Invacare Storm 3 Competition / FFH User manual

Storm³
SERVICE MANUAL
These instructions contain information
about:
Troubleshooting
Repair
Edition: 01.2002

Service Manual Storm³
As at: 07.03.02 Page 1
General information
These repair instructions contains all the information necessary for maintenance and overhaul
of the wheelchair.
• All maintenance and overhaul work must be carried out in accordance with these repair
instructions.
• Please observe all safety instructions.
• Information about operation or about general maintenance and care work should be taken
from the wheelchair Operating Manual.
• You can find information about ordering spare parts in the spare parts catalogue.
• We reserve the right to make any alterations on the grounds of technical improvements.
• The wheelchair may only be maintained and overhauled by qualified personnel.
• The minimum requirement for service technicians is relevant training, such as in the cycle or
orthopaedic mechanics fields, or suitably long-term job experience.
- Experience and knowledge of electrical measuring devices (Multimeter)
is also a requirement.
- Special Invacare training sessions are recommended.
• If you have any problems or questions please contact INVACARE SERVICE:
(Customer Service):+44 - (0) 1656 - 647 372
Fax (Customer Service):+44 - (0) 1656 - 649 016
Address:
Invacare® Ltd
South Road
Bridgend
Mid Glamorgan - CF31-3PY
United Kingdom
• Alterations to the wheelchair which occur as a result of incorrectly or improperly executed
maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE.

Storm³ Service Manual
Page 2 As at:07.03.02
Notes on transport
• If the wheelchair has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
• You should also include as accurate a fault description as possible.
The following symbols are used in these repair instructions:
Note:
This symbol identifies general information which indicate special points or simplifications
in dismantling / reassembly.
CAUTION:
it is imperative that you observe any >safety instructions< identified with this symbol.
This symbol identifies service work.
"

Service Manual Storm³
As at: 07.03.02 Page 3
Contents
1SAFETY AND ASSEMBLY INSTRUCTIONS 7
1.1 Before any inspection or repair work 7
1.2 During dismantling/reassembly 7
1.3 Before operation / after completion of work: 8
2TOOL LIST 9
2.1 Tightening torques and Loctite 10
3LAYOUT OF MODULES, COMPONENTS AND DISPLAYS AND
CONTROLS 11
4SERVICE PLAN (1X ANNUALLY) 12
5OPERATIONAL FAULTS 14
5.1 General 14
5.2 Fault causes 14
6JOYSTICK BOX ERROR CODES 16
7MODULE COMPOSITION / VARIATIONS 17
8RUNNING GEAR 18
8.1 Frame (chassis) 18
8.1.1 Service work to frame (chassis) 19
8.2 Lifter 20
8.2.1 Replacing motor for electrical seat tilting 21
8.2.2 Replacing the electrical lifter motor 21
8.2.3 Replacing the gas pressure spring for lifter support 22
8.3 Drive unit, disengage lever, support wheels 23
8.3.1 Drive unit 23
8.3.2 Replacing drive unit, pressure spring 25
8.3.3 Replacing carbon brushes 25
8.4 Disengage lever 26
8.4.1 Replacing the disengage lever 27
8.4.2 Function check for disengage lever 28
8.4.3 Replacing the support wheels 28
8.5 Wheel lock 29
8.5.1 Replacing wheel lock / Bowden cable 30

Storm³ Service Manual
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9WHEELS 31
9.1 Steering wheels / front wheels 3.00 – 6 / front wheel suspension 31
9.1.1 Replacing castor wheel / front wheel 33
9.1.2 Replacing wheel rim halves 33
9.1.3 Repairing / replacing tyres or inner tube 33
9.1.4 Replacing the wheel fork 34
9.1.5 Replacing deep groove ball bearings 34
9.1.6 Drive wheels 3.00 - 8 35
9.1.7 Replacing the drive wheels 36
9.1.8 Replacing wheel rim halves 36
9.1.9 Repairing / replacing tyres or inner tube 36
9.1.10 Replacing wheel hubs, brake linings 37
9.2 Batteries, battery case 37
9.2.1 Replacing batteries 39
9.2.2 Replacing the fuse strip 39
10 LIGHTING 40
10.1 Front headlight 40
10.1.1 Replacing bulbs 41
10.1.2 Replacing complete headlight 41
10.1.3 Replacing headlight 42
10.2 Back lights 42
10.2.1 Replacing bulbs 43
10.2.2 Replacing back light supports or back lights 43
11 REMOTE 44
11.1 ACS remote REM24 SC 44
11.1.1 Replacing joystick knob 44
11.1.2 Replacing the tachometer holder or hand protector 45
11.1.3 Replacing remote holder (height-adjustable, hinged) 45
11.1.4 Replacing the remote 45
11.2 Remote holder with many different operation capabilities 46
11.2.1 Tray can be swivelled for operation 46
11.2.2 Replacing the tray 47
11.2.3 ACS operation for attendant (switchable) 47
11.2.4 Replacing the ACS operation box for attendant (switchable) 48
11.2.5 Replacing the ACS joystick (switchable) 48
11.2.6 ACS chin control 48
11.2.7 Replacing the ACS chin control (complete) 50
11.2.8 Replacing the foam rubber ball over the joystick knob 50
11.3 Troubleshooting the ACS control system 50
11.3.1 Error codes 51
11.4 Electronics 52
11.4.1 Replacing the equipment rack 54
11.4.2 Replacing electronic components 54
12 SEAT UNIT 54
12.1 Standard seat complete 55
12.1.1 Replacing the seat 56

