Handicare FORTRESS-CALYPSO Service Manual Download

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SERVICE MANUAL

FORTRESS-CALYPSO

3- & 4- WHEEL SCOOTER

Summary of Contents for FORTRESS-CALYPSO

Page 1: ...SERVICE MANUAL FORTRESS CALYPSO 3 4 WHEEL SCOOTER ...

Page 2: ...the right to make changes and modifications to its products The information provided applies to the standard version of the product Handicare can not be held liable for any damage resulting from product specifications which do not conform to the standard configuration The information made available has been compiled with the greatest care However Handicare can not be held liable for any possible e...

Page 3: ...olumn 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 ...

Page 4: ...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 documen...

Page 5: ...ter 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 Changing the position of the steering column section 4 1 6 Symbols used in this manual CAUTION Operations or manoeuvres which are not ...

Page 6: ...nd 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 reg...

Page 7: ... the rights of the Client and or User towards Handicare in case of defects are limited to the provisions set forth in this warranty For the duration of the warranty period Handicare guarantees that the product is without defects In case of any defects the User is required within two weeks after discovery of the defect to contact the dealer He has to complete a return form and return the product or...

Page 8: ...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 CAL...

Page 9: ...n 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...

Page 10: ...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 ha...

Page 11: ...old 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 bac...

Page 12: ...ht 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 comf...

Page 13: ...p 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 programmer please contact Handicare DWIZ ADAPT 1009567 The specific and optimised Fortress Calypso settings are summarized in the table below The...

Page 14: ...km 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 ...

Page 15: ...Electrical diagram Version 2015v1 15 4 Electrical diagram ...

Page 16: ... 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 Se...

Page 17: ...re 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 w...

Page 18: ...ake 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 ...

Page 19: ...ered 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 W...

Page 20: ...t 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 ...

Page 21: ...st 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 ...

Page 22: ...6 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 ...

Page 23: ...ard 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 ...

Page 24: ... 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 ...

Page 25: ...Parts list Version 2015v1 25 001 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 ...

Page 26: ...Parts list 26 Version 2015v1 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 ...

Page 27: ...Parts list Version 2015v1 27 003 Bumper rear assy Pos Article number Units Description 1 1008954 1 Reflector rear 2 1008955 1 Bumper rear assy ...

Page 28: ...015v1 004 Top console assy Pos Article number Units Description 1 1001341 1 Knob speed selector 2 1008958 1 PCB board with battery indicator 3 1009156 1 Console speed plastic key pad membrane 4 1008956 1 Switch speed selector ...

Page 29: ... 29 005 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 ...

Page 30: ...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 ...

Page 31: ...r 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 ...

Page 32: ...Parts list 32 Version 2015v1 008 Cover battery assy Pos Article number Units Description 1 051 00031 000 2 Reflector yellow 2 1008971 1 Cover battery assy ...

Page 33: ... 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 ...

Page 34: ...10 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 ...

Page 35: ...Parts list Version 2015v1 35 011 Front fork assy Pos Article number Units Description 1 1009162 1 Axle front wheel assy 2 1008982 1 Fork assy ...

Page 36: ...Parts list 36 Version 2015v1 012 Cover front 3W assy Pos Article number Units Description 1 1009163 1 Headlight assy 2 1008983 1 Cover front 3W assy ...

Page 37: ...e number Units Description 1 1008979 2 Bearing 20MMx42MMx12MM 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 ...

Page 38: ...Parts list 38 Version 2015v1 014 Swing arm right assy Pos Article number Units Description 1 1008985 1 Swing arm right assy ...

Page 39: ...Parts list Version 2015v1 39 015 Swing arm left assy Pos Article number Units Description 1 1008986 1 Swing arm left assy ...

Page 40: ...Parts list 40 Version 2015v1 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 ...

Page 41: ...Version 2015v1 41 017 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 ...

Page 42: ... 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 ...

Page 43: ...Version 2015v1 43 019 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 ...

Page 44: ...xle 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 ...

Page 45: ...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 ...

Page 46: ...Parts list 46 Version 2015v1 022 Armrest adjustable assy Pos Article number Units Description 1 232103 1 Armpad foam captain 2 1009001 1 Detent button ...

Page 47: ...ion 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 fra...

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