Fortress Calypso
TECHNICAL MANUAL
EN
Mobility scooter
2 | Fortress Calypso
| 3Fortress Calypso
© 2016 Sunrise Medical
All rights reserved.
The information provided herein may not be reproduced and/or published in any form, by print, photoprint, microlm or any other
means whatsoever (electronically or mechanically) without the prior written authorization of Sunrise Medical.
The information provided is based on general data concerning the construction known at the time of the publication of this
manual. Sunrise Medical executes a policy of continuous improvement and reserves the right to changes and modications.
The information provided is valid for the product in its standard version. Sunrise Medical can therefore not be held liable for
any damage resulting from specications of the product deviating from the standard conguration. Illustrations contained in the
manual may deviate from the conguration of your product.
The information made available has been prepared with all possible diligence, but Sunrise Medical cannot be held liable for any
errors contained in the information or the consequences thereof.
Sunrise Medical accepts no liability for loss resulting from work executed by third parties.
Names, trade names, trademarks etc. used by Sunrise Medical may not, as per the legislation concerning the protection of trade
names, be considered as being available.
4 | Fortress Calypso
Table of content
1 Introduction ........................................................................................................................................................... 6
1.1 This manual 6
1.2 Identication of the product 6
1.3 Symbols used in this manual 6
1.4 Intended use 7
2 Safety ................................................................................................................................................................... 8
2.1 Personnel qualication 8
2.2 Identication on the product 8
2.3 Temperature 8
2.4 Electromagnetic radiation and interference 8
2.5 Markings on the scooter 9
2.6 Transportation 10
2.7 Technical specications 10
2.8 Modications / Adaptations 10
3 Tools ................................................................................................................................................................... 11
3.1 Tools 11
3.2 Programmer 11
4 Spare parts ......................................................................................................................................................... 12
4.1 Use of the parts lists 12
A Overview 3W 13
B Overview 4W 15
01 Wheel front assy 17
02 Wheel rear assy 18
03 Bumper rear assy 19
04 Top console assy 20
05 Bottom console assy 21
06 Tiller assy 22
07 Tiller strut assy 23
08 Cover battery assy 24
09 Cover motor assy 25
10 Frame front 3W assy 26
11 Front fork assy 27
12 Cover front 3W assy 28
13 Frame front 4W assy 29
14 Swing arm right assy 30
15 Swing arm left assy 31
16 Cover front 4W assy 32
17 Rear frame top assy 33
18 Rear frame assy 34
19 Rear frame bottom assy 35
20 Transaxle assy 36
21 Captain seat assy 37
22 Armrest adjustable assy 38
4.2 Options 39
5 Service instructions ............................................................................................................................................ 40
5.1 Maintenance plan 40
5.2 Batteries 40
5.3 Tyres 41
5.4 Adjustment options and repairs 41
| 5Fortress Calypso
6 Troubleshooting .................................................................................................................................................. 42
7 Technical product information ............................................................................................................................. 43
7.1 CE Declaration and standards 43
7.2 Technical specications 43
7.3 Driving programs 44
7.4 Scooter settings 45
7.5 Electrical diagram 46
8 Warranty ............................................................................................................................................................. 47
8.1 Denitions of terms 47
8.2 Warranty period table 48
6 | Introduction
Fortress Calypso
1 Introduction
1.1 This manual
This manual contains the instructions for repairs and general maintenance of the Fortress Calypso electrical scooter.
Mechanics who do repairs on this scooter must be well trained and familiar with the repair methods and the maintenance of the
Fortress Calypso scooter.
Always make sure that the work is carried out safely, particularly with respect to procedures requiring the scooter to be lifted up.
We advise that you contact our service department before doing repair work on a scooter that has been involved in an accident.
The following specications are important when ordering parts:
• Model
• Year of manufacture
• Colour
• ID-number
• Part number
• Name of the part concerned
This information is provided on the identication plate. See 1.2 'Identication of the product'
Available documentation
The following technical documentation is available / required to service this scooter:
• Technical manual
• Owner manual
References from the technical to the owner manual are indicated as:
&Scooter
Service and technical support
For information concerning specic settings, maintenance or repair works please contact the Sunrise Medical HCM Customer
Service department. They are always prepared to help you. Ensure you have at hand:
• Model
• Year of manufacture
• ID-number
This information can be found on the information plate.
