Handicare CALYPSO Service Manual
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Handicare CALYPSO Service Manual

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SERVICE MANUAL
CALYPSO

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Summary of Contents for Handicare CALYPSO

  • Page 1 SERVICE MANUAL CALYPSO...
  • Page 2 Handicare accepts no liability for loss resulting from work executed by third parties. Names, trade names, etc. used by Handicare may not, as per the legislation concerning the protection of trade names, be considered as being available.

  • Page 3: Table Of Contents

    Contents This manual ................................. 4 Product reference ............................... 5 Available documentation ............................6 Service and technical support........................... 7 Identification plate ..............................7 Identification of the product ............................7 Warranty ..................................8 Used scooters and the environment ........................9 Use according to purpose ............................

  • Page 4: This Manual

    Preface 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.

  • Page 5: Product Reference

    Preface Product reference XXXXXX-010004000-en.doc The product has the following decals and labels. A. Charging connection B. Automatic fuse C. Drive – Freewheel D. Tyre pressure wheels Version 2015v1...

  • Page 6: Available Documentation

    Preface A. Charging connection For charging the batteries, see 'charging'. PICPRO-010004210-en.doc B. Automatic fuse The scooter has a safety fuse feature. See 'automatic fuse' and 'faults'. PICPRO-010004270-en.doc C. Driving The drive of the motor is switched on: the scooter can be electrically driven. D.

  • Page 7: Service And Technical Support

    Preface Service and technical support For information concerning specific settings, maintenance or repair work please contact your dealer. He is always prepared to help you. Ensure you have at hand: Model Manufacture year Identification number This information can be found on the identification plate. See 'Identification of the product'. XXXXXX-010006000-nl.doc Identification plate See fig.

  • Page 8: Warranty

    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. Handicare 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.

  • Page 9: Used Scooters And The Environment

    Used batteries belong to chemical waste. Use according to purpose The scooter Calypso was designed for the transport of persons to a weight of maximally 125 kg (344 lbs). Your dealer should give you good user's instructions before you can independently operate the product and participate in traffic.

  • Page 10: Approval

    Preface Approval The product meets the following standards: 1. Essential standards as specified in Annex 1 of the EU directive 93/42 EEC. 2. NEN-EN 12182 Technical tools for the handicapped – General standards and testing methods October 1997. 3. NEN-EN 12184 Electrically driven wheelchairs, scooters and associated charging equipment – Standards and testing methods, April 1999.

  • Page 11: General Safety Regulations And Instructions

    1 General safety regulations and instructions Handicare accepts no liability whatsoever for damage or injury caused by the failure to (strictly) adhere to the safety guidelines and instructions or else due to carelessness during the use and cleaning of the scooter and possible accessories.

  • Page 12: Adjustment Options

    General safety regulations and instructions 2 Adjustment options XXXXXX-010500000-en.doc Seat adjustments The Calypso seat offers a number of adjustment options to increase the sitting and driving comfort. The following may be adjusted: A. Seat height B. Seating width C. Arm-rests D.

  • Page 13: Programmer

    Programmer 3 Programmer A programmer is nescesarry for programming the Calypso. A programmer will always be deliverd with a user manual. The standard adjustments are stated in the table below. Function SP1B Programming < 2002 Programming > 2002 8 km/hr...

  • Page 14: Electrical Diagram

    Programmer Electrical diagram SPEED CONSOLE BROUW BLUE GREEN YELLOW BLACK CANNON JACK CONNECTOR FUSE 10A WHITE BLACK WHITE BLACK LAMP 24V 5W x2 BATTERY (12V) GRAY BATTERY (12V) CONNECTOR ORANGE LAMP 24V 5W x2 GRAY CONTROLLER BLUE BLACK BRAKE CIRCUIT BREAKER DC MOTOR Connections printed circuit board...
  • Page 15 Programmer Cable function Number of the connections Colour of the cables Horn Black Console main connector Black Brown Orange Green Blue Key switch White Yellow Speed control Black Blue Controller connection Purple Blue Green Yellow Grey Black White Orange Lighting switch Black Front light Black...

  • Page 16: Technical Specifications

    4 Technical specifications XXXXXX-010900000-nl.doc Product specifications Manufacturer: Handicare XXXXXX-010901000-nl.doc 4.1.1 Calypso Technical specification according to ISO 7176-15 Model Calypso 3-wheel version Calypso 4-wheel version Maximum user's weight 125 kg Description Min. Max. Total length 1180 mm Total width 620 mm Total weight incl.

  • Page 17: Approval

    3. The Calypso 3-wheel scooter is classified according to EN12184 (1999) in class A & B. 4. The Calypso 4-wheel scooter is classified according to EN 12184 (1999) in class B. 5. ISO 7176-8 Requirements and test methods for impact, static, and fatigue strength July 1998.

