Invacare Mobility Aid Arrow RWD User Manual

Service Manual

3G Storm Series^®

Wheelchairs

Arrow RWD

Torque^™SP RWD

Ranger X^™RWD

DEALER: KEEP THIS MANUAL. THE PROCEDURES

IN THIS MANUAL MUST BE PERFORMED BY A

QUALIFIED TECHNICIAN.

3G Storm Series Wheelchairs

Part No. 1104849

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TABLE OF CONTENTS

NOTE: The information in this owner's manual applies to the ARROW, TORQUE SP, RANGER X,

and the RECLINER wheelchairs except where specified.

SPECIAL NOTES............................................................................... 2

TYPICAL PRODUCT PARAMETERS ................................................... 6

ARROW ..........................................................................................................................................................6

TORQUE SP ..................................................................................................................................................8

RANGER X ................................................................................................................................................. 10

SECTION 1 - GENERAL GUIDELINES............................................... 12

REPAIR OR SERVICE INFORMATION ............................................................................................. 12

OPERATING INFORMATION............................................................................................................. 12

LABEL LOCATION .................................................................................................................................. 15

WARNING/CAUTION LABEL LOCATION ................................................................................... 16

SHIPPING TIE DOWN RESTRAINTS ............................................................................................... 16

SECTION 2 - TROUBLESHOOTING .................................................. 17

FIELD LOAD TEST ................................................................................................................................... 17

MOTOR TESTING ................................................................................................................................... 18

MOTOR BRUSH INSPECTION ........................................................................................................... 18

ELECTRO-MECHANICAL PARKING BRAKE TESTING............................................................ 19

SECTION 3 - HARDWARE TORQUE SPECIFICATIONS...................... 20

STANDARD SEAT FRAME .................................................................................................................... 20

VAN SEAT................................................................................................................................................... 21

ASBA ............................................................................................................................................................. 22

BASE FRAME - CONVENTIONAL MOTOR/GEARBOX ............................................................ 23

BASE FRAME - STANDARD GEARLESS/BRUSHLESS AND

HEAVY DUTY GEARLESS/BRUSHLESS MOTORS ................................................................... 24

SECTION 4 - ARMS ........................................................................ 25

REPLACING VAN SEAT ARMREST PADS....................................................................................... 25

SECTION 5 - UPHOLSTERY/POSITIONING STRAP ........................... 26

REPLACING VAN SEAT POSITIONING STRAP .......................................................................... 26

REPLACING BACK UPHOLSTERY .................................................................................................... 27

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TABLE OF CONTENTS

SECTION 6 - SEAT FRAME ............................................................. 29

PREPARATION FOR REMOVING/INSTALLING SEAT FRAME

(STANDARD FRAME, ASBA AND VAN SEAT)........................................................................ 29

REPLACING SAME SIZE STANDARD SEAT FRAME .................................................................. 31

REMOVING/INSTALLING STANDARD SEAT FRAME SUBASSEMBLY ................................ 31

CHANGING SEAT DEPTH................................................................................................................... 32

CHANGING SEAT WIDTH (STANDARD AND ASBA) ............................................................ 36

INSTALLING/REMOVING ASBA SUBASSEMBLY AND/OR

COMPONENT REPLACEMENT.................................................................................................... 38

INSTALLING/REMOVING VAN SEAT ASSEMBLY ....................................................................... 40

REPLACING VAN SEAT AND/OR VAN SEAT FRAME .............................................................. 40

CONVERTING FROM STANDARD SEAT FRAME TO

ASBA OR VICE VERSA ...................................................................................................................... 41

CONVERTING FROM ASBA TO VAN SEAT OR VICE VERSA ............................................... 42

CONVERTING FROM STANDARD SEAT FRAME TO VAN SEAT OR VICE VERSA...... 43

REMOVING/INSTALLING SEAT PAN .............................................................................................. 43

SEAT ANGLE ADJUSTMENT ............................................................................................................... 45

SECTION 7 - BASE FRAME ............................................................. 46

REPLACING SEAT MOUNTING PLATES ....................................................................................... 46

REPLACING SEAT SUPPORT BRACKETS ...................................................................................... 47

REPLACING SEAT SUPPORT BRACKET T-NUTS ...................................................................... 48

REPLACING BATTERY CHARGER BRACKET AND T-NUT................................................... 49

REMOVING/INSTALLING SEAT STOP SCREWS......................................................................... 50

SECTION 8 - BACK FRAME ............................................................ 51

REMOVING/INSTALLING CJ BACK BRACKETS ......................................................................... 51

CHANGING BACK HEIGHT ............................................................................................................... 53

BACK ANGLE ADJUSTMENT ............................................................................................................. 55

SECTION 9 - BATTERIES................................................................ 56

WARNINGS FOR HANDLING AND REPLACING BATTERIES ............................................. 56

USING THE PROPER BATTERIES ...................................................................................................... 57

INSTALLING/REMOVING BATTERIES INTO/FROM BATTERY BOXES .............................. 59

DISCONNECTING/CONNECTING BATTERY CABLES .......................................................... 60

WHEN TO CHARGE BATTERIES...................................................................................................... 65

CHARGING BATTERIES........................................................................................................................ 65

REPLACING BATTERIES ....................................................................................................................... 69

REMOVING/INSTALLING BATTERY BOXES................................................................................. 71

SECTION 10 - WIRING HARNESS ................................................... 75

REMOVING/INSTALLING THE WIRING HARNESS................................................................... 75

ADJUSTING LIMIT SWITCH................................................................................................................ 79

