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SERVICE MANUAL
FORTRESS-CALYPSO
3- & 4- WHEEL SCOOTER
VERSION 1 -2016
Page 2
© 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 authorisati on 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.
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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 4 W ................................................................................................................................................... 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 ass y .............................................................................................................................. 46
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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
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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. 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.
1. 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 ‘Chang in g 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.
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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 illustr ation 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 accordanc e with EN1 218 4 (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.
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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 Warranty period
Examples include, but are not limited to the
parts mentioned below
Frame
2 years
Weldment/frame
Drive system*
1 year
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 warrant y on equipment during
the warranty period.
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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 transportatio n o f pe opl e 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.
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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 you r
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 prom otes 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, resul ti n g in these parts wearing out unnecessarily
quickly.
• Never drive the scooter while under the influ ence of drugs, alcohol or prescription medications
which could affect your driving ability.
• Your eyesight must be adequate for you to drive the scooter safely.
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General safety rules and regulations
• If visibility is not ideal, then it is o bligatory 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 a ngled 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 lo ad than fits in the basket. Never hang
anything on the tiller.
• Never use the scooter for pulling a trailer. The s cooter 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 fron t 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 fi elds, 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.
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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 handl e 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 dri ve your scooter if the backrest is inclined too far back.
A
A
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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 , pul l ha nd le ( A ) dow nw ar d s whil e pu ll i ng th e st ee rin g
column towards you with the other hand until it is in the most comfortable
position.
• Release the ha ndl e. 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 steerin g 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.
B
A
A
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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: dealer@mobilityftp.handicare.com
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 programm er, please contac t Sunrise Medical HCM.
DWIZ-ADAPT 1009567
The specific and optimised Fortress Calypso settings are summarized in the table below.
*These settings have no influence, are set via dip-switches on Tiller PCB (see Chapter 6.3)
User Personalisation
10km/h or 6mph
8km/h or 5mph
Swap Throttle Direction
No
No
Enable Beeper
Yes
Yes
Flash Code Beeper
No
No
Sleep Beeper
Yes
Yes
Reversing Beeper*
Yes
Yes
Beeper On Time (ms)
300
300
Beeper Off Time (ms)
700
700
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Programmer
