briefl y
Leave dealer menu Any other button
Starting the service menu for advanced electronics (ID-no QBxxxxx onwards)
Pushing the hazard-button (G) together with the claxon-button (E) more than 2 seconds, the service menu shall be visible.
• First information shown after starting the service menu is the “Total km-1”
• Pushing the hazard button again (G) allows you to scroll through the menu shown below.
• If any other button (other than the DSS (I), horn (E), hazard button (G)) is switched during the service menu, the display
returns to the user menu and will show “actual speed”
When the batteries of the scooter are removed the service information shall not get lost for at least 1 year.
The display will blink at a frequency of 1-2HZ, indicating this value can be changed.
1. Total km-1 (S)
The amount of km the scooter has 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 (B)
The actual battery voltage measured real time
4. Hours ON
The amount of hours the scooter has been switched on in its life.
First one character of the display show: H
Page 86
5. Hours Driven
The amount of hours the scooter has driven more than 5% of its maximum speed in its life.
First one character of the display show: h
6. Software version
First one character of the display show: F
7. Signal Actual throttle input: Range
Actual input of the active throttle available (R)
First characters of the display show: C
The Icons on the tiller display will indicate the active throttle:
• right hand is lit: right hand side throttle is active
• left hand is lit: left hand side throttle is active
• no hand icons are lit: foot throttle is active
Foot throttle information is converted by the MC into a drive signal. This signal will be presented here. OK
8. Miles / hour reset (P)
Set speed and distance calculations to km or miles.
• Km icon on display is shown = km: km per hour
• m icon on display is shown = miles: miles per hour
Default: km
Change by pressing the DSS (I) switch ≥ 2 seconds.
Trophy 20 86 | Service instructions 86 | Service instructions
9. Scooter type selection.
This refl ects the diameter of the wheels used.
• “t30” Trophy speed algorithm (Trophy 30)
• “t20” Trophy speed algorithm (Trophy 20)
Default: “t30”
Change by pressing the DSS (I) switch ≥ 2 seconds.
10. This refl ects if a beeping sound is 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 options are standard available. Some options are only available as ordered at Sunrise Medical HCM. Not activated values
will not be shown in the service menu.
11. Cruise Control enable (S)
• “0” disabled
• “1” enabled
Default: “0” = disabled
Change by pressing the DSS (I) switch ≥ 2 seconds.
First two characters of the display show: CC
12. Manual / intelligent throttle switch
• “0” off
• “1” Manual Throttle Switching (MTS)
• “2” Intelligent Throttle Switching (ITS)
• “3” ITS and MTS active
Default: “0” = off
Change by pressing the DSS (I) switch ≥ 2 seconds.
First two characters of the display show: tS
Page 87
Troubleshooting | 87
Trophy 20
Troubleshooting | 87
6 Troubleshooting
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 fi rmly connected.
C. Check whether the freewheel 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 fl ash. Use the table below to determine the cause of the problem.
Indication on the displayDescription of problemCorrective action
The complete LED bar fl ashes
rapidly.
The socket LED is lit continuously
after the scooter is switched on.
The fi rst red LED of the LED bar is
lit continuously.
LED bar left to right chase.The batteries are being charged.Disconnect the battery charger from the scooter.
Two LEDs of the LED bar are lit.There is a poor connection to the motor. Check all connections between the controller and
Three LEDs of the LED bar are lit. There is a short circuit in the motor.Check the motor cables or replace the motor.
Seven LEDs of the LED bar are lit. The throttle was held in during start up.
Eight LEDs of the LED bar are lit.The controller is malfunctioning.Replace the controller.
Nine LEDs of the LED bar are lit.The neutral handle is in the neutral
Ten LEDs of the LED bar are lit.The battery is malfunctioning.Check the connections between the batteries and
The Controller security has found
something that causes a problem.
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.
The batteries require charging or there
is a poor connection to the batteries.
Speed potentiometer fault.
position.
The brake is malfunctioning.