1.2 Identication of the product
The identication plate contains the following data:
A. Model
B. Year of manufacture
C. ID-number
D. Usage: indoor, outdoor or both
E. Maximum load in kg
F. Manufacturers address
SUNRISE MEDICAL HCM B.V.
VOSSENBEEMD 104
5705 CL HELMOND
THE NETHERLANDS
TYPE/TYPE/TYP:
YEAR/JAAR/JAHR:
IDNR.:
USAGE:
GEBRUIKSGEBIED:
GEBRAUCHSGEBIET:
MAX.LOAD/ MAX.BELASTB./ZUL.GESAMTGEW.:
A
B
D EF
C
See for the location of the identication plate ´2.5 markings on the scooter´.
1.3 Symbols used in this manual
Note!
Pointing out possible problems to the user of this manual.
Caution!
Advice for the user of this manual to prevent damage to the product.
Warning!
Warnings for the user of this manual to prevent personal injury.
Not following these instructions may result in physical injury, damage to the product or damage to the environment!
Introduction | 7Introduction | 7
Fortress Calypso
Reference symbol
When necessary this service manual refers to other manuals as shown below:
& Battery charger: refers to the user manual of the battery charger
& Scooter: refers to the general user manual of the scooter
1.4 Intended use
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 clear instructions before the user starts operating the product independently. The rst test drives of the
scooter are best carried out under the supervision of an experienced dealer.
The scooter is not classied as a road vehicle and therefore may not be used on the road (crossing over the road being the only
exception).
The scooter has a maximum speed of 10 or 12 km/h (6 or 7,5 mph).
For more information and a denition of the intended use see the owner manual (
&Scooter ‘Use for intended purposes’)
Warning!
Ensure that you are fully acquainted with the contents of this manual before starting to drive the scooter.
Note!
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.
For more information about the disposal of used scooters see the owner manual (
&Scooter ‘Used scooters and the
environment’)
8 | Safety
Fortress Calypso
2 Safety
2.1 Personnel qualication
Repairs may only be carried out by trained and authorised service technicians.
During the execution of their work, they are at all times fully responsible for the fullment of locally applicable safety guidelines
and standards.
Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an
authorised service technician.
2.2 Identication on the product
Safety
Safety information is indicated with the warning symbol.
Warning!
Follow the instructions carefully next to these warning symbols! Not paying careful attention to these instructions could result in
physical injury or damage to the scooter or the environment. Wherever possible, safety information is also provided in this manual
in the relevant chapter.
2.3 Temperature
Warning!
Avoid physical contact with the scooter’s motor. The motor is continuously in motion during use and can reach high temperatures.
After use, the motor will cool down slowly. Physical contact may cause burns.
Ensure that the scooter is not exposed to direct sunlight for extended periods of time. Certain parts of the scooter, such as the
seat, the backrest, the armrests and the steering device become hot if exposed to the sun for too long. This may cause burns or
skin irritation.
2.4 Electromagnetic radiation and interference
The scooter has been tested for compliance with the applicable requirements regarding electromagnetic radiation (EMC
requirements).
The Fortress Calypso’s immunity level is 20 volt/metre.
Note!
It cannot be excluded that electromagnetic radiation emanating from mobile telephones, medical apparatus and other sources,
may have an inuence on the scooter.
It cannot be excluded that the scooter will interfere with the electromagnetic elds of, for example, shop doors, burglar alarm
systems and/or garage door openers.
In the unlikely event that such problems do occur, you are requested to notify your dealer immediately.
Powered wheelchairs and scooters can be affected by sources of radio waves, such as radio and TV transmitters, amateur radio
stations, lifts, transmitting equipment, stereo radios and mobile telephones If the scooter’s electronics are not well shielded,
sensitive electrical devices, such as shop alarm systems and garage door openers, can be affected. The scooter has been tested
for such interference. Please report any problems of this nature to your dealer immediately.
The following advices are intended to prevent the electric scooter from being driven unintentionally, which could lead to serious
injury.