Throttle Configuration
10km/h or 6mph
8km/h or 5mph
Throttle Type
Wig-wag
Wig-wag
Throttle Input
Single
Single
Throttle Neutral Offset (V)
0.00
0.00
Throttle Full Scale Deflectio
70
70
Throttle Response (%)
60
60
Throttle Dead-band (%)
25
25
Motor Management
10km/h or 6mph
8km/h or 5mph
Motor Reverse
No
No
Load Compensation (mOhm)
80
80
Current Limit (A)
50
50
Boost Current (A)
8
8
Boost Time (s)
8.0
8.0
Transaxle power
450 watt for 2 hrs
Load of ±20A at 24V
Park Brake Management
10km/h or 6mph
8km/h or 5mph
Park Brake Neutral Delay (ms)
500.0
500.0
Park Brake Release Delay (ms)
0.0
0.0
Battery Management
10km/h or 6mph
8km/h or 5mph
Battery Resistance (mOhm)
15
15
Fuel Gauge High Warning (V)
29.0
29.0
Fuel Gauge Low Warning (V)
23.4
23.4
System Options
10km/h or 6mph
8km/h or 5mph
Service Scheduler
No
No
Service Period (hours)
5000
5000
Input Pin
Function
Active
Slows to
Latches
Pin 4 Function
None
Low
100
No
Pin 6 Function
None
Low
100
No
Pin 12 Function
None
Low
100
No
Pin 14 Function
None
Low
100
No
Prog/Inh Pin Function
Charger Inhi
Low
100
No
Multi-function Outputs Configuration
Flash Code Type
Scooter
Pin 3 Function
Beeper
Pin 10 Function
Status High
Pin 11 Function
Status
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Electrical diagram
4 Electrical diagram
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Technical specifications
5 Technical specificati on s
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)
Maximum user weight
125 kg
Description
3W
4W
Total length
mm (inches)
1207 (47.5)
1214 (47.8)
Total width
mm (inches)
622 (24.5)
622 (24.5)
Minimum height*
mm (inches)
710 (28)
710 (28)
Total weight excluding batter ies:
kg (pounds)
70 (154.3)
75 (165.3)
Total weight including batter ies:
kg (pounds)
100 (220.5)
105 (231.5)
Weight of heaviest component
kg (pounds)
27 (59.5)
32 (70.5)
Static stability in the downward direction
°
15 (27%)
15 (27%)
Static stability in the upward direction
°
15 (27%)
15 (27%)
Lateral static stability
°
15 (27%)
15 (27%)
Distance range (ISO 7176-4)**
km (miles)
40 (24.9)
40 (24.9)
Dynamic stability (max. safe slope)
°
9 (16%)
9 (16%)
Maximum speed forwards
km/h (mph)
10 (6)
10 (6)
Back angle, Captain Seat
°
0-103-126
0-103-126
Seat depth, Captain Seat
mm (inches)
445 (17.5)
445 (17.5)
Seat width, Captain Seat
mm (inches)
457 (18)
457 (18)
Back height (excl. headrest), Captain Seat
mm (inches)
406 (16)
406 (16)
Seat height (to platform), Captain Seat
mm (inches)
432-490
(17-19.3)
432-490
(17-19.3)
Armrest height, Captain Seat
mm (inches)
229-273
(9-10.8)
229-273
(9-10.8)
Distance between armrests, Captain Seat
mm (inches)
457-610
(18-24)
457-610
(18-24)
Back angle, Master Seat
°
85-180
85-180
Seat depth, Master Seat
mm (inches)
430 (16.9)
430 (16.9)
Seat width, Master Seat
mm (inches)
500 (19.7)
500 (19.7)
Back height (excl. headrest), Master Seat
mm (inches)
550 (21.7)
550 (21.7)
Seat height (to platform), Master Seat
mm (inches)
432-510
(17-20.1)
432-510 (17-
20.1)
Armrest height, Master Seat
mm (inches)
150-340
(5.9-13.4)
150-340
(5.9-13.4)
Distance between armrests, Master Seat
mm (inches)
500 (19.7)
500 (19.7)
Description
3W
4W
Turning radius (ISO 7176-5)
mm (inches)
1170 (46.1)
1600 (63)
Obstacle height (max. user weight)
mm (inches)
76 (3)
76 (3)
Ground clearance (max. user weight)
mm (inches)
101 (4)
101 (4)
Test data
Test weight
125 kg
Operating force
Drive lever operation
< 60 N
Resetting the automatic fuse (circuit breaker)
< 60 N
Electronic switches
< 15 N
Connecting the charger plug
< 60 N
16 Version 2016v1
Page 17
Technical specifications
Technical specifications for wheels
Front wheel diameter (3W)
mm (inches)
260 x 85 (10.2 x 3.3)
Front wheel diameter (4W)
mm (inches)
260 x 85 (10.2 x 3.3)
Rear wheel diameter
mm (inches)
260 x 85 (10.2 x 3.3)
Tyre pressure 4W, front wheel
bar (psi)
3.5 (50)
Tyre pressure 4W, rear wheel
bar (psi)
3.5 (50)
Tyre pressure 3W, front wheel
bar (psi)
3.5 (50)
Tyre pressure 3W, rear wheel
bar (psi)
3.5 (50)
Batteries
3W
4W
Maximum dimensions of batteries (lxbxh)
mm
(inches)
197x168x175
(7.8x6.6x6.9)
197x168x175
(7.8x6.6x6.9)
Max. battery capacity
Ah
60 (C20)
60 (C20)
Maximum permitted charging current
Ampère
8
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
Page 18
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 w ork.