SECTION 11 - RETENTION STRAP/RETAINER ................................ 81

REPLACING BATTERY BOX RETAINER BAR/RETAINER CLIP ............................................. 81

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TABLE OF CONTENTS

SECTION 12 - WHEELS/MOTORS ..................................................... 83

REPLACING PNEUMATIC TIRES/TUBES - DRIVE WHEELS/CASTERS ............................... 83

REMOVING/INSTALLING DRIVE WHEELS.................................................................................... 83

REMOVING/INSTALLING DRIVE WHEEL HUB ........................................................................... 85

REMOVING/INSTALLING GB MOTOR SPACER ......................................................................... 86

REMOVING/INSTALLING ADPATER PLATE WITH STUDS.................................................... 86

INSTALLING WHEEL LOCK BRACKET ONTO WHEELCHAIR ........................................... 87

REMOVING/INSTALLING THE RIM AND/OR TIRES ................................................................. 88

REMOVING/INSTALLING CASTERS................................................................................................. 89

REPLACING FORKS................................................................................................................................ 90

REMOVING/INSTALLING THE MOTOR......................................................................................... 91

INSTALLING/REMOVING FENDERS ................................................................................................ 96

SECTION 13 - ELECTRONICS ........................................................ 100

REPOSITIONING MKIV JOYSTICK - VAN SEAT MODELS ....................................................100

REMOVING/INSTALLING THE MKIV CONTROLLER .............................................................101

SECTION 14 - RECLINER.............................................................. 109

POSITIONING LIMIT SWITCH.........................................................................................................109

ADJUSTING LIMIT SWITCH..............................................................................................................110

REPLACING RECLINER CABLE ASSEMBLIES..............................................................................111

REPLACING/ADJUSTING GAS CYLINDERS................................................................................113

CHANGING BACK HEIGHT .............................................................................................................114

CHANGING SEAT DEPTH.................................................................................................................116

CHANGING SEAT WIDTH ...............................................................................................................117

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP

RECLINER SEAT FRAME ONTO ARROW OR X BASE FRAME ......................................117

SECTION 15 - RWD WHEELCHAIRS .............................................. 119

REMOVING/INSTALLING GROUP 24 BATTERY BOX SUB-FRAME ..................................119

REMOVING/INSTALLING 22NF BATTERY BOX TRAY ..........................................................121

CONVERTING 22NF BATTERY BOX TRAY TO GROUP 24

BATTERY BOX SUB-FRAME .........................................................................................................121

SHOCK OR RUBBER ELEMENT REPLACEMENT......................................................................124

SHOCK SPRING REPLACEMENT....................................................................................................127

REMOVING/INSTALLING GEARBOX ............................................................................................129

ADJUSTING WEIGHT DISTRIBUTION .........................................................................................130

REPOSITIONING THE MOTOR .......................................................................................................131

REPLACING SUSPENSION ARM FOR WHEELCHAIRS WITH

MOTOR/GEARBOX ASSEMBLY...................................................................................................135

REPLACING THE SUSPENSION ARM FOR WHEELCHAIRS WITH

GEARLESS/BRUSHLESS MOTOR .................................................................................................136

ANTI-TIPPER WHEEL REPLACEMENT .........................................................................................137

REMOVING/INSTALLING THE 3-INCH ANTI-TIP ASSEMBLY.............................................137

LIMITED WARRANTY .................................................................. 139

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TYPICAL PRODUCT PARAMETERS - ARROW

SEAT WIDTH RANGE:

Standard:

Recliner:

12 to 24-inches

14 to 24-inches

SEAT DEPTH RANGE:

Standard:

Recliner:

12 to 24-inches

14 to 24-inches

BACK HEIGHT RANGE:

Standard:

Recliner:

12 to 24-inches

18½ to 26-inches

BACK ANGLE RANGE:

Standard:

Recliner:

80^oto 100^o

90^oto 170^o

SEAT-TO-FLOOR

(approximate)

Standard:

17½-inches

19¾-inches

21-inches

Optional:

OVERALL WIDTH OF BASE:

(w/o joystick)

25-inches

Overall Height:

Standard:

Minimum:

34¼-inches

44¼-inches

Maximum:

Recliner

Low Seat Frame:

Med. Seat Frame:

High Seat Frame:

51½-inches

53¾-inches

55½-inches

OVERALL LENGTH

(without front riggings)

Standard:

29½-inches

32½-inches

Long Frame:

WEIGHT:

GEARLESS/BRUSHLESS MOTOR

W/O GP24 Batteries:

With GP24Batteries:

Shipping (approx.):

174 lbs

278 lbs

214 lbs

4 POLE MOTOR (BEFORE 1/26/04)

Without Batteries:

With Batteries:

162 lbs

266 lbs

202 lbs

Shipping (approx.):

DRIVE AXLE:

ꢀ Non-Recliners ONLY.

ꢀAdjustable

DRIVE WHEELS/TIRES:

(Foam Filled or Pneumatic)

Standard:

14 x 3-inches

14 x 4-inches

Optional (Before 1/26/04):

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TYPICAL PRODUCT PARAMETERS - ARROW

PHYSICAL DIMENSIONS

CASTERS W/PRECISION SEALED BEARINGS

SEMI-PNEUMATIC:

Standard:

Option:

8 X 2¼-inches

6 X 2-inches (w/ shock fork)

PNEUMATIC OR FOAM FILLED:

Standard:

Option:

8 