Handicare Fortress Calypso mobility scooter Service manual

The Fortress Calypso is a 3- & 4- wheel scooter designed for transporting people weighing up to 125 kg on pavements, footpaths and cycle paths, as well as in and around the house. It has a maximum speed of 10 km/h (6 mph) and features adjustable seating, steering column, and rear suspension. The scooter is equipped with brake lights, indicator lights, and a horn.

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SERVICE MANUAL

FORTRESS-CALYPSO

3- & 4- WHEEL SCOOTER

The information contained in this manual may not be reproduced and/or published in any form, by print, photoprint, microfilm or by any other means, whether electronically or mechanically, without the prior written authorisation of Handicare.

The information provided is based on the general data relating to the design of the product known at the time of publication of this manual.

Handicare has a policy of continuous improvement and reserves the right to make changes and modifications to its products.

The information provided applies to the standard version of the product. Handicare can not be held liable for any damage resulting from product specifications which do not conform to the standard configuration.

The information made available has been compiled with the greatest care. However, Handicare can not be held liable for any possible errors in the information or for the consequences thereof.

Handicare accepts no liability for loss as a result of work carried out by third parties.

Under regulations concerning the protection of trade names, the names and trade names etc. used by Handicare may not be regarded as openly available.

2 Version 2015v1

Table of contents

This manual ................................................................................................................................................................. 4

Available documentation ........................................................................................................................................... 4

Productlabels .............................................................................................................................................................. 4

Symbols used in this manual: ................................................................................................................................... 5

Service and technical support................................................................................................................................... 6

Identification plate ...................................................................................................................................................... 6

Identifying the product ............................................................................................................................................... 6

Approvals .................................................................................................................................................................... 6

CE declaration ............................................................................................................................................................. 6

Used scooters and the environment ........................................................................................................................ 6

Warranty ...................................................................................................................................................................... 7

Use for intended purposes

(1)

.................................................................................................................................... 8

1 General safety rules and regulations ................................................................................................................ 9

1.1

Labels and instructions on the scooter ........................................................................................................... 9

1.2

Technical specifications ................................................................................................................................. 9

1.3

Adaptations ..................................................................................................................................................... 9

1.4

Safety ............................................................................................................................................................. 9

2 Adjustment options ........................................................................................................................................... 11

2.1

Adjusting the seat ......................................................................................................................................... 11

2.1.1

Adjusting the seat height ....................................................................................................................... 11

2.1.2

Adjusting the seat depth (sliding system) ............................................................................................ 11

2.1.3

Adjusting the backrest ........................................................................................................................... 11

2.1.4

Adjusting the armrest ........................................................................................................................... 12

2.1.5

Adjusting the headrest .......................................................................................................................... 12

2.2

Adjusting the steering column ...................................................................................................................... 12

2.3

Adjusting the rear suspension ...................................................................................................................... 12

3 Programmer ....................................................................................................................................................... 13

4 Electrical diagram .............................................................................................................................................. 15

5 Technical specifications ................................................................................................................................... 16

5.1

Fortress Calypso product specifications ...................................................................................................... 16

6 Service instructions .......................................................................................................................................... 18

6.1

Maintenance diagram ................................................................................................................................... 18

6.2

Maintenance instructions .............................................................................................................................. 18

6.3

Instructions for repair .................................................................................................................................... 18

7 Use of the parts list ........................................................................................................................................... 19

8 Parts list .............................................................................................................................................................. 20

A: Overview 3W ................................................................................................................................................... 21

B: Overview 4W ................................................................................................................................................... 23

001: Wheel front assy .......................................................................................................................................... 25

002: Wheel rear assy ........................................................................................................................................... 26

003: Bumper rear assy ........................................................................................................................................ 27

004: Top console assy ......................................................................................................................................... 28

005: Bottom console assy ................................................................................................................................... 29

006: Tiller assy ..................................................................................................................................................... 30

007: Tiller strut assy ............................................................................................................................................ 31

008: Cover battery assy ....................................................................................................................................... 32

009: Cover motor assy ........................................................................................................................................ 33

010: Frame front 3W assy ................................................................................................................................... 34

011: Front fork assy ............................................................................................................................................. 35

012: Cover front 3W assy .................................................................................................................................... 36

013: Frame front 4W assy ................................................................................................................................... 37

014: Swing arm right assy ................................................................................................................................... 38

015: Swing arm left assy ..................................................................................................................................... 39

016: Cover front 4W assy .................................................................................................................................... 40

017: Rear frame top assy .................................................................................................................................... 41

018: Rear frame assy .......................................................................................................................................... 42

019: Rear frame bottom assy .............................................................................................................................. 43

020: Transaxle assy ............................................................................................................................................ 44

021: Captain seat assy ........................................................................................................................................ 45

022: Armrest adjustable assy .............................................................................................................................. 46

Version 2015v1 3

Introduction

This manual

This manual contains the basic instructions for repairs and general maintenance of the Calypso electric scooter.