Switch off the scooter.
Check all connectors.
Check the condition of the batteries.
Consult the manufacturer if the LED bar continues
fl ashing after the scooter has been switched on.
Contact the manufacturer.
Check all connections between the controllers
and the batteries. If the connections are OK, try
recharging the batteries.
the motor.
Restart the scooter without pressing the throttle.
Check or replace the speed potentiometer.
Put the neutral handle in the drive position.
Check the connections between the brake and the
controller.
Replace the brake.
the controller.
Check the batteries.
The table below provides explanation for the trip codes that can be indicated by the controller. These trip codes can be read with
the manual programming unit (SP1) or the mobility programmer PG.
LED codeTrip codeError typeExplanation
12c00Low battery errorLow battery voltage
12c01Low battery errorLow battery voltage
23B01Motor fault 1Motor disconnected
31400Bridge fault 1Motor wiring fault
47000Startup with push selectedParking brake off
47001Push activated in drive modeParking brake off
61e03Inhibit activatedInhibit active
70810Tiller fault 1Throttle trip
70814Tiller reference errorThrottle trip
70815Tiller lo reference errorThrottle trip
70816Tiller high reference iso errorThrottle trip
70817Tiller lo reference errorThrottle trip
70300Speed Limit Potentiometer wiper openThrottle trip
71d02Front end spec change tripThrottle potentiometer trip
72f01Tiller displaced errorThrottle displaced at power up
80002Eeprom calibration checksum error 2Possible controller trip
80003Eeprom program checksum error 2Possible controller trip
80100Running checksum 1Possible controller trip
80203Eeprom calibration checksum error 1Possible controller trip
80204Eeprom program checksum error 1Possible controller trip
81501Brake fault 2Possible controller trip
81705Relay fault 1Possible controller trip
81802Watchdog voltage ref errorPossible controller trip
This product complies with the regulations of the Medical Devices Directive and therefore
bears the CE mark.
StandardDefi nition/descriptionWeight test dummy
EU guideline 93/42 EEC Applicable as mentioned in Appendix 1N/A
The requirements from EN12182 as mentioned in NEN-EN 12184 (1999):
NEN-EN 12182 (2009)
NEN-EN 12184 (2009)
Class B
ISO 7176-8
ISO 7176-9Climate tests for electric wheelchairs and scootersN/A
ISO 7176-14
ISO 7176-16Requirements for resistance to ignition of upholstered parts May 1997N/A
7.2 Technical specifi cations
ManufacturerSunrise Medical HCM
ModelTrophy 20 3 wheels (3W)
Maximum user weight160 kg (25.2 stone)
Technical aids for the handicapped – General requirements and test methods
October 1997
Electric wheelchairs, scooters and accompanying battery chargers –
Requirements and test methods 2009
Requirements and test methods for static, impact and fatigue strengths July
1998
Requirements and test methods for control systems for electric wheelchairs
1997
®
Trophy 20 4 wheels (4W)
160 kg
160 kg
160 kg
N/A
Description3W4W
Total lengthmm (inches)
Total widthmm (inches)
Minimum height*mm (inches)
Total weight excluding batterieskg (stones)
Total weight including batteries (74 Ah C20)kg (stones)
Weight of heaviest componentkg (stones)
Static stability in the downward direction°
Static stability in the upward direction°
Lateral static stability°
Distance range (ISO 7176-4)**km (miles)
Dynamic stability (max. safe slope)°
Maximum speed forwardskm/h (mph)
Back angle, Captain Seat°
Seat depth, Captain Seatmm (inches)
Seat width, Captain Seatmm (inches)
Back height (excl. headrest), Captain Seatmm (inches)
Seat height (to platform), Captain Seatmm (inches)
Drive lever operation < 20 [N]
Resetting the automatic fuse (circuit breaker)< 60 [N]
Electronic switches< 13.5 [N]
Connecting the charger plug< 60 [N]
Technical specifi cations for wheels
Front wheel diameter (3W)mm (inches)320 x 60 (12.5 x 2.25)
Front wheel diameter (4W)mm (inches)320 x 60 (12.5 x 2.25)
Rear wheel diametermm (inches)360 x 80 (14.2 x 3.1)
Tyre pressure 4W, front wheelbar (psi)2,5 (36.3)
Tyre pressure 4W, rear wheelbar (psi)3,5 (50.8)
Tyre pressure 3W, front wheelbar (psi)
2,5 (36.3)
Tyre pressure 3W, rear wheelbar (psi)3,5 (50.8)
Batteries
Maximum dimensions of batteries (lxbxh)mm (inches)
* 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)
*** seat height < 425 mm: an elevated footplate is required or by removing the slider
7.3 Driving programs
The driving programs for Sunrise Medical HCM products can be found on the FTP server.
