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
Page 4 As at:07.03.02
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

Storm³ Service Manual
Page 6 As at:07.03.02
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
Page 8 As at:07.03.02
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

Storm³ Service Manual
Page 10 As at:07.03.02
2.1 Tightening torques and Loctite
The tightening torques stated in the following table are dependent on the thread diameters for
the nuts and bolts for which no special values are determined. All values apply to dry and
grease-free threads.
Thread diameter
Unit M5 M6 M8 M10 M12 M16
Undoing torque Nm 3.4-4.9 5.9-7.8 14-19 25-34 44-61 115-155
Undoing torque mkp 0.35-0.80 0.60-0.80 1.4-1.9 2.6-3.5 4.5-6.2 11.5-16
Spanner width mm 8 10 13 17 19 24
For comparison!
Lever arm on ring
spanner DIN 838
mm 180 190 215 240 265 285
Therefore achievable
torque
Nm 56 63 70 84 101 125
Caution:All other nuts or plastic connectors not noted here must be tightened
FINGERTIGHT!
Caution: Tighten the front wheel on the castor fork fingertight and without play! Apply
micro-encapsulated adhesive to the thread! INVACARE uses VIBRATITE VC3
for this purpose.
Caution: When reassembling the front wheel fork in the head tube, ensure that the
fork is free-moving! The union should be tightened fingertight, and should
not result in stiff movement of the head tube bearing.

Service Manual Storm³
As at: 07.03.02 Page 11
3 Layout of modules, components and displays and controls
The following figures show the layout of "Storm³" modules.
Removal and reassembly of spare parts is described from Chapter 8 onwards.
1 Frame (chassis)
2 Drive unit, disengaging
mechanism, support
wheels
3 Brake (no diagram)
4 Castor wheel (front
wheel)
5 Drive wheel
6 Battery unit
7 Lighting
8 Joystick box
9 Seat unit, seat angle
adjustment, armrests,
side panels
10 Backrest
11 Leg supports
12 Accessories (not
illustrated) kerb
climber, cane holder

Storm³ Service Manual
Page 12 As at:07.03.02
4 Service plan (1x annually)
Component Check Remedy Chapter
: "
Armrests and
side panels • Armrest damage and
fastening
• Side panel damage and
fixing
⇒ Tighten screws, replace
padding
⇒ Tighten screws, replace
side panels
12.3
12.3
Seat unit / seat
angle
adjustment
• Cushion
• Check seat angle
adjustment
⇒ Replace covers /
upholstery
⇒ Replace parts
12
Backrest unit
mechanical
Backrest unit
electrical
• Damage and seams
• Fixings
• check cabling
• Check function
⇒ Replace parts
⇒ Tighten screws
⇒ Replace cable or motor if
necessary
13
13.3
Frame (chassis)
/ battery strap • Check fixings, welded
seams and battery strap ⇒ Tighten screws, replace components
8.1
Wheel
suspension and
wheels
• Check drive wheels for
tight fit and side play
• Check steering wheels for
tight fit, float and side play
• Check castor wheel forks
• Check tyres
⇒ Adjust, replace wheel
hubs
⇒ Replace wheels, wheel
fork or wheel bearings
⇒ Replace
⇒ Fit new
9.16
9.1.10
9.1.1
9.1.5
9.1.3
9.1.9
Drive units,
disengager • Check functions in drive
and push modes
• Check disengager
⇒ Replace motor if
necessary
⇒ Tighten screws / nuts,
adjust or replace if
necessary
8.3
8.4.1
Footrests • Check welded seams,
interlocking, screws,
footplates
⇒ Tighten, replace
15
Electrical
footrests • Check cabling
• Check contacts
• Check functions
⇒ Replace cable if
necessary
14.5.1
Lighting • Check cabling ⇒ Replace bulbs or cables if
necessary
10

Service Manual Storm³
As at: 07.03.02 Page 13
• Check function necessary
Component Check Remedy Chapter
: "
Batteries • Damage to batteries /
strip fuse, contact
corrosion
• Check contacts, terminals
• Check battery voltage
⇒ Replace batteries / strip
fuse Clean contacts
⇒ Tighten, replace
⇒ Charge batteries / replace
9.2.1
9.2.2
-
9.2
Remote /
electronics • Remote,
status display blinking
• Fixing
• Cable, connecting plug
• Joystick function
• Power supply
⇒ Evaluate blinking code
⇒ Tighten, replace
⇒ Replace
⇒ Replace joystick
⇒ Replace cable, connector
plug or console
6
11.1.4
-
11.1.1
11.1.4
Wheelchair • Check all parts for soiling ⇒ Clean seat -