Mechanics who do repairs on this scooter must be well trained and familiar with the repair methods and the maintenance of the Calypso electric scooter.

It is important to see to it that work is always done safely, particularly with respect to activities where the scooter must be lifted up.

We advise that you contact our service department before doing repair work on a scooter that has been involved in an accident.

The following specifications are important when ordering parts:

•

Model

•

Manufacture year

•

Identification number

•

Part number

•

Name of the relevant part

This information can be found on the identification plate. See 'Identification of the product'.

Available documentation

The following technical documentation is available / required to service this scooter:

•

User manual

•

Service manual

Productlabels

The following stickers and labels can be found on the product:

A. Charging point

B. Circuit breaker

C. Tyre pressure

D. Neutral position

E. Adjustment of steering column angle

4 Version 2015v1

Introduction

A. Charging point

See the chapter on ‘Charging the batteries’, section 5.1, for how to charge the batteries.

B. Circuit breaker

The scooter is equipped with a fuse which interrupts the electric current on overload. See

‘Automatic circuit breaker’, section 7.2.

C. Tyre pressure

See the ‘product specifications’ for the correct tyre pressure.

D. Neutral position – Free wheel facility

Lever fully forward (“BRAKE applied”):

When the motor drive is engaged the scooter can be driven electrically and the brakes are also applied when the scooter is switched off.

When the lever is in the lowest position the motor drive is disengaged. The scooter can then be pushed manually.

E. Adjusting the steering column angle

The steering column can be adjusted to the position you find most comfortable when driving. See ‘Changing the position of the steering column’, section 4.1.6.

Symbols used in this manual:

CAUTION

Operations or manoeuvres which are not carried out correctly may result in damage to the product or the environment, or in user injury.

ATTENTION!

Suggestions for making specific operations or manoeuvres easier to carry out.

First consult the source(s) of information given.

Disconnect the charging cable from the charging point on the scooter before carrying out any maintenance on the scooter.

Version 2015v1 5

Introduction

Service and technical support

Your dealer should be contacted for information about specific adjustments, maintenance or repair and will be happy to help you.

When contacting your dealer, please ensure you have the following information to hand:

•

Model

Serial number

This information can be found on the information plate. See the illustration below.

Identification plate

Product information is recorded on plate (A). See: ‘Identifying the product’.

Identifying the product

A. Model

B. Date of manufacture

C. Serial number / identification number

D. Usage: Indoor use, outdoor use or both

E. Maximum load in kg

Approvals

The product meets the following requirements:

•

EN12184; 1999 Electrically powered wheelchairs and scooters, class B.

•

EN12182; 1999 Technical aids for disabled persons.

•

ISO7176-8 Requirements for static, impact and fatigue strengths.

•

ISO7176-9 Climatic tests for electric wheelchairs and scooters.

ISO7176-14 Requirements and test methods for power and control systems for electric wheelchairs.

ISO7176-16 Requirements for resistance to ignition of upholstered parts.

The product has been EMC-approved (for electromagnetic compatibility) in accordance with EN12184 (1999).

CE declaration

The product complies with the regulations of the Medical Devices Directive and therefore bears the CE mark.

Used scooters and the environment

If your scooter is no longer required or needs to be replaced, it will usually be possible to arrange for your dealer to take it back. If this should not be possible, consult with your local authority to find out if the scooter can be recycled or if the materials used in it can be processed in an environmentally friendly way.

Various plastics and metals were used in the manufacture of the scooter. The scooter also contains electronic components which should be disposed of accordingly. The batteries constitute chemical waste.

6 Version 2015v1

Introduction

Warranty

Definitions of terms used in this warranty:

•

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 Handicare’s general terms and conditions of sale);

Client: Those who purchase the product directly from Handicare;

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 fit 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 by Handicare 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 Handicare’s Customer Service;

Service part: Part that is durable and may be subjected to natural wear and tear or natural contamination during normal operation within the lifetime of the product.;

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: Handicare B.V., Vossenbeemd 104, 5705 CL Helmond, The Netherlands.

•

Notwithstanding the rights and obligations of Handicare, Client and User set forth in Handicare’s general terms and conditions of sale, the rights of the Client and/or User towards Handicare in case of defects are limited to the provisions set forth in this warranty. For the duration of the warranty period Handicare 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. Handicare will, at its sole discretion, take the corrective action it seems fit 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.

Warranty period table

Power wheelchairs / scooters

Description Warranty period Examples include, but are not limited to the parts mentioned below

Frame

2 years Weldment/frame

Drive system

Electronics

1 year

Transaxle, motor, motor brake

Controller, controlling mechanism, wiring harness, electronic components

Service Parts

New: 1 year after invoice

Repaired: 90 days after invoice

Brakes

40 days after invoice Wheels, push handles etc.