Log on to the FTP server:
• Open internet explorer
• Go to ftp://mobilityftp.handicare.com
• Enter user name and password
User name: dealer@mobilityftp.handicare.com
Password: dealer
• You will be logged on
• Select your wheelchair and the appropriate controller
• Click the fi le to download
Page 91
Trophy 20
)
7.4 Controller settings PG Drives
PGDT S-Drive 90A for original electronics (ID-no PBxxxxx only)
Braking Current Limit (Amps)120
Timed Foldback Braking Current (Amps) 120
Timed Foldback Speed (%)100
Enhanced Motor Compensation (Up) (%)190
Enhanced Motor Compensation (Down) (%)180
Enhanced Motor Compensation (Up) Gain90
Throttle Settings
Throttle Type1(0 = Single-ended, 1 = Wig-wag, 2 = Unipolar)
Throttle Deadband (%)
Throttle Gain (%)
Throttle Operated at Power-up
ISO Test Resistor
Timed Throttle Invert0(0 = Off, 1 = Inhibit 2, 2 = Inhibit 3)
(S Drive II Only)
15
140
2(0 = Drive, 1 = Inhibit, 2 = Trip)
OnThrottle Reference Test
Off
(S Drive 120,140,180A) (S Drive II)
(S Drive 120,140,180A) (S Drive II)
(S Drive II Only)
(S Drive Only)
(S Drive Only)
(S Drive Only)
(S Drive Only)
(S Drive 180A) (S Drive II)
(S Drive 180A) (S Drive II)
(S Drive 180A) (S Drive II)
(S Drive II Only)
(S Drive II Only)
(S Drive II Only)
Page 95
Trophy 20
7.5 Data sheet
Description Remarks
Nominal voltage24V
Current main fuse50A
Max slope percentage16%
Max slope with a start9° @ 160kg°
Motor nominal power950Watt
Gearing ratio (motor gearbox)4100/195i
Wheel diameter front320x60mm
Wheel diameter rear360x80mm
Type of tyre front12½ x 2¼Type of tyre rear3,00-8Tyre pressure maximum front2,5bar
Tyre pressure minimum rear3.5bar
Maximum dimenstions batteriesL262xW173xH211mm
Battery connection typeAndersonMaximum allowable charger voltage30V
Maximum allowable charger current
charger
Maximum battery capacity C2074Ah
Maximum battery capacity C563Ah
Forces on levers etc.
Electronic switches<13.5 [N]
Drive lever operation<20 [N]
Parking brake<60 [N]
Connection of charger<60 [N]
8 RMSA
Technical product information | 95
Weight3W4W
bat. size40Ah60Ah74Ah40Ah60Ah74Ah
Frame707070808080
Chair191919191919
Basket+2,42,42,42,42,42,4
Batteries28,838,648,628,838,648,6
Total120130140130140150
Page 96
7.6 Electrical diagram Trophy 20
Original electronics (ID-no PBxxxxx only)
Trophy 2096 | Technical product information
Page 97
Trophy 20
Advanced electronics (ID-no QBxxxxx onwards)
Technical product information | 97
Page 98
Trophy 2098 | Technical product information
7.7 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.