Service Manual Storm³
As at: 07.03.02 Page 5
12.1.2 Replacing the seat plate 56
12.2 Split seat plate 57
12.3 Armrests and side panels 59
12.3.1 Replacing armrest padding / changing its position 61
12.3.2 Replacing the side panel 61
12.3.3 Replacing the side panel plate 61
12.3.4 Replacing the side panel mounting 62
13 BACKREST ADJUSTMENT 62
13.1 Standard (manual) 62
13.1.1 Replacing the backrest tube 63
13.1.2 Replacing the backrest adjustment 64
13.2 Contour backrest (manual) 64
13.2.1 Replacing the fitting attachment 65
13.2.2 Replacing the backrest attachment and connecting tube 65
13.3 Contour backrest (electrical) 66
13.3.1 Replacing the backrest adjustment motor 68
13.3.2 Replacing the angular sensor 68
13.4 Flex backrest (manual) 69
13.5 Headrest 70
13.5.1 Replacing the headrest shell 71
13.5.2 Replacing the headrest arms 71
13.5.3 Replacing the headrest attachment 72
14 FOOTREST HANGER 72
14.1 Footrest support 73
14.1.1 Replacing the footrest adapter (electrical / manual) 74
14.2 Footrest hanger (VARI F, 90°-65°) 75
14.2.1 Replacing the interlock 76
14.2.2 Replacing the footrest hanger, press cone 76
14.3 Footrest hanger (VARI A, 80°) manually height-adjustable with angle adjustment77
14.3.1 Replacing the interlock, angle adjustment 78
14.4 Footrest hanger (ADM) with manual height adjustment 79
14.4.1 Replacing the ADM adjustment 80
14.5 Footrest hanger (ADE) with electrical height adjustment 82
14.5.1 Replacing the footrest hanger, interlock, lift motor 83
14.6 Replacing the calf support 85
15 FOOTREST LOWER PART 85
15.1 Angle-adjustable footrests 86
15.1.1 Replacing the footplate 87
15.1.2 Angle and depth-adjustable footplate 87
15.1.3 Replacing the footplate 87
15.1.4 Fixed footplate 88

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15.1.5 Replacing the footplate 89
16 ACCESSORIES 89
16.1 Kerb climber 89
16.1.1 Replacing the kerb climber 90
16.1.2 Replacing the kerb climber assy. 90
16.1.3 Replacing the gas pressure springs 90
16.2 Cane holder (standard) 91
16.2.1 Replacing the cane holder 92

Service Manual Storm³
As at: 07.03.02 Page 7
1 Safety and assembly instructions
The safety instructions are intended as prevention of accidents at work and it is imperative that
they are observed.
1.1 Before any inspection or repair work
• Read and observe this repair manual and the associated operating manual.
• Observe the minimum requirements for carrying out the work (see chapter entitled "General
information”).
Caution:
• Please note the heavy weight of some components. This applies especially to removal
of drive units and batteries.
• The wheelchair must be switched off before removal of voltage-carrying components.
To do this, disconnect the batteries or remove them.
• When making measurements on voltage-carrying components, avoid short-circuiting
the contacts.
Danger of fire and combustion !
• Use only undamaged tools in good condition.
1.2 During dismantling/reassembly
• Mark all current settings for the wheelchair (seat, armrests, backrest etc.), and the cable
connecting plugs associated, before any removals. This makes reassembly easier.
Caution:
• Prop up the lifted wheelchair with appropriate supports before starting the
disassembly or assembly.
• Never use standard nuts instead of self-locking nuts.
• Always use correctly dimensioned washers or spacers.
Note:
• All plugs are fitted with mechanical safety devices which prevent release of the
connecting plugs during operation.
• To release the connecting plugs the safety devices must be pressed in.
• When reassembling ensure that these safety devices are correctly engaged.
• Cable binders which have been cut off during disassembly should be replaced by
new ones during reassembly.
"

Storm³ Service Manual
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1.3 Before operation / after completion of work:
Caution:
• Check all fixings for tight fit.
• Check all parts for correct interlocking.
• Only operate wheelchair with correct tyre pressure (2.5 bar).
• Check electrical components for correct functioning, incorrect polarity of cables
can result in damage to the electronics.
As a last check, always carry out a trial run.

Service Manual Storm³
As at: 07.03.02 Page 9
2 Tool list
You will need a standard tool set with at least the following:
• set of open and ring spanners (6 – 24 mm)
• set of Allen keys (1.5 - 10 mm)
• torque wrench (commercial)
• socket spanner set
• set of screwdrivers (0.5 - 1.6 mm)
• oblique pliers
• flat-nosed pliers
• circlip pliers
• pointed pliers
• cable lug pliers
• wooden or plastic hammer
• tyre repair kit (commercial)
• tyre pressure indicator
• valve removal tool
• wheel bearing puller
• Multimeter with probes and various cable clips
• soldering iron 30 W
• front wheel hub puller (available from INVACARE Service)
• circlip pliers for star lock caps (commercially available, make Tigtemeyer)
• pop riveting tool
• stepped mandrel