1. Do not turn on any manually controlled equipment for personal communication, such as a radio transmitter or mobile
telephone, while the electric scooter is switched on.
2. Keep at a distance from transmitter equipment, such as radio and TV stations.
3. If the scooter starts making unintended movements, or if the brake goes into freewheel / neutral mode, turn off the powered
wheelchair or scooter by removing the ignition key from the lock.
4. Be aware of the fact that any accessories, components or adaptations installed on the scooter may increase the effect of radio
waves.
Note:
There is no easy way of testing the effects of radio waves on the general immunity of powered wheelchairs or scooters.
5. All cases of unintended movements of the scooter spontaneously going into freewheel / neutral mode should be reported to
your dealer or to the scooter manufacturer. When reporting, please indicate whether a source of radio waves was nearby at
the time.
Safety | 9Safety | 9
Fortress Calypso
2.5 Markings on the scooter
Never remove or cover up the markings, symbols and instructions afxed to the scooter. These safety measures must remain
present and clearly legible throughout the entire lifestam of the scooter.
Replace or repair any markings, symbols or instructions that have become illegible or damaged immediately. Please contact your
dealer for assistance.
Product labels
The following sticker/label can be found on the product:
1. Identifcation plate (in battery compartment)
The identication plate can be found in the battery compartment, as shown in the gure. The plate contains the following data:
A. Model
B. Year of manufacture
C. ID-number
D. Usage: indoor, outdoor or both
E. Maximum load in kg
F. Manufacturer address
2. Circuit breaker
The scooter is equipped with a fuse which interrupts the electric current on overload. See owner manual
(
&Scooter 7.2 ‘Automatic circuit breaker’).
3. Tyre pressure
See 7.2 ‘technical specications’ for the correct tyre pressure.
SUNRISE MEDICAL HCM B.V.
VOSSENBEEMD 104
5705 CL HELMOND
THE NETHERLANDS
TYPE/TYPE/TYP:
YEAR/JAAR/JAHR:
IDNR.:
USAGE:
GEBRUIKSGEBIED:
GEBRAUCHSGEBIET:
MAX.LOAD/ MAX.BELASTB./ZUL.GESAMTGEW.:
A
B
D EF
C
10 | Safety
Fortress Calypso
4. Neutral position
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.
Lever in lowest position:
When the lever is in the lowest position the motor drive is disengaged. The scooter can then be pushed manually.
5. Adjustment of steering column angle
The steering column can be adjusted to the position you nd most comfortable when driving. See owner manual
(
&Scooter ‘Changing the steering column’).
6. Charging point
See owner manual for how to charge the batteries (
&Scooter ‘Charging the batteries’).
2.6 Transportation
See the owner manual (&Scooter ‘Dismantling the scooter for storage and/or transportation’ and 'Transporting the scooter in its
entirety').
Warning!
The scooter is not intended to be used as seat in motor vehicle.
2.7 Technical specications
No changes may be made to the technical specications.
2.8 Modications / Adaptations
Modications, not executed by Sunrise Medical HCM, to components and electronics of this product are not permitted.
Tools | 11Tools | 11
Fortress Calypso
3 Tools
3.1 Tools
The tools below are needed for various mechanical settings and maintenance:
Quantity Description
1 Screwdriver, crosshead PH1
1 Screwdriver, crosshead PH2
Use only high-quality tools for the adjustment(s) described.
Make sure that the hexagon of the spanner is attached securely to the hexagon of the fastening article. This prevents the 'rotation'
of hexagons of fastening articles and spanners that may affect proper adjustment.
3.2 Programmer
The scooter 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. The DWIZ adaptor (DWIZ-ADAPT) can be ordered with article
number 1009567.
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.
If you wish to order parts for your programmer, please contact Sunrise Medical HCM.
12 | Spare parts
Fortress Calypso
4 Spare parts
4.1 Use of the parts lists
This document is meant as a reference book to be used to order parts for the scooter that is shown on the front cover (3-wheel
and 4-wheel version).
How to order
When ordering parts, please specify:
• ID-number (see the identication plate)
• Group (to which the relevant part belongs)
• Article number
• Number of parts required
• Description (in the relevant language)
• Dimensions (if applicable)
Remark
• If a part does not have an article number, it means that the part concerned cannot be purchased separately. The part
concerned is part of the assembly shown. This assembly must be ordered as one piece. It has to be replaced in its entirety.