  • Page 18: Use Of The Parts Lists

    Spare parts 5 Use of the parts lists This document is meant as a reference book to be able to order parts for the scooter as shown on the front. How to order: To order parts please specify: Serial number (see the identification plate). Group (to which the relevant part belongs).

  • Page 19: 001: Front Tyre Assy (3W)

    Spare parts 001: Front tyre assy (3w) Article number Units Description 05010.4100 Tyre 05010.4000 Tube 143001 Outer rim 00000.1701 Lock nut M6 00000.2302 Flat washer M6 00000.4104 Hex bolt M6x60 131905 Axle front wheel 4B2006 Bearing 6202ZZ 133002 Collar front wheel 00000.3500 Set screw M6x5 00001.1463...

  • Page 20: 002: Rear Tyre Assy (3-4W)

    Spare parts 002: Rear tyre assy (3-4w) Article number Units Description 1008952 Tyre 05010.4000 Tube 143102 Inner rim 143003 Outer rim 00000.4104 Hex bolt M6x60 00000.2302 Flat washer M6 00000.1701 Lock nut M6 00001.1463 Label max 3.5 bar B24R02 Rear tyre assy Version 2015v1...

  • Page 21: 003: Front Tyre Assy (4W)

    Spare parts 003: Front tyre assy (4w) Article number Units Description 05010.4100 Tyre 05010.4000 Tube 143001 Outer rim 00000.1701 Lock nut M6 00000.2302 Flat washer M6 00000.4104 Hex bolt M6x60 4B2006 Bearing 6202ZZ 00001.1463 Label max 3.5 bar B24F02 Front tyre Version 2015v1...

  • Page 22: 004: Free Wheel Lever Assy

    Spare parts 004: Free wheel lever assy Article number Units Description No spare part Free wheel handel No spare part Plastic washer 00000.3207 Screw M5x20 No spare part Free wheel lever 00000.1700 Lock nut M5 00000.3503 Set screw M5x6 105.00091.000 Free wheel lever assy Version 2015v1...

  • Page 23: 005: Rear Frame Assy

    Spare parts 005: Rear frame assy Article number Units Description C35001 Rear bumper 225001 Plastic wheel 001.03010.002 Hex bolt M8x65 00000.2003 Flat washer M8 00000.1702 Lock nut M8 110.00121.000 Rear frame bottom 00000.2103 Flat washer M8 3D 00000.2203 Spring washer M8 00000.4112 Hex bolt M8x55 No spare part...

  • Page 24: 006: Rear Chassis Assy

    Spare parts 006: Rear chassis assy Article number Units Description 110.00111.000 Rear frame top See 005 Rear frame bottom assy 110.00131.000 Bush 00000.2003 Flat washer M8 No spare part Screw M6xP1.0x38 No spare part Screw M6xP1.0x13 92500040 Front rear latch plate 00000.3206 Screw M5x16 00000.1700...

  • Page 25: 007: Rear Section Assy

    Article number Units Description See 006 Rear chassis assy 100.00021.000 Transaxle assy 8K 100.00011.000 Transaxle assy 10K 100.00031.000 Transaxle assy 12K (Calypso HP) 113115 Axle holder Hex bolt M6x40 00000.2102 Flat washer M6 3D 00000.1701 Lock nut M6 133501 Rear collar...

  • Page 26: 008: Rear Section Assy

    Spare parts 008: Rear section assy Article number Units Description See 007 Rear section pro assy 112401 Power connector assy No spare part Rivet pop 4-4 105.00091.000 Free wheel lever assy 221704 Swing lever bushing 222003 Free wheel lever knob 321101 Circuit breaker 25A 336102...

  • Page 27: 009: Front Floorpan Assy

    Article number Units Description No spare part Front cover 126.00081.000 Battery bumper pad No spare part Snap button 008.00000.301 Label Calypso 1001276 Holding elastic band No spare part Rivet pop 4-4 00000.2009 Flat washer M3 243001 Battery strap 052.00361.000 Front floorpan assy 3w green + mat...

  • Page 28: 010: Front Frame Assy (3W)

    Spare parts 010: Front frame assy (3w) Article number Units Description 015.07000.001 Head set bearing 11321030 Front frame 3W C11003 Fork B24F02 Front tyre assy 00000.4315 Screw M10x20 00000.2204 Spring washer M10 00000.2004 Flat washer M10 Version 2015v1...

  • Page 29: 011: 3W Scooter Assy

    Spare parts 011: 3w scooter assy Article number Units Description See: 010 Front frame assy See: 009 Front floorpan assy 00000.3291 Screw M5x12 00000.1700 Lock nut M5 001.20020.005 Latch 00000.3218 Screw M4x12 00000.1705 Lock nut M4 Version 2015v1...