Consumable parts

Options/Accessories

2 years Mirror, mudguards etc.

Not being service part or consumable part.

Handicare 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 modified or items having been added by others than Handicare;

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 (flood, fire, etc.).

Version 2015v1 7

Introduction

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..

Use for intended purposes

(1)

The Fortress Calypso scooter was developed for:

•

The transportation of people weighing up to 125 kg

Use on pavements, footpaths and cycle paths

•

Use in and around the house

The dealer must give you clear instructions before you start operating the product independently.

Your first test drives of the Fortress Calypso are best carried out under the supervision of an experienced dealer.

The Fortress Calypso scooter is not classified as a road vehicle and therefore may not be used on the road

(crossing over the road being the only exception).

The Fortress Calypso has a maximum speed of 10 km/h (6 mph).

ENSURE THAT YOU ARE FULLY ACQUAINTED WITH THE CONTENTS OF THIS MANUAL BEFORE

STARTING TO DRIVE THE FORTRESS CALYPSO.

If you use the scooter in a dangerous fashion, or use the scooter for purposes other than those intended,

Handicare will accept no liability for any personal injury or damage to property caused by such misuse.

(1)

Intended use, as specified by EN 292-1, means the use for which the technical product is suitable according to the manufacturer’s declaration, including the manufacturer’s instructions in the sales brochure. In the event of doubt, use is taken to mean the use as construed from the design, construction and function of a product. The instructions contained in the user manual must also be followed within the scope of intended use.

8 Version 2015v1

General safety rules and regulations

1 General safety rules and regulations

Handicare accepts no liability for loss or injury caused by not following the safety rules and regulations fully, or otherwise for loss or injury as a result of negligence during use or when cleaning the scooter and any accessories.

Supplementary safety regulations may apply depending on the specific circumstances for operation or on the accessories used. Please contact your dealer immediately if you should ascertain any potential hazards when using the product.

The user of the scooter (see ‘Intended use’) is at all times responsible for following local safety rules and guidelines.

1.1 Labels and instructions on the scooter

The markings, symbols and instructions on the scooter constitute a part of the safety guidelines for the scooter. For this reason they may never be covered or removed and must be present and clearly legible for the entire period of time the scooter is in existence.

Illegible or damaged labels, symbols and instructions must be replaced or repaired immediately. Contact your dealer in such cases.

1.2 Technical specifications

No changes may be made to the technical specifications.

1.3 Adaptations

Adaptations to components of this product are not permitted.

1.4 Safety

It is of great importance that attention be paid to the following safety regulations for the prevention of accidents and undesirable situations.

Take extra care when driving on slopes:

• Never remove safety devices, such as the anti-tip wheels.

• Never drive the Fortress Calypso up slopes with a gradient greater than that specified in

section 5.4.3 of this manual.

• Always drive up slopes slowly and take extra care.

• Never descend a slope at full speed.

• Do not drive down slopes covered with loose gravel or with a sandy surface, as one of the back

wheels may slip.

• Do not turn on slopes.

• Never take corners at full speed. Reduce speed before taking a corner.

• When driving up a slope, adopt a position which promotes stability, as described in section

5.4.3 of this manual.

• Ensure that clothing does not trail as this can become entangled in the wheels.

• Ensure that your fingers do not become trapped in the mechanism for adjusting the position of

the steering column.

You must adjust your driving to the prevailing conditions:

• Drive carefully on roads which have become slippery due to rain, black ice or snow!

• Reduce speed in busy surroundings.

• Do not use the scooter on unsurfaced roads.

• Ensure that the Fortress Calypso A does not come into contact with salt water. Salt water is

corrosive and can damage the scooter.

• Ensure that the Fortress Calypso does not come into contact with sand. Sand can find its way

into the moving parts of the scooter, resulting in these parts wearing out unnecessarily quickly.

• Never drive the scooter while under the influence of drugs, alcohol or prescription medications

which could affect your driving ability.

• Your eyesight must be adequate for you to drive the scooter safely.

Version 2015v1 9

General safety rules and regulations

• If visibility is not ideal, then it is obligatory for the lights to be turned on. The scooter is

equipped with brake lights which illuminate on braking.

• Use the indicator lights only to indicate a change in driving direction.

• Only use the horn for warning pedestrians or other road users of possibly hazardous

situations.

• Never place metal components on top of the batteries. Doing so could cause a short circuit,

leading to damage.

• Do not transport any passengers on the scooter. The scooter has been specifically designed to

transport you alone.

• Do not drive the scooter with the seat backrest angled too far to the rear. This can affect weight

distribution and the stability to the rear of the scooter, in particular when driving up slopes or over obstacles.