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).
No signal
Only indicators and alarm signal (when contact is switched on)
Only reverse beep
All audible signals are activated (when contact is switched on)
ON
1 2
ON
1 2
ON
1 2
ON
1 2
18 Version 2016v1
Page 19
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 loc al 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
Page 20
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
Page 21
Parts list
A: Overview 3W
Pos
Article number
Units
Description
1
See list 010
1
Frame front assy 3W
2 See list 006
1
Tiller assy
3 See list 004
1
Top console assy
4 See list 005
1
Bottom console assy
5 See list 007
1
Tiller strut assy
6 1009235
1
Bracket basket support
7 C91001
1
Basket front
8 1009237
1
Side board plastic left
9 See list 012
1
Cover front 3W assy
10
1009239
1
Tiller protect plastic
11
1009240
1
Mat floor 3W
12
See list 008
1
Cover battery assy
13
See list 009
1
Cover motor assy
14
1009242
1
Knop M5
15
See list 003
1
Bumper rear assy
16
See list 018
1
Rear frame assy
17
1009243
1
Seat post Captain Seat
9001495
1
Seat post Master Seat
18
1009244
1
Captain Seat
1002241
1
Master Seat
19
No spare part
2
Flat washer
20
No spare part
2
Lock nut M10xP1,25
21
No spare part
2
Bushing 9,2mm
22
No spare part
2
Flat washer
23
No spare part
2
Hex bolt M10x25mm
(see also next page)
Version 2016v1 21
Page 22
Parts list
A: Overview 3W (continued)
Pos
Article number
Units
Description
24
1009245
2
Bushing shoulder 4,7mm
25
1009246
2
Bushing shoulder 11mm
26
1009247
2
Bushing 20,5mm
27
1009248
1
Shaft 85mm
28
No spare part
2
Retaining ring
29
No spare part
1
Hex bolt M8x50mm
30
No spare part
1
Lock nut M8xP1,25
31
No spare part
1
Flat washer
32
No spare part
2
Screw M6x20mm
33
No spare part
2
Spring washer
34
1009249
1
Horn
35
1009238
1
Side board plastic right
22 Version 2016v1
Page 23
Parts list
B: Overview 4W
10
3
26
25
35
Pos
Article number
Units
Description
1
See list 013
1
Frame front assy 4W
2 See list 006
1
Tiller assy
3 See list 004
1
Top console assy
4 See list 005
1
Bottom console assy
5 See list 007
1
Tiller strut assy
6 1009235
1
Bracket basket support
7 C91001
1
Basket front
8 1009237
1
Side board plastic left
9 See list 016
1
Cover front 4W assy
10
1009239
1
Tiller protect plastic
11
1009241
1
Mat floor 4W
12
See list 008
1
Cover battery assy
13
See list 009
1
Cover motor assy
14
1009242
1
Knop M5
15
See list 003
1
Bumper rear assy
16
See list 018
1
Rear frame assy
17
1009243
1
Seat post Captain Seat
9001495
1
Seat post Master Seat
18
1009244
1
Captain Seat
1002241
1
Master Seat
19
No spare part
2
Flat washer
20
No spare part
2
Lock nut M10xP1,25
21
No spare part
2
Bushing 9,2mm
22
No spare part
2
Flat washer
(see also next page)
Version 2016v1 23
Page 24
Parts list
B: Overview 4W (continued)
10
3
26
25
35
Pos
Article number
Units
Description
23
No spare part
2
Hex bolt M10x25mm
24
1009245
2
Bushing shoulder 4,7mm
25
1009246
2
Bushing shoulder 11mm
26
1009247
2
Bushing 20,5mm
27
1009248
1
Shaft 85mm
28
No spare part
2
Retaining ring
29
No spare part
1
Hex bolt M8x50mm
30
No spare part
1
Lock nut M8xP1,25
31
No spare part
1
Flat washer
32
No spare part
2
Screw M6x20mm
33
No spare part