  • Page 30: 012: Front Axle (4W)

    Spare parts 012: Front axle (4w) Article number Units Description C12002 Front axle 4W C12102 Knuckle spin left C12101 Knuckle spin right 4B2006 Ball bearing 6001ZZ 00000.2005 Flat washer M12 00000.4121 Hex bolt M12x70 00000.2005 Flat washer M12 00000.1704 Lock nut M12 176.00241.000 Tie rod long assy No spare part...

  • Page 31: 013: Front Frame Assy (4W)

    Spare parts 013: Front frame assy (4w) Article number Units Description 110.00101.000 Front frame 4W 015.07000.001 Head set bearing C13010 Steering axle Version 2015v1...

  • Page 32: 014: Front Section Assy (4W)

    Spare parts 014: Front section assy (4w) Article number Units Description See: 013 Front frame assy 4W 176.00221.000 Front axle assy 4S2001 Suspension spring 123103 Guide pin 00000.4319 Hex bolt M8x90 00000.2003 Flat washer M8 00000.1702 Lock nut M8 No spare part Hex bolt M12x55 00000.2005 Flat washer M12...

  • Page 33: 015: Front Floorpan Assy (4W)

    Article number Units Description No spare part Front cover 231002 Floor mat 126.00081.000 Battery bumper pad 008.00000.301 Label Calypso 1001276 Holding elastic band No spare part Rivet pop 4-4 00000.2009 Flat washer M3 243001 Battery strap 052.00541.000 Front floorpan assy green 052.00531.000...

  • Page 34: 016: 4W Scooter Assy

    Spare parts 016: 4w scooter assy Article number Units Description See: 014 Front section assy 4W See: 015 Front floorpan assy 4W 00000.3200 Screw M5x12 00000.1700 Lock nut M5 001.20020.005 Latch 00000.3218 Screw M4x12 00000.1705 Lock nut M4 114301 Front bumper angle 00000.4309 Hex bolt M6x20 00000.2002...

  • Page 35: 017: Transaxle Assy

    Spare parts 017: Transaxle assy Article number Units Description 100.00051.000 Transaxle 101.00061.000 Motor 8K 101.00071.000 Motor 10K 108.00231.000 Brake 103.00141.000 Motor brush 104.00071.000 Mounting pad 4K1002 Transaxle key 100.00021.000 Transaxle assy 8K 100.00011.000 Transaxle assy 10K 100.00031.000 Transaxle assy 12K 1003506 Motor brush cover 8/10K 1003639...

  • Page 36: 018: Head Light Support Assy

    Spare parts 018: Head light support assy Article number Units Description 90000020 Head light assy 00000.2004 Washer M10 124.00091.000 Head light assy 00000.2201 Spring washer M5 00000.2001 Flat washer M5 No spare part Plastic washer 00000.3200 Screw M5x12 C15003 Tilting connector 6B10801 Hex bolt M8x125 00000.2003...

  • Page 37: 019: Console Bottom Cover Assy

    Spare parts 019: Console bottom cover assy Article number Units Description 305301 Console bottom cover red 161.00071.000 Console bottom cover green 1003102 Console bottom cover silver 165.00071.000 Potentiometer assy 00000.3218 Screw M4x12 164.00072.000 PCB main board No spare part Screw M3x16 1001325 Horn No spare part...

  • Page 38: 020: Tilting Tiller Assy

    Spare parts 020: Tilting tiller assy 黑 紅 白 Article number Units Description C14005 Tilting tiller 242001 Hand grip 110506 Console mounting plate 00000.3205 Screw M5x30 00000.1700 Lock nut M5 See: 020 Console bottom cover assy 110519 Handle cover bracket top 00000.3218 Screw M4x12 110421...

  • Page 39: 021: 3W Scooter Assy

    Spare parts 021: 3w scooter assy P& G T erm in al Article number Units Description See: 011 3W scooter assy See: 007 Rear section assy 00000.3219 Screw M4x16 See: 018 Head light support assy See: 020 Tilting tiller assy 00000.2003 Flat washer M8 3D 143101...

  • Page 40: 022: 4W Scooter Assy

    Spare parts 022: 4w scooter assy P&G T erm ina l Article number Units Description No spare part 4W scooter pro assy See: 008 Rear section assy 00000.3219 Screw M4x16 See: 018 Head light support assy See: 020 Tilting tiller assy 00000.2003 Flat washer M8 143101...

  • Page 41: 023: Basket Support Assy

    Spare parts 023: Basket support assy Article number Units Description C91102 Basket support 242003 Basket bracket pad Version 2015v1...

  • Page 42: 024: Wig-Wag Assy

    Spare parts 024: Wig-wag assy Article number Units Description C16001 Wig wag lever 9003092 Wig wag cap yellow 9003093 Wig wag cap green No spare part Set screw M5x5 Version 2015v1...

