Sunrise Fortress Calypso, Service Manual

Page 1: ...SERVICE MANUAL FORTRESS CALYPSO 3 4 WHEEL SCOOTER VERSION 1 2016...

Page 2: ...es 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 specificat...

Page 3: ...ions 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...

Page 4: ...e 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 Par...

Page 5: ...f 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 posi...

Page 6: ...ths 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 resistanc...

Page 7: ...ty 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 Sun...

Page 8: ...otpaths 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...

Page 9: ...s 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...

Page 10: ...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 s...

Page 11: ...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 ad...

Page 12: ...ollows 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...

Page 13: ...care 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...

Page 14: ...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 Fu...

Page 15: ...Electrical diagram 4 Electrical diagram Version 2016v1 15...

Page 16: ...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...

Page 17: ...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 9 197...

Page 18: ...cooter 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 an...

Page 19: ...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...

Page 20: ...e 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 R...

Page 21: ...t 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...

Page 22: ...r 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...

Page 23: ...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 lis...

Page 24: ...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 spa...

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: ...le 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 se...

Page 29: ...ole 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 re...

Page 30: ...ption 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 101475...

Page 31: ...ticle 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 1...

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: ...umber 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...

Page 34: ...ssy 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 Cal...

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: ...ription 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 spr...

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: ...17 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 Versio...

Page 42: ...iption 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 10...

Page 43: ...19 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 Versio...

Page 44: ...e 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 5 101...

Page 45: ...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 Armre...

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: ...rrent 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 Till...

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