2
Spring washer
34
1009249
1
Horn
35
1009238
1
Side board plastic right
24 Version 2016v1
Page 25
Parts list
001: Wheel front assy
Pos
Article number
Units
Description
1
05010.4100
1
Tyre front 10''
2 05010.4000
1
Tube inner 10''
3 1008951
1
Wheel front 10'' assy
Version 2016v1 25
Page 26
Parts list
002: Wheel rear assy
Pos
Article number
Units
Description
1
1008952
1
Tyre rear 10''
2 05010.4000
1
Tube inner 10''
3 1008953
1
Wheel rear 10'' assy
26 Version 2016v1
Page 27
Parts list
003: Bumper rear assy
Pos
Article number
Units
Description
1
1008954
1
Reflector rear
2 1008955
1
Bumper rear assy
Version 2016v1 27
Page 28
Parts list
004: Top console assy
Pos
Article number
Units
Description
1
1001341
1
Knob speed selector
2 1008958
1
PCB board with batter y indic ator
3 1009156
1
Console speed plastic key pad membrane
4 1008956
1
Switch speed selector
28 Version 2016v1
Page 29
Parts list
005: Bottom console assy
Pos
Article number
Units
Description
1
1008974
2
Light bulb amber 24v 5w
2 1009159
1
Charger port assy
3 No spare part
1
Cover charger port
4 1009157
1
Shroud front assy
5 1009158
1
Shroud rear assy
Version 2016v1 29
Page 30
Parts list
006: Tiller assy
Pos
Article number
Units
Description
1
1008959
1
Shroud top tiller
2
1008960
1
Potmeter throttle
3
1008961
1
PCB fuse assy
4
1008962
1
Jack plug receptacle
5-11
1009160
1
Steering rod assy
12
9003722
1
Finger control assy
13
1014751
1
Steering wheel
-
1001372
1
Contact key
30 Version 2016v1
Page 31
Parts list
007: Tiller strut assy
Pos
Article number
Units
Description
1
1008965
1
Shroud tiller strut
2
1008966
1
Strut tiller
3
1008967
2
Bushing plastic
4
1008968
1
Adjustable tiller handle
5
1015177
1
Main harness + controller harness
6
1014750
1
Tiller tube
Version 2016v1 31
Page 32
Parts list
008: Cover battery assy
Pos
Article number
Units
Description
1
051.00031.000
2
Reflector yellow
2 1008971
1
Cover battery assy
32 Version 2016v1
Page 33
Parts list
009: Cover motor assy
Pos
Article number
Units
Description
1
1008972
1
Light rear assy – right
2 1008973
1
Light rear assy – left
3 1008974
2
Light bulb amber 24v 5w
4 1001281
4
Light bulb clear 24v 5w
5 1008976
1
Harness rear light assy
6 1008977
1
Cover motor assy
Version 2016v1 33
Page 34
Parts list
010: Frame front 3W assy
Pos
Article number
Units
Description
1
1008978
1
Bumper front
2
1008979
2
Bearing 20MMx42MMx12MM
3
1008980
2
Strap battery with buckle
4-6
1009161
1
Latch assy
7
1014743
1
Front frame Fortress Calypso 3 wheel
34 Version 2016v1
Page 35
Parts list
011: Front fork assy
Pos
Article number
Units
Description
1
1009162
1
Axle front wheel assy
2 1008982
1
Fork assy
Version 2016v1 35
Page 36
Parts list
012: Cover front 3W assy
Pos
Article number
Units
Description
1
1009163
1
Headlight assy
2 1008983
1
Cover front 3W assy
36 Version 2016v1
Page 37
Parts list
013: Frame front 4W assy
Pos
Article number
Units
Description
1
1008979
2
Bearing 20MMx42MMx12M M
2
1008984
1
Bumper front 4W
3
1009164
1
Steering rod assy 4W
4
1014744
1
Front frame Fortress Calypso 4 wheel
5
1014747
1
Steering axle
6
1014748
2
Front spring
7
1014749
2
Front suspension bearing bush
Version 2016v1 37
Page 38
Parts list
014: Swing arm right assy