• Ensure that your scooter does not transport a greater load than fits in the basket. Never hang

anything on the tiller.

• Never use the scooter for pulling a trailer. The scooter has not been designed for such use and

doing so can cause serious damage to your scooter.

• Do not stand on the platform in order to reach up to objects.

• Do not position your feet too close to the front wheel and fork when driving. Always keep your

feet on the rubber mat and not up against the front tiller cover.

The scooter is electronically driven. Specific parameters have been factory-set. These settings have been made in order to ensure that use of the Fortress Calypso is comfortable and efficient and they can not be changed.

The standard version of your scooter has been tested in accordance with the most stringent requirements for electromagnetic interference.

If you use a mobile telephone near to a specially adapted scooter, it is advisable to switch the scooter off first.

Your scooter can affect electromagnetic fields, such as alarm systems. 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.

• Beware of ultraviolet light. Ultraviolet light can cause premature wear of materials such as

rubber, plastic and enamel.

• Pay attention to objects sticking out from the scooter. These can cause damage to your

surroundings or to the scooter itself.

• Keep the scooter away from open flames.

• Avoid extreme weather conditions or extremely wet conditions. Maintain and store the scooter

in a clean and dry state.

10 Version 2015v1

Adjustment options

2 Adjustment options

There are a number of adjustments which can be made to the Fortress Calypso in order to improve its seating and driving comfort levels.

Some adjustments are permanent adjustments made by the dealer using tools.

Other adjustments can be made by the user without the use of tools.

Adjustments can be made to the following by your dealer:

•

Seat height

•

Rear suspension

Adjustments can be made to the following by the user:

•

Seat depth

•

Backrest angle

Armrest width

Armrest height

Headrest

•

Steering column

2.1 Adjusting the seat

2.1.1 Adjusting the seat height

The entire seat can be adjusted in height in order to obtain the optimal seating position. This adjustment is carried out by the dealer.

2.1.2 Adjusting the seat depth (sliding system)

(

seat may vary from the illustration)

The seat depth can be adjusted as follows:

•

Lift and hold handle (A).

Slide the seat forwards or backwards.

•

Release the handle once the seat is in the required position. Now slide the seat slightly forwards or backwards so that it locks into place.

The seat depth has now been adjusted.

2.1.3 Adjusting the backrest

The backrest angle can be adjusted as follows:

•

Lift handle (A) whilst sitting on the seat.

•

The backrest now automatically moves forwards.

Push the backrest to the rear by leaning against it until it is in the position

• you find the most comfortable.

Once adjusted, release the handle. The backrest remains in the position you selected.

Caution: Exercise caution when using the handle when no one is sitting on the seat. The backrest is equipped with a spring mechanism which causes it to be driven quickly forwards with some force.

The backrest can be adjusted to provide good back support while driving.

If the backrest is adjusted to an angle too far to the rear, the driver’s seating position is then less stable, particularly on slopes.

It is therefore important never to drive your scooter if the backrest is inclined too far back.

Version 2015v1 11

Adjustment options

2.1.4 Adjusting the armrest

The armrests can be adjusted as follows:

•

Rotary knobs (A) for adjusting the distance between the armrests are located at the back of the seat.

•

Turn the knob in an anti-clockwise direction to loosen the armrest.

Once you have adjusted the distance between the armrests, tighten the rotary knobs by turning in a clockwise direction. Then check to see whether the armrests are firmly in place.

•

The rotary knobs (B) for adjusting the height of the armrests are located on the rods supporting the armrests.

Turn the knob in an anti-clockwise direction to loosen the armrest.

Press the nipple and slide the armrest upwards or downwards into one of the three positions.

Once you have adjusted the height, tighten the rotary knobs by turning in a clockwise direction. Then check to see whether the armrests are firmly in place.

2.1.5 Adjusting the headrest

The headrest can be adjusted to various heights.

The headrest height is adjusted as follows:

•

Press the plastic button at the point where the headrest is attached to the seat, at the same time moving the headrest to the required height. The headrest can also be removed if required.

•

Release the button and move the headrest slightly so that it locks into one of the positions.

2.2 Adjusting the steering column

The steering column can be adjusted to make driving more comfortable and to make it easier for you to mount and dismount from the scooter.

The steering column is adjusted as follows:

•

Using one hand, pull handle (A) downwards while pulling the steering column towards you with the other hand until it is in the most comfortable position.

•

Release the handle. Then release the steering column.

If you release the steering column while still pulling the handle down, the pneumatic spring will cause the steering column to jump into the most forward position automatically.

Exercise caution while adjusting the steering column and ensure that your fingers do not become trapped.

2.3 Adjusting the rear suspension

The rear suspension of the scooter can be adjusted to provide optimal comfort. This adjustment is carried out by the dealer.

