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SERVICE MANUAL
FORTRESS-CALYPSO
3- & 4- WHEEL SCOOTER
VERSION 1 -2016
© 2011 Sunrise Medical HCM
All rights reserved.
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 Sunrise Medical HCM.
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.
Sunrise Medical HCM 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. Sunrise Medical HCM 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, Sunrise Medical HCM can not be held liable for any possible errors in the information or for the consequences thereof.
Sunrise Medical HCM 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 Sunrise Medical HCM may not be regarded as openly available.
2 Version 2016v1
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
2.2
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 2016v1 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 2016v1
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
1.
1.
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 2016v1 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 2016v1
Introduction
Warranty
•
•
•
•
Definitions 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 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 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 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
Scooters
Description
Frame
Drive system*
Warranty period
2 years
1 year
Examples include, but are not limited to the parts mentioned below
Weldment/frame
Transaxle, motor, motor brake
Electronics* 1 year
Controller, controlling mechanism, wiring harness, electronic components
After sales service parts
New: 1 year after invoice
Repaired: 90 days after invoice
Brakes
Consumable parts 40 days after invoice Carbon brushes, etc.
Options/Accessories 2 years
Mirror, mudguards etc.
Delivered with the initial product
* also in case of after sales service part delivery
Sunrise Medical HCM will only accept shipment costs and corrective costs related to warranty on equipment during the warranty period.
Version 2016v1 7
Introduction
•
•
This warranty will void in case of:
• The product and/or its parts being modified;
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.).
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,
Sunrise Medical HCM 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 2016v1
General safety rules and regulations
1 General safety rules and regulations
Sunrise Medical HCM 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 2016v1 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 2016v1
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 A
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.
A
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 2016v1 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
B
A 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
A
The rear suspension of the scooter can be adjusted to provide optimal comfort. This adjustment is carried out by the dealer.
12 Version 2016v1
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 Sunrise Medical HCM 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 Sunrise Medical HCM.
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
No
Yes
No
Yes
Yes
300
700
8km/h or 5mph
No
Yes
No
Yes
Yes
300
700
*These settings have no influence, are set via dip-switches on Tiller PCB (see Chapter 6.3)
Version 2016v1 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
70
60
25
10km/h or 6mph
No
80
50
8
8.0
450 watt for 2 hrs
Load of ±20A at 24V
10km/h or 6mph
500.0
0.0
15
29.0
23.4
10km/h or 6mph
8km/h or 5mph
Wig-wag
Single
0.00
70
60
25
8km/h or 5mph
No
80
50
8
8.0
8km/h or 5mph
500.0
0.0
8km/h or 5mph
15
29.0
23.4
System Options
Service Scheduler
Service Period (hours)
10km/h or 6mph
No
5000
Input Pin
Pin 4 Function
Pin 6 Function
Pin 12 Function
Pin 14 Function
Prog/Inh Pin Function
Function
None
None
None
None
Charger Inhi
Multi-function Outputs Configuration
Flash Code Type
Pin 3 Function
Pin 10 Function
Pin 11 Function
Active
Low
Low
Low
Low
Low
Scooter
Beeper
Status High
Status
Slows to
100
100
100
100
100
8km/h or 5mph
No
5000
Latches
No
No
No
No
No
14 Version 2016v1
4 Electrical diagram
Electrical diagram
Version 2016v1 15
Technical specifications
5 Technical specifications
Sunrise Medical HCM 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 kg (pounds) 27 (59.5) 32 (70.5)
°
°
°
3W 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)
15 (27%)
15 (27%)
15 (27%) mm (inches) 406 (16) mm (inches) 432-490
(17-19.3)
4W
710 (28)
15 (27%)
15 (27%)
15 (27%) km (miles) 40 (24.9) 40 (24.9)
° 9 (16%) 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
< 60 N
< 15 N
< 60 N
3W mm (inches) 76 (3) mm (inches) 101 (4)
4W mm (inches) 1170 (46.1) 1600 (63)
76 (3)
101 (4)
16 Version 2016v1
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)
3.5 (50)
3.5 (50)
3.5 (50)
Batteries
Maximum dimensions of batteries (lxbxh)
Max. battery capacity
Maximum permitted charging current mm
(inches)
Ah
Ampère
3W
197x168x175
(7.8x6.6x6.9)
60 (C20)
8
4W
197x168x175
(7.8x6.6x6.9)
60 (C20)
8
* 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 2016v1 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).