Pos
Article number
Units
Description
1
1008985
1
Swing arm right assy
38 Version 2016v1
Page 39
Parts list
015: Swing arm left assy
Pos
Article number
Units
Description
1
1008986
1
Swing arm left assy
Version 2016v1 39
Page 40
Parts list
016: Cover front 4W assy
Pos
Article number
Units
Description
1
1009163
1
Headlight assy
2 1009165
1
Mat foot 4w set
3 1008987
1
Cover front 4W assy
40 Version 2016v1
Page 41
Parts list
017: Rear frame top assy
Pos
Article number
Units
Description
1-2
1009161
1
Latch assy
3
1015727
1
Controller Dynamic DR-90 v2.07
4
1008989
1
Shock absorber rear
5
1014745
1
Rear frame upper part
Version 2016v1 41
Page 42
Parts list
018: Rear frame assy
Pos
Article number
Units
Description
1
1008990
1
Cable battery harness
2
1015177
1
Main harness + controller harness
3
1014753
1
Rear wheel spacer
-
9002752
2
Set battery connection covers
-
1014125
1
Battery cable with red connector
-
1014126
1
Battery cable with black connector
42 Version 2016v1
Page 43
Parts list
019: Rear frame bottom assy
Pos
Article number
Units
Description
1-6
1009167
1
Wheel anti tip assy
7
1008992
1
Bracket mount transaxle
8
1014746
1
Rear frame bottom
9-10
1014752
1
Freewheel lever
Version 2016v1 43
Page 44
Parts list
020: Transaxle assy
Pos
Article number
Units
Description
1
1009166
1
Transaxle Assy 10K
9003576
1
Transaxle Assy 12K
2 1008993
2
Brush motor
3 1008994
2
Cap brush motor
4 1015605
1
Motor brake
5 1015606
1
Motor brake cover
4-5
1015607
1
Motor brake kit
44 Version 2016v1
Page 45
Parts list
021: Captain seat assy
1
5
2
Pos
Article number
Units
Description
1
1008995
1
Seat capt regular with headrest
2 1008996
1
Seat plate weldment
3 1008997
1
Lever seat weldment
4 1008998
1
Armrest assy left adjustable
5 1008999
1
Armrest assy right adjustable
Version 2016v1 45
Page 46
Parts list
022: Armrest adjustable assy
Pos
Article number
Units
Description
1
232103
1
Armpad foam captain
2 1009001
1
Detent button
46 Version 2016v1
Page 47
Version list
Version 2013v1
Version 2014v1
01-10-2014:
Version 2014v2
Version 2015v1
Version 2016v1
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)
Page
Drawing
Position
Changes
13 - -
Added reference to the FTP server where the driving programs can be
downloaded
41
17
2
Changed article number 1008988 into 1015727 and added version number in
description
42
18 - Added article numbers 1014125 and 1014126
Page
Drawing
Position
Changes
17 - -
Changed specification maximum permitted charging current 5A into 8A
Page
Drawing
Position
Changes
7
Updated warranty text
14 - -
Added transaxle power information
30 6 13
Added article number 1014751 Steering wheel
31 7 6
Added article number 1014750 Tiller tube
34
10 7 Added article number 1014743 Front frame Fortress Calypso 3 wheel
37
13
4
5
6
7
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
41
17 5 Added article number 1014745 Rear frame upper part
42
18 3 Added article number 1014753 Rear wheel spacer
43
19
8
9-10
Added article number 1014746 Rear frame bottom
Added article number 1014752 Freewheel lever
Page
Drawing
Position
Changes
Replaced Handicare by Sunrise Medical HCM
Version 2016v1 47
Page 48
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