12 Version 2015v1

Programmer

3 Programmer

The Fortress Calypso can be programmed with both the DX-HHP Hand-Held-Programmer and the Wizard. In both cases, use the orange DWIZ adaptor and connect to the charger socket of the scooter.

For the standard settings of the programmer, see the R series DR-50 and DR-90 installation manual that can be downloaded on www.dynamiccontrols.com

The driving programs for Handicare products can be found on our FTP server.

Log on to the FTP server:

•

Open internet explorer

•

Go to ftp://mobilityftp.handicare.com

•

Enter user name and password

User name: [email protected]

Password: dealer

•

You will be logged on

•

Select your wheelchair and the appropriate controller

•

Click the file to download

If you wish to order parts for your programmer, please contact Handicare.

DWIZ-ADAPT 1009567

The specific and optimised Fortress Calypso settings are summarized in the table below.

User Personalisation

Swap Throttle Direction

Enable Beeper

Flash Code Beeper

Sleep Beeper

Reversing Beeper*

Beeper On Time (ms)

Beeper Off Time (ms)

10km/h or 6mph

Yes

300

700

8km/h or 5mph

Yes

300

700

*These settings have no influence, are set via dip-switches on Tiller PCB (see Chapter 6.3)

Version 2015v1 13

Programmer

Throttle Configuration

Throttle Type

Throttle Input

Throttle Neutral Offset (V)

Throttle Full Scale Deflectio

Throttle Response (%)

Throttle Dead-band (%)

Motor Management

Motor Reverse

Load Compensation (mOhm)

Current Limit (A)

Boost Current (A)

Boost Time (s)

Transaxle power

Park Brake Management

Park Brake Neutral Delay (ms)

Park Brake Release Delay (ms)

Battery Management

Battery Resistance (mOhm)

Fuel Gauge High Warning (V)

Fuel Gauge Low Warning (V)

10km/h or 6mph

Wig-wag

Single

0.00

10km/h or 6mph

8.0

450 watt for 2 hrs

Load of ±20A at 24V

10km/h or 6mph

500.0

0.0

10km/h or 6mph

29.0

23.4

8km/h or 5mph

Wig-wag

Single

0.00

8km/h or 5mph

8.0

8km/h or 5mph

500.0

0.0

8km/h or 5mph

29.0

23.4

System Options

Service Scheduler

Service Period (hours)

10km/h or 6mph

5000

Input Pin

Pin 4 Function

Pin 6 Function

Pin 12 Function

Pin 14 Function

Prog/Inh Pin Function

Function

None

Charger Inhi

Multi-function Outputs Configuration

Flash Code Type

Pin 3 Function

Pin 10 Function

Pin 11 Function

Active

Low

Scooter

Beeper

Status High

Status

Slows to

100

8km/h or 5mph

5000

Latches

14 Version 2015v1

4 Electrical diagram

Electrical diagram

Version 2015v1 15

Technical specifications

5 Technical specifications

Handicare B.V.: Vossenbeemd 104

5705 CL, Helmond

The Netherlands

5.1 Fortress Calypso product specifications

Model Fortress Calypso 3 wheels (3W)

Fortress Calypso 4 wheels (4W)

125 kg Maximum user weight

Description

Total length

Total width

Minimum height*

Total weight excluding batteries:

Total weight including batteries:

Weight of heaviest component

Static stability in the downward direction

Static stability in the upward direction

Lateral static stability

Distance range (ISO 7176-4)**

Dynamic stability (max. safe slope)

Maximum speed forwards

Back angle, Captain Seat

Seat depth, Captain Seat

Seat width, Captain Seat

Back height (excl. headrest), Captain Seat

Seat height (to platform), Captain Seat

Armrest height, Captain Seat

Distance between armrests, Captain Seat

Back angle, Master Seat

Seat depth, Master Seat

Seat width, Master Seat

Back height (excl. headrest), Master Seat

Seat height (to platform), Master Seat

Armrest height, Master Seat

° km (miles)

mm (inches) 1207 (47.5) 1214 (47.8) mm (inches) 622 (24.5) 622 (24.5) mm (inches) 710 (28) kg (pounds) 70 (154.3) 75 (165.3) kg (pounds) 100 (220.5) 105 (231.5) kg (pounds) 27 (59.5)

15 (27%)

15 (27%) 15 (27%)

40 (24.9)

9 (16%) mm (inches) 406 (16) mm (inches) 432-490

(17-19.3)

710 (28)

32 (70.5)

15 (27%)

40 (24.9)

9 (16%) km/h (mph) 10 (6)

° 0-103-126

10 (6)

0-103-126 mm (inches) 445 (17.5) 445 (17.5) mm (inches) 457 (18) 457 (18)

406 (16)