ON
No signal
1 2
ON
1 2
ON
1 2
ON
1 2
Only indicators and alarm signal (when contact is switched on)
Only reverse beep
All audible signals are activated (when contact is switched on)
18 Version 2016v1
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 2016v1 19
Parts list
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 2016v1
A: Overview 3W
Parts list
19
20
21
22
23
7
8
9
10
11
12
13
14
15
16
Pos Article number
1 See list 010
2
3
See list 006
See list 004
4
5
6
See list 005
See list 007
1009235
C91001
1009237
See list 012
1009239
1009240
See list 008
See list 009
1009242
17
18
See list 003
See list 018
1009243
9001495
1009244
1002241
No spare part
No spare part
No spare part
No spare part
No spare part
Version 2016v1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units Description
1 Frame front assy 3W
1
1
Tiller assy
Top console assy
1
1
1
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)
21
Parts list
A: Overview 3W (continued)
28
29
30
31
32
33
34
35
Pos Article number
24
25
26
27
1009245
1009246
1009247
1009248
No spare part
No spare part
No spare part
No spare part
No spare part
No spare part
1009249
1009238
Units Description
2 Bushing shoulder 4,7mm
2
2
Bushing shoulder 11mm
Bushing 20,5mm
1
2
1
1
Shaft 85mm
Retaining ring
Hex bolt M8x50mm
Lock nut M8xP1,25
1
2
2
1
1
Flat washer
Screw M6x20mm
Spring washer
Horn
Side board plastic right
22 Version 2016v1
B: Overview 4W
3
Parts list
35
26
25
8
9
10
11
12
13
14
15
16
4
5
6
7
Pos Article number
1 See list 013
2
3
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
17
18
19
20
21
22
See list 003
See list 018
1009243
9001495
1009244
1002241
No spare part
No spare part
No spare part
No spare part
Version 2016v1
10
1
1
2
2
1
1
1
1
2
2
1
1
1
1
1
1
1
Units Description
1 Frame front assy 4W
1
1
Tiller assy
Top console assy
1
1
1
1
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)
23
Parts list
B: Overview 4W (continued)
3
35
26
25
32
33
34
35
Pos Article number
23
24
No spare part
1009245
25
26
27
28
29
30
31
1009246
1009247
1009248
No spare part
No spare part
No spare part
No spare part
No spare part
No spare part
1009249
1009238
10
Units Description
2 Hex bolt M10x25mm
2
2
Bushing shoulder 4,7mm
Bushing shoulder 11mm
2
1
2
1
1
1
Bushing 20,5mm
Shaft 85mm
Retaining ring
Hex bolt M8x50mm
Lock nut M8xP1,25
Flat washer
2
2
1
1
Screw M6x20mm
Spring washer
Horn
Side board plastic right
24 Version 2016v1
001: Wheel front assy
Parts list
Pos Article number
1 05010.4100
2
3
05010.4000
1008951
Units Description
1 Tyre front 10''
1
1
Tube inner 10''
Wheel front 10'' assy
Version 2016v1 25
Parts list
002: Wheel rear assy
Pos Article number
1 1008952
2
3
05010.4000
1008953
Units Description
1 Tyre rear 10''
1
1
Tube inner 10''
Wheel rear 10'' assy
26 Version 2016v1
003: Bumper rear assy
Parts list
Pos Article number
1 1008954
2 1008955
Units Description
1 Reflector rear
1 Bumper rear assy
Version 2016v1 27
Parts list
004: Top console assy
Pos Article number
1 1001341
2
3
1008958
1009156
4 1008956
Units Description
1 Knob speed selector
1
1
1
PCB board with battery indicator
Console speed plastic key pad membrane
Switch speed selector
28 Version 2016v1
005: Bottom console assy
Parts list
Pos Article number
1 1008974
2
3
1009159
No spare part
4
5
1009157
1009158
Units Description
2 Light bulb amber 24v 5w
1
1
Charger port assy
Cover charger port
1
1
Shroud front assy
Shroud rear assy
Version 2016v1 29
Parts list
006: Tiller assy
Pos Article number
1 1008959
2
3
1008960
1008961
4 1008962
5-11 1009160
12
13
-
9003722
1014751
1001372
Units Description
1 Shroud top tiller
1
1
1
1
Potmeter throttle
PCB fuse assy
Jack plug receptacle
Steering rod assy
1
1
1
Finger control assy
Steering wheel
Contact key
30 Version 2016v1
007: Tiller strut assy
Parts list
Pos Article number
1 1008965
2
3
1008966
1008967
4
5
6
1008968
1015177
1014750
Units Description
1 Shroud tiller strut
1
2
Strut tiller
Bushing plastic
1
1
1
Adjustable tiller handle
Main harness + controller harness
Tiller tube
Version 2016v1 31
Parts list
008: Cover battery assy
Pos Article number
1 051.00031.000
2 1008971
Units Description
2 Reflector yellow
1 Cover battery assy
32 Version 2016v1