PartPlan service check
Motor brushAt least once a year or every 2000 km
Clean the collector on the anchor of the motor with pressed air from dust.
18
8
New brush – maximum (18 mm) and minimum (8 mm) dimensions.
Page 99
Warranty | 99
Trophy 20
Warranty | 99
8 Warranty
8.1 Defi nitions of terms
Defi nitions of terms used in this warranty:
• After sales service part: Part purchased after the intial product that is durable and may be subjected to natural wear and tear or
natural contamination during normal operation within the lifetime of the product.;
• Consumable part: Part that is subjected to natural wear and tear or natural contamination during normal operation within the
lifetime of the product (section 9 of Sunrise Medical HCM’s general terms and conditions of sale);
• Client: Those who purchase the product directly from Sunrise Medical HCM;
• Corrective action: Repair, replace or refund of the product;
• Dealer: Those who re-sell the product to the User;
• Defect: Any circumstance due to which the product is not sound or fi t to use, caused by a lack of quality of the material used to
manufacture the product as well as the quality of the manufacturing process;
• Option: An accessory delivered with the initial product by Sunrise Medical HCM to extend the standard product model;
• Product: Product that is delivered according to brochure or contract (e.g. wheelchair, scooter, battery-charger etc.);
• Part: Part of product that can be exchanged or replaced. This can be an option, accessory, service part or consumable part;
• Returns: Product or part that needs to be returned;
• RMA-process: Process to return goods, contact your Sunrise Medical HCM Customer service;
• User: Those who use the product;
• Warranty: The rights and obligations set forth in this document;
• Warranty period: The period of time during which the warranty is valid;
• Warranty provider: Sunrise Medical HCM B.V., Vossenbeemd 104, 5705 CL Helmond, The Netherlands.
Notwithstanding the rights and obligations of Sunrise Medical HCM, Client and User set forth in Sunrise Medical HCM’s general
terms and conditions of sale, the rights of the Client and/or User towards Sunrise Medical HCM in case of defects are limited to
the provisions set forth in this warranty. For the duration of the warranty period Sunrise Medical HCM guarantees that the product
is without defects.
In case of any defects the User is required –within two weeks after discovery of the defect- to contact the dealer. He has to
complete a return form and return the product or part via the RMA-process. Sunrise Medical HCM will, at its sole discretion, take
the corrective action it seems fi t under the given circumstances within a reasonable period of time (depends on nature of claim)
from receipt of the completed return form. The warranty period will not be extended after a corrective action.
8.2 Warranty period table
Scooters
DescriptionWarranty period
Frame2 yearsWeldment/frame
Drive system*1 yearTransaxle, motor, motor brake
Electronics*1 year
After sales service parts
Consumable parts40 days after invoiceCarbon brushes, etc.
Options/Accessories2 years
Sunrise Medical HCM will only accept shipment costs and corrective costs related to warranty on equipment during the warranty
period.
This warranty will void in case of:
• The product and/or its parts being modifi ed;
• Changes in cosmetic appearance by use;
• Failure to observe the instructions for use and maintenance, use other than normal use, wear and tear, negligence, collateral
damage by neglect of earlier symptoms, overloading, third-party accidents, non-original parts used and defects not caused by
the product;
• Circumstances beyond our control (fl ood, fi re, etc.).
New: 1 year after invoice
Repaired: 90 days after invoice
Examples include, but are not limited to the parts
mentioned below
Mirror, mudguards etc.
Delivered with the initial product
* also in case of after sales service part delivery
Page 100
Trophy 20 100 | Warranty
This warranty does not cover:
• Tyres and inner tubes
• Batteries (covered by the battery manufacturer’s warranty).
Clients and/or Users have legal (statutory) rights under applicable national laws relating to the sale of consumer products. This
warranty does not affect statutory rights you may have nor those rights that cannot be excluded or limited, nor rights against the
entity from whom the product was purchased. Clients may assert any rights they have at their sole discretion.
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