432-490

(17-19.3) mm (inches) 229-273

(9-10.8) mm (inches) 457-610

(18-24)

229-273

(9-10.8)

457-610

(18-24)

° 85-180 85-180 mm (inches) 430 (16.9) 430 (16.9) mm (inches) 500 (19.7) 500 (19.7) mm (inches) 550 (21.7) 550 (21.7) mm (inches) 432-510

(17-20.1) mm (inches) 150-340

(5.9-13.4)

432-510 (17-

20.1)

150-340

(5.9-13.4) mm (inches) 500 (19.7) 500 (19.7) Distance between armrests, Master Seat

Description

Turning radius (ISO 7176-5)

Obstacle height (max. user weight)

Ground clearance (max. user weight)

Test data

Test weight

Operating force

Drive lever operation

Resetting the automatic fuse (circuit breaker)

Electronic switches

Connecting the charger plug

125 kg

< 60 N

< 15 N

< 60 N

mm (inches) 76 (3) mm (inches) 101 (4)

mm (inches) 1170 (46.1) 1600 (63)

76 (3)

101 (4)

16 Version 2015v1

Technical specifications

Technical specifications for wheels

Front wheel diameter (3W)

Front wheel diameter (4W)

Rear wheel diameter

Tyre pressure 4W, front wheel

Tyre pressure 4W, rear wheel

Tyre pressure 3W, front wheel

Tyre pressure 3W, rear wheel mm (inches) 260 x 85 (10.2 x 3.3) mm (inches) 260 x 85 (10.2 x 3.3) mm (inches) 260 x 85 (10.2 x 3.3) bar (psi) bar (psi) bar (psi) bar (psi)

3.5 (50)

Batteries

Maximum dimensions of batteries (lxbxh)

Max. battery capacity

Maximum permitted charging current mm

(inches)

197x168x175

(7.8x6.6x6.9)

60 (C20)

Ampère 8

197x168x175

(7.8x6.6x6.9)

60 (C20)

* height of steering column, collapsed, excluding seat

** range dependent on user weight, condition of tyres, type of terrain, condition of battery and weather conditions.

Version 2015v1 17

Service instructions

6 Service instructions

6.1 Maintenance diagram

Every year or every 1000 km the following parts must be checked or replaced:

•

Battery

Lights

Fuses

•

Tyres

Transaxle

Carbon brushes

6.2 Maintenance instructions

•

Check condition of the battery/leakage

Check lights

Check fuses

Check tyres (wear and tension)

Check Transaxle (free wheel lever, leakage etc.)

Replace carbon brushes

Lubrication (seat post and slider)

•

6.3 Instructions for repair

Make sure that the scooter is disconnected from the batteries before executing any repair work.

When replacing the transaxle, always reset the current free wheel lever.

(De-)activating of audible signal for indicator, alarm and reverse-beep.

These dip-switches are located at the botom-side of the Tiller PCB (004-2). First remove the shroud front assy

(005-4) and the shroud rear assy (005-5) by unscrewing the 4x cross-head screws. Now you’ve acces to the 4 cross-head screws of the top console assy (004).

1 2

No signal

1 2

Only indicators and alarm signal (when contact is switched on)

1 2

Only reverse beep

All audible signals are activated (when contact is switched on)

18 Version 2015v1

Use of the parts list

7 Use of the parts list

This document is intended as a reference list for the ordering of parts for the Fortress Calypso 3W and 4W.

How to order:

To order parts, please specify:

•

Serial number (See the identification plate)

•

Group (to which the relevant part belongs)

Article number

•

Number of parts required

Description (in the relevant language)

Comment:

•

If a specific part does not have a position number, this means that it can not be ordered separately. The relevant part is then a component of the composite shown. Only the composite can be ordered, and will therefore need to be replaced in its entirety.

The position numbers included in the tables refer to the relevant drawing.

•

Ordering address:

Please send you orders by post or fax to your dealer.

Technical technicians:

Repairs can only be executed by trained and authorized technicians. When executing their work they are at all times responsible for full compliance with local safety standards and directives. Temporary workers and personnel in training may only execute repair and replacement work under the supervision of an authorized service technician.