Storm³ Service Manual
Page 14 As at:07.03.02
5 Operational faults
5.1 General
If faults occur in drive mode or power supply proceed as follows:
• First assess the fault causes described in Chapter 5.2.
• Check the status display on the remote and assess the error codes in accordance with
Chapter 6.
• Carry out the necessary testing / repairs. While doing this please note the references to the
appropriate chapter in the manual or to the appropriate documentation.
5.2 Fault causes
Wheelchair will not
start
engage motors
batteries
defective
replace batteries
Delete status display on
remote
pre-charge
batteries
completely
discharge battery
check battery
fuses
check voltage at
remote
power supply
interrupted
check voltage at
batteries
Status display
blinking on
wheelchair
assess error code
error code 1-12
Operating
manual
chapt. 9.2.2
chapt. 6
chapt. 6
chapt. 9.2
Disengaging switch
(right-hand motor)
defective
replace brakes /
motor
chapt. 8.3.2
chapt. 8.4.1
chapt. 8.4.2
chapt. 9.3.1
Drive motors
disengaged
Check plug
connections at
modules 11.4.2

Service Manual Storm³
As at: 07.03.02 Page 15
replace drive unit /
check carbon
brushes
Drive unit
defective
Wheelchair judders in drive mode
chapt. 8.3.2
replace battery
replace charging
device
Batteries defective
Charging device defective
Cannot charge batteries
chapt. 9.3.1
Warning horn defective replace remote
Lighting defective check / replace
cabling or bulbs
chapt.
11.1.4
chapt. 10
Electrical leg support defective check / replace
cabling or motor
Manual backrest adjustment defective
check / replace
gearbox, handwheel,
handwheel shaft,
armature shaft
chapt. 14.5
chapt.
13.1.21
Electrical backrest adjustment defective check / replace
cabling, remote,
motor / check limit
switch
chapt. 13.3
chapt.
13.3.2
Wheelchair runs too slowly
replace contact pins
Contact pins in seat frame defective (legrest
attachment)
Chapt.
11.4.2
Remote defective
Power module defective
Lifter not at bottom (2x blink)
replace remote
replace power
module
lower lifter / reed
sensor defective /
magnet missing
chapt.
11.1.4
chapt.
11.4.2
chapt. 9.2.2
(note)

Storm³ Service Manual
Page 16 As at:07.03.02
6 Joystick box error codes
Before assessing the error codes, carry out the following test:
• Turn the remote on and off several times. Wait approx. 5 seconds before switching on.
The test checks whether the error can be automatically rectified by the electronics, and if
necessary deactivates the blinking status display at the remote. If this is not the case, you can
locate the fault using the blink codes as follows:
• turn the remote on and off
• check which blink code is showing by counting
• wait for the blink code pause (approx. 2-3 seconds)
• re-count the code.
Blink code: Meaning: Immediate measure:
1 x blink Module defective - Replace module
chapt. 11.4.2
2 x blink Accessory error (e.g.
bulb short-circuit)
Lifter raised
Backrest not in driving
position
• Check accessory
connections, check
accessories
• Lower lifter
completely
• Put backrest in
driving position
Check lighting
chapt. 10
-
-
3 x blink Fault in right-hand motor.
Connection
loose/defective or motor
defective
• Check connecting
plugs
Check drive unit /
battery chapt.
8.3.2 / 9.2
4 x blink Fault in left-hand motor.
Connection
loose/defective or motor
defective
• Check connecting
plugs
Check drive unit /
battery chapt.
8.3.2 / 9.2
5 x blink Fault/brake fault on right-
hand motor. Connection
loose/defective or motor
defective
Microswitch defective
• Check connecting
plugs
• Check microswitch
and engaging
mechanism
Check drive unit /
battery chapt.
8.3.2 / 9.2
-
6 x blink Fault/brake fault on left-
hand motor. Connection
loose/defective or motor
defective.
• Check connecting
plugs
Check drive unit /
battery chapt.
8.3.2 / 9.2
7 x blink Completely discharge
battery • Pre-charge battery Check battery
chapt. 9.2
8 x blink Battery voltage too high • Switch light on if
necessary
• Check battery
charger
Check battery
chapt. 9.2
-