• Boxed position numbers refer to the relevant drawing.
Order address
Please mail or fax your orders to your supplier.
Service technicians
Repairs may only be carried out by trained and authorised service technicians. During the execution of their work they are at all
times fully responsible for the fullment of locally applicable safety guidelines and standards.
Temporary employees and persons in training may only carry out repair and replacement work under the supervision of an
authorised service technician.
Spare parts | 13
Fortress Calypso
Pos Qty Article number Description
A Overview 3W
1 1 See list 010 Frame front assy 3W
2 1 See list 006 Tiller assy
3 1 See list 004 Top console assy
4 1 See list 005 Bottom console assy
5 1 See list 007 Tiller strut assy
6 1 1009235 Bracket basket support
7 1 C91001 Basket front
8 1 1009237 Side board plastic left
9 1 See list 012 Cover front 3W assy
10 1 1009239 Tiller protect plastic
11 1 1009240 Mat oor 3W
12 1 See list 008 Cover battery assy
13 1 See list 009 Cover motor assy
14 1 1009242 Knop M5
15 1 See list 003 Bumper rear assy
16 1 See list 018 Rear frame assy
17a 1 1009243 Seat post Captain Seat
17b 1 9001495 Seat post Master Seat
18a 1 1009244 Captain Seat
18b 1 1002241 Master Seat
19 2 No spare part Flat washer
20 2 No spare part Lock nut M10xP1,25
21 2 No spare part Bushing 9,2mm
22 2 No spare part Flat washer
23 2 No spare part Hex bolt M10x25mm
24 2 1009245 Bushing shoulder 4,7mm
25 2 1009246 Bushing shoulder 11mm
26 2 1009247 Bushing 20,5mm
27 1 1009248 Shaft 85mm
28 2 No spare part Retaining ring
29 1 No spare part Hex bolt M8x50mm
30 1 No spare part Lock nut M8xP1,25
14 | Spare parts
Fortress Calypso
Continued from A Overview 3W
Pos Qty Article number Description
31 1 No spare part Flat washer
32 2 No spare part Screw M6x20mm
33 2 No spare part Spring washer
34 1 1009249 Horn
35 1 1009238 Side board plastic right
Spare parts | 15
Fortress Calypso
B Overview 4W
Pos Qty Article number Description
1 1 See list 013 Frame front assy 4W
2 1 See list 006 Tiller assy
3 1 See list 004 Top console assy
4 1 See list 005 Bottom console assy
5 1 See list 007 Tiller strut assy
6 1 1009235 Bracket basket support
7 1 C91001 Basket front
8 1 1009237 Side board plastic left
9 1 See list 016 Cover front 4W assy
10 1 1009239 Tiller protect plastic
11 1 1009241 Mat oor 4W
12 1 See list 008 Cover battery assy
13 1 See list 009 Cover motor assy
14 1 1009242 Knop M5
15 1 See list 003 Bumper rear assy
16 1 See list 018 Rear frame assy
17a 1 1009243 Seat post Captain Seat
17b 1 9001495 Seat post Master Seat
18a 1 1009244 Captain Seat
18b 1 1002241 Master Seat
19 2 No spare part Flat washer
20 2 No spare part Lock nut M10xP1,25
21 2 No spare part Bushing 9,2mm
22 2 No spare part Flat washer
23 2 No spare part Hex bolt M10x25mm
24 2 1009245 Bushing shoulder 4,7mm
25 2 1009246 Bushing shoulder 11mm
26 2 1009247 Bushing 20,5mm
27 1 1009248 Shaft 85mm
16 | Spare parts
Fortress Calypso
Continued from B Overview 4W
Pos Qty Article number Description
Pos Qty Article number Description
28 2 No spare part Retaining ring
29 1 No spare part Hex bolt M8x50mm
30 1 No spare part Lock nut M8xP1,25
31 1 No spare part Flat washer
32 2 No spare part Screw M6x20mm
33 2 No spare part Spring washer
34 1 1009249 Horn
35 1 1009238 Side board plastic right