Version 2015v1 19

Spare parts

8 Parts list

•

In addition to the standard parts (shown in the following pages) the following parts/options are also available as spare parts and service parts:

•

Mirror Left: 1009250

•

Mirror Right: 1009251

Cane/Crutch holder assy: 1009552

Rear basket assy: 1009549

20 Version 2015v1

A: Overview 3W

Parts list

Pos Article number

See list 010

See list 006

See list 004

See list 005

See list 007

1009235

C91001

1009237

See list 012

1009239

1009240

See list 008

See list 009

1009242

See list 003

See list 018

1009243

9001495

1009244

1002241

No spare part

Version 2015v1

Units Description

1 Frame front assy 3W

Tiller assy

Top console assy

Bottom console assy

Tiller strut assy

Bracket basket support

Basket front

Side board plastic left

Cover front 3W assy

Tiller protect plastic

Mat floor 3W

Cover battery assy

Cover motor assy

Knop M5

Bumper rear assy

Rear frame assy

Seat post Captain Seat

Seat post Master Seat

Captain Seat

Master Seat

Flat washer

Lock nut M10xP1,25

Bushing 9,2mm

Flat washer

Hex bolt M10x25mm

(see also next page)

Parts list

A: Overview 3W (continued)

Pos Article number

1009245

1009246

1009247

1009248

No spare part

1009249

1009238

Units Description

2 Bushing shoulder 4,7mm

Bushing shoulder 11mm

Bushing 20,5mm

Shaft 85mm

Retaining ring

Hex bolt M8x50mm

Lock nut M8xP1,25

Flat washer

Screw M6x20mm

Spring washer

Horn

Side board plastic right

22 Version 2015v1

B: Overview 4W

Parts list

Pos Article number

See list 013

See list 006

See list 004

See list 005

See list 007

1009235

C91001

1009237

See list 016

1009239

1009241

See list 008

See list 009

1009242

See list 003

See list 018

1009243

9001495

1009244

1002241

No spare part

Version 2015v1

Units Description

Frame front assy 4W

Tiller assy

Top console assy

Bottom console assy

Tiller strut assy

Bracket basket support

Basket front

Side board plastic left

Cover front 4W assy

Tiller protect plastic

Mat floor 4W

Cover battery assy

Cover motor assy

Knop M5

Bumper rear assy

Rear frame assy

Seat post Captain Seat

Seat post Master Seat

Captain Seat

Master Seat

Flat washer

Lock nut M10xP1,25

Bushing 9,2mm

Flat washer

(see also next page)

Parts list

B: Overview 4W (continued)

Pos Article number

No spare part

1009245

1009246

1009247

1009248

No spare part

1009249

1009238

Units Description

2 Hex bolt M10x25mm

Bushing shoulder 4,7mm

Bushing shoulder 11mm

Bushing 20,5mm

Shaft 85mm

Retaining ring

Hex bolt M8x50mm

Lock nut M8xP1,25

Flat washer

Screw M6x20mm

Spring washer

Horn

Side board plastic right

24 Version 2015v1

001: Wheel front assy

Parts list

Pos Article number

05010.4100

05010.4000

1008951

Units Description

1 Tyre front 10''

Tube inner 10''

Wheel front 10'' assy

Version 2015v1 25

Parts list

002: Wheel rear assy

Pos Article number

1008952

05010.4000

1008953

Units Description

1 Tyre rear 10''

Tube inner 10''