009: Cover motor assy
Parts list
Pos Article number
1 1008972
2
3
1008973
1008974
4
5
6
1001281
1008976
1008977
Units Description
1 Light rear assy – right
1
2
Light rear assy – left
Light bulb amber 24v 5w
4
1
1
Light bulb clear 24v 5w
Harness rear light assy
Cover motor assy
Version 2016v1 33
Parts list
010: Frame front 3W assy
Pos Article number
1 1008978
2
3
1008979
1008980
4-6 1009161
7 1014743
Units Description
1 Bumper front
2
2
Bearing 20MMx42MMx12MM
Strap battery with buckle
1
1
Latch assy
Front frame Fortress Calypso 3 wheel
34 Version 2016v1
011: Front fork assy
Parts list
Pos Article number
1 1009162
2 1008982
Units Description
1 Axle front wheel assy
1 Fork assy
Version 2016v1 35
Parts list
012: Cover front 3W assy
Pos Article number
1 1009163
2 1008983
Units Description
1 Headlight assy
1 Cover front 3W assy
36 Version 2016v1
013: Frame front 4W assy
Parts list
4
5
6
7
Pos Article number
1 1008979
2
3
1008984
1009164
1014744
1014747
1014748
1014749
Units Description
2 Bearing 20MMx42MMx12MM
1
1
Bumper front 4W
Steering rod assy 4W
1
1
2
2
Front frame Fortress Calypso 4 wheel
Steering axle
Front spring
Front suspension bearing bush
Version 2016v1 37
Parts list
014: Swing arm right assy
Pos Article number
1 1008985
Units Description
1 Swing arm right assy
38 Version 2016v1
015: Swing arm left assy
Parts list
Pos Article number
1 1008986
Units Description
1 Swing arm left assy
Version 2016v1 39
Parts list
016: Cover front 4W assy
Pos Article number
1
2
3
1009163
1009165
1008987
Units Description
1
1
1
Headlight assy
Mat foot 4w set
Cover front 4W assy
40 Version 2016v1
017: Rear frame top assy
Parts list
Pos Article number
1-2 1009161
3
4
5
1015727
1008989
1014745
Units Description
1 Latch assy
1
1
1
Controller Dynamic DR-90 v2.07
Shock absorber rear
Rear frame upper part
Version 2016v1 41
Parts list
018: Rear frame assy
-
-
-
Pos Article number
1 1008990
2
3
1015177
1014753
9002752
1014125
1014126
Units Description
1 Cable battery harness
1
1
Main harness + controller harness
Rear wheel spacer
2
1
1
Set battery connection covers
Battery cable with red connector
Battery cable with black connector
42 Version 2016v1
019: Rear frame bottom assy
Parts list
Pos Article number
1-6 1009167
7
8
1008992
1014746
9-10 1014752
Units Description
1 Wheel anti tip assy
1
1
1
Bracket mount transaxle
Rear frame bottom
Freewheel lever
Version 2016v1 43
Parts list
020: Transaxle assy
Pos Article number
1
1009166
9003576
2
3
1008993
1008994
4
5
1015605
1015606
4-5 1015607
Units Description
1 Transaxle Assy 10K
1
2
Transaxle Assy 12K
Brush motor
2
1
1
1
Cap brush motor
Motor brake
Motor brake cover
Motor brake kit
44 Version 2016v1
021: Captain seat assy
1
5
2
Pos Article number
1 1008995
2
3
1008996
1008997
4
5
1008998
1008999
Units Description
1 Seat capt regular with headrest
1
1
Seat plate weldment
Lever seat weldment
1
1
Armrest assy left adjustable
Armrest assy right adjustable
Parts list
Version 2016v1 45
Parts list
022: Armrest adjustable assy
Pos Article number
1 232103
2 1009001
Units Description
1 Armpad foam captain
1 Detent button
46 Version 2016v1
Version 2013v1
Version list
Page Drawing Position Changes
42 18 - Added article number 9002752
44 20 4, 5, 4-5 Added article numbers 1015605, 1015606 and 1015607 (Motor brake, motor brake cover and motor brake kit)
Version 2014v1
Page Drawing Position Changes
13 - - Added reference to the FTP server where the driving programs can be downloaded
41
42
17
18
2
-
Changed article number 1008988 into 1015727 and added version number in description
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
Version 2015v1
Page Drawing Position Changes
7 Updated warranty text
14
30
-
6
-
13
Added transaxle power information
Added article number 1014751 Steering wheel
31
34
37
41
7
10
13
17
6
7
4
5
6
7
5
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
42
43
18
19
3
8
9-10
Added article number 1014753 Rear wheel spacer
Added article number 1014746 Rear frame bottom
Added article number 1014752 Freewheel lever
Version 2016v1
Page Drawing Position Changes
Replaced Handicare by Sunrise Medical HCM
Version 2016v1 47
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