  • Page 43: 025: Armrest Assy Rh

    Spare parts 025: Armrest assy RH Article number Units Description 120139 Arm post Hex bolt M6x40 00000.2002 Flat washer M6 No spare part Plastic washer 00000.1701 Lock nut M6 C44003 Arm rest 232103 Arm rest pad 00000.2002 Flat washer M6 00000.2202 Spring washer M6 1001317...

  • Page 44: 026: Armrest Assy Lh

    Spare parts 026: Armrest assy LH Article number Units Description 120139 Arm post Hex bolt M6x40 00000.2002 Flat washer M6 No spare part Plastic washer 00000.1701 Lock nut M6 C44003 Arm rest 232103 Arm rest pad 00000.2002 Flat washer M6 00000.2202 Spring washer M6 1001317...

  • Page 45: 027: Seat Assy

    Spare parts 027: Seat assy Article number Units Description C41005 Seat frame C43004 Seat lever 4S3001 Torsion spring No spare part Plastic washer 00000.2002 Flat washer M6 Hex bolt M6x40 00000.1701 Lock nut M6 234001 Lever pocket 10310 Seat No spare part Seat cloth 00000.4312 Screw M8x16...

  • Page 46: 028: Seat Post Assy

    Spare parts 028: Seat post assy Article number Units Description C42003 Seat post 221601 Seat post bush Version 2015v1...

  • Page 47: 029: Front Cover Tiller Assy

    Spare parts 029: Front cover tiller assy Article number Units Description 214001 Front cover tiller red 052.00551.000 Front cover tiller green 1003103 Front cover tiller silver 321301 Cannon jack 055.00291.000 Charger harness 00000.3231 Screw M3x10 00000.1506 Nut M3 No spare part Label battery No spare part Label charger...

  • Page 48: 030: Battery Cover Assy

    Flat washer M3 00000.3231 Screw M3x10 051.00031.000 Reflector No spare part Velcro loop 00001.1347 Label CE No spare part Label circuit diagram No spare part Sticker Handicare 052.00561.000 Battery cover red 052.00571.000 Battery cover green 1003108 Battery cover bleu Version 2015v1...

  • Page 49: 031: Console Top Cover Assy

    Speed control knob 322201 Key switch assy 330303 Console fuse 1001327 Toggle switch assy 1003397 Label 12K (Calypso HP) No spare part Toggle switch cover 1001331 Fuse 2A 161.00111.000 Console top cover assy red 161.00131.000 Console top cover assy green...

  • Page 50: 032: Rear Motor Cover Assy

    Reflector 512201 Circuit breaker decal No spare part Label circuit breaker No spare part Velcro hook 008.00000.301 Sticker Calypso No spare part Label engage/release 1001281 Rear light 24V 5W 055.00251.000 Warning light cable assy 055.00261.000 Rear indicator light cable assy...

  • Page 51: 033: 3W Scooter Assy

    Spare parts 033: 3w scooter assy Article number Units Description No spare part 3W scooter pro assy See: 032 Rear motor cover assy See: 024 Wig wag assy See: 031 Console top cover assy No spare part Screw M3x16 See: 030 Front cover tiller assy 214101 Rear cover tiller...

  • Page 52: 034: 4W Scooter Assy

    Spare parts 034: 4w scooter assy Article number Units Description No spare part 4W scooter pro assy See: 032 Rear motor cover assy See: 024 Wig wag assy See: 031 Console top cover assy No spare part Screw M3x16 See: 030 Battery cover assy 214101 Rear cover tiller...

  • Page 53: 035: Parts Pack

    Spare parts 035: Parts pack Article number Units Description No spare part Part case No spare part PE bag 1008998 Arm rest assy left 1008999 Arm rest assy right 1001372 229001 Thumb screw 242002 Battery pad 138.00021.000 Battery straps No spare part Plastic bag Version 2015v1...

  • Page 54: 036: Seat Frame Assy

    Spare parts 036: Seat frame assy Article number Units Description C41005 Seat frame C43004 Seat lever 4S3001 Torsion spring No spare part Plastic washer 00000.2002 Flat washer M6 No spare part Hex bolt M6x40 00000.1701 Nut M6 234001 Lever pocket 221601 Seat post bush C42003...
  • Page 55 Spare parts 01-01-2013 Version 2013v1 Page Drawing Position Changes Changed article number 233002 into 1008952 Changed article number 1003099 into 1003539 Changed article number 243002 into 1001276 Changed article number 322501 into 1001325 Changed article numbers 1001357 and 1001358 into 9003092 and 9003093 Changed article number 4Z2001 into 1001284 Changed article number 320503 into 1001327 Deleted article number 1003106...

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