Wheel rear 10'' assy

26 Version 2015v1

003: Bumper rear assy

Parts list

Pos Article number

1008954

1008955

Units Description

1 Reflector rear

1 Bumper rear assy

Version 2015v1 27

Parts list

004: Top console assy

Pos Article number

1001341

1008958

1009156

1008956

Units Description

1 Knob speed selector

PCB board with battery indicator

Console speed plastic key pad membrane

Switch speed selector

28 Version 2015v1

005: Bottom console assy

Parts list

Pos Article number

1008974

1009159

No spare part

1009157

1009158

Units Description

2 Light bulb amber 24v 5w

Charger port assy

Cover charger port

Shroud front assy

Shroud rear assy

Version 2015v1 29

Parts list

006: Tiller assy

Pos Article number

1008959

1008960

1008961

1008962

5-11 1009160

12 9003722

1014751

1001372

Units Description

1 Shroud top tiller

Potmeter throttle

PCB fuse assy

Jack plug receptacle

Steering rod assy

Finger control assy

Steering wheel

Contact key

30 Version 2015v1

007: Tiller strut assy

Parts list

Pos Article number

1008965

1008966

1008967

1008968

1015177

1014750

Units Description

1 Shroud tiller strut

Strut tiller

Bushing plastic

Adjustable tiller handle

Main harness + controller harness

Tiller tube

Version 2015v1 31

Parts list

008: Cover battery assy

Pos Article number

051.00031.000

1008971

Units Description

2 Reflector yellow

1 Cover battery assy

32 Version 2015v1

009: Cover motor assy

Parts list

Pos Article number

1008972

1008973

1008974

1001281

1008976

1008977

Units Description

1 Light rear assy – right

Light rear assy – left

Light bulb amber 24v 5w

Light bulb clear 24v 5w

Harness rear light assy

Cover motor assy

Version 2015v1 33

Parts list

010: Frame front 3W assy

Pos Article number

1008978

1008979

4-6

1008980

1009161

1014743

Units Description

1 Bumper front

Bearing 20MMx42MMx12MM

Strap battery with buckle

Latch assy

Front frame Fortress Calypso 3 wheel

34 Version 2015v1

011: Front fork assy

Parts list

Pos Article number

1009162

1008982

Units Description

1 Axle front wheel assy

1 Fork assy

Version 2015v1 35

Parts list

012: Cover front 3W assy

Pos Article number

1009163

1008983

Units Description

1 Headlight assy

1 Cover front 3W assy

36 Version 2015v1

013: Frame front 4W assy

Parts list

Pos Article number

1008979

1008984

1009164

1014744

1014747

1014748

1014749

Units Description

2 Bearing 20MMx42MMx12MM

Bumper front 4W

Steering rod assy 4W

Front frame Fortress Calypso 4 wheel

Steering axle

Front spring

Front suspension bearing bush

Version 2015v1 37

Parts list

014: Swing arm right assy

Pos Article number

1 1008985

Units Description

1 Swing arm right assy

38 Version 2015v1

015: Swing arm left assy

Parts list

Pos Article number

1 1008986

Units Description

1 Swing arm left assy

Version 2015v1 39

Parts list

016: Cover front 4W assy

Pos Article number

1009163

1009165

1008987

Units Description

1 Headlight assy

Mat foot 4w set

Cover front 4W assy

40 Version 2015v1

017: Rear frame top assy

Parts list

Pos Article number

1-2

1009161

1015727

1008989

1014745

Units Description

1 Latch assy

Controller Dynamic DR-90 v2.07

Shock absorber rear

Rear frame upper part

Version 2015v1 41

Parts list

018: Rear frame assy

Pos Article number

1008990

1015177

1014753

9002752

1014125

1014126

Units Description

Cable battery harness

Main harness + controller harness

Rear wheel spacer

Set battery connection covers

Battery cable with red connector

Battery cable with black connector

42 Version 2015v1

019: Rear frame bottom assy

Parts list

Pos Article number

1-6

1009167

1008992

8 1014746

9-10 1014752

Units Description

1 Wheel anti tip assy

Bracket mount transaxle

Rear frame bottom

Freewheel lever

Version 2015v1 43

Parts list

020: Transaxle assy

Pos Article number

1009166

9003576

4-5

1008993

1008994

1015605

1015606

1015607

Units Description

1 Transaxle Assy 10K

Transaxle Assy 12K

Brush motor

Cap brush motor

Motor brake

Motor brake cover

Motor brake kit

44 Version 2015v1

021: Captain seat assy

Pos Article number

1008995

1008996

1008997

1008998

1008999

Units Description

1 Seat capt regular with headrest

Seat plate weldment

Lever seat weldment

Armrest assy left adjustable

Armrest assy right adjustable

Parts list

Version 2015v1 45

Parts list

022: Armrest adjustable assy

Pos Article number

232103

1009001

Units Description

Armpad foam captain

Detent button

46 Version 2015v1

01-01-2013:

Version 2013v1

Version overview

Page Drawing Position Changes

- Added article number 9002752

4, 5, 4-5 Added article numbers 1015605, 1015606 and 1015607 (Motor brake, motor brake cover and motor brake kit)

01-01-2014:

Version 2014v1

Page Drawing Position Changes

Added reference to the FTP server where the driving programs can be downloaded

Changed article number 1008988 into 1015727 and added version number in description

42 18 - Added article numbers 1014125 and 1014126

01-10-2014:

Version 2014v2

Page Drawing Position Changes

17 - - Changed specification maximum permitted charging current 5A into 8A

01-01-2015:

Version 2015v1

Page Drawing Position Changes

Updated warranty text

Added transaxle power information

Added article number 1014751 Steering wheel

9-10

Added article number 1014750 Tiller tube

Added article number 1014743 Front frame Fortress Calypso 3 wheel

Added article number 1014744 Front frame Fortress Calypso 4 wheel

Added article number 1014747 Steering axle

Added article number 1014748 Front spring

Added article number 1014749 Front suspension bearing bush

Added article number 1014745 Rear frame upper part

Added article number 1014753 Rear wheel spacer

Added article number 1014746 Rear frame bottom

Added article number 1014752 Freewheel lever

Version 2015v1 47

Key features

3 & 4 wheel scooter
Maximum load 125 kg
Adjustable seat
Adjustable steering column
Adjustable rear suspension
Brake lights
Indicator lights
Horn

Frequently asked questions

The Fortress Calypso has a maximum weight capacity of 125 kg.

The Fortress Calypso has a maximum speed of 10 km/h (6 mph).

It is intended for use on pavements, footpaths, and cycle paths, as well as in and around the house. The scooter is not classified as a road vehicle and therefore may not be used on the road (crossing over the road being the only exception).

The seat height, seat depth, backrest angle, armrest width and height, headrest, and steering column can be adjusted.