Service Manual Storm³
As at: 07.03.02 Page 17
9 or 10 x blink Faulty data transmission
between modules
- Check drive unit /
battery chapt.
8.3.2 / 9.2
11 x blink Motors overloaded /
overheated • Switch remote on
and off / wait if
necessary
-
12 x blink Module used has
compatibility problems • Remove incorrect
module
Check drive unit /
battery chapt.
8.3.2 / 9.3.1
7 Module composition / variations
The Storm³ can be supplied the following options from start of production:
• Batteries (chapt.9.2)
# 70 Ah
• Brake (chapt.8.5)
• Drive wheels / steering wheels (chapt. 9.1.6. 9.1)
# 3.00 - 8 drive wheels (pneumatic, puncture-proof)
# 3.00 - 6 castor wheels (pneumatic, puncture-proof)
• Lighting (chapt. 10)
• Remote and accessories (chapt. 11)
# ACS REM24 SC
# ACS operation for attendant (switchable)
# ACS tray control
# centre joystick swingaway
# chin control
# G80 I
# remote holder height-adjustable / swingaway
• Backrest elements (chapt. 13)
# backrest adjustment manual
# backrest adjustment electrical
• Headrest (chapt. 13.5)
• Legrests/footrests (chapt. 14. 15)

Storm³ Service Manual
Page 18 As at:07.03.02
# vari 90° - 65° (VARI F)
# footrest hanger manually height-adjustable (VARI A)
# footrest hanger with manual height adjustment (ADM)
# footrest hanger with electrical height adjustment (ADE)
# fixed footplates
# angle-adjustable footplates
# angle and depth-adjustable footplates
# footplate
• Kerb climber (chapt. 16.1)
• Cane holder (chapt. 16.2)
Service and repair work
8 Running gear
8.1 Frame (chassis)
POS QTY. ITEM NO./PCS. ITEM DESCRIPTION
1 4 1418533 ANTI-TIP WHEEL KAMA 80 X 30
2 4 F00002 HEXAGON NUT M8 SELF-LOCKING
3 4 D50170 MACHINE SCREW WITH ALLEN KEY HEAD M8 X 50

Service Manual Storm³
As at: 07.03.02 Page 19
4 4 G10103 WASHER 8.4 X 25 X 2
5 4 1419233-0003 HEADED BUSH
6 1 1419341
CHASSIS WITH LIFTER & BATTERY CASE ASSY.
GREEN
6 1 1421681
CHASSIS WITH LIFTER & BATTERY CASE ASSY.
SILVER
6.1 1 1417949-
1101060
CHASSIS GREEN PREASSEMBLED
6.1 1 1417949-9006 CHASSIS SILVER PREASSEMBLED
6.2 1 1418527 LIFTING UNIT PREASSEMBLED
6.3 1 1417955-9005 BATTERY FRAMES PREASSEMBLED
7 4 1419254 ANGULAR BALL BEARING 7202B 2RS
8 1 1422049-9005 FRONT FIXING LH
9 1 1422050-9005 FRONT FIXING RH
10 4 D60178 HEXAGON BOLT M8 X 12
11 4 G00107 WASHER 8.4 X 17 X 1.6
12 1 1421022-9005 TAXI STRAP
13 2 G00117 WASHER 10.5 X 21 X 2
14 2 D00094 HEX BOLT M10 X 50
15 1 1419333 BACK LIGHT SUPPORT LH
15 1 1421815
LIGHT SUPPORT LH WITH LUGGAGE CARRIER
CUTOUT
16 1 1419334 BACK LIGHT SUPPORT RH
16 1 1421814
LIGHT SUPPORT RH WITH LUGGAGE CARRIER
CUTOUT
17 2 1421650-9005 SIDE FIXING
- 4 D90187
CHEESE HEAD SCREW WITH ALLEN KEY HEAD M6
X 20
- 4 G00115 WASHER 6.4 X 12.5 X 1.6
8.1.1 Service work to frame (chassis)
Note:
Repair work to the frame (chassis) is easier to carry out if the complete seat unit has
been dismantled beforehand (see page 56, chapt. 12.1.1).
"