Sunrise Fortress Calypso User manual

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 HCMcan 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 HCMmay 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
1General 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
2Adjustment options...........................................................................................................................................11
2.1 Adjusting the seat.........................................................................................................................................11
2.2 Adjusting the steering column......................................................................................................................12
2.3 Adjusting the rear suspension......................................................................................................................12
3Programmer .......................................................................................................................................................13
4Electrical diagram..............................................................................................................................................15
5Technical specifications...................................................................................................................................16
5.1 Fortress Calypso product specifications ......................................................................................................16
6Service instructions ..........................................................................................................................................18
6.1 Maintenance diagram...................................................................................................................................18
6.2 Maintenance instructions..............................................................................................................................18
6.3 Instructions for repair....................................................................................................................................18
7Use of the parts list ...........................................................................................................................................19
8Parts 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
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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 ‘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.
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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 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.
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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 warranty 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 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.
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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 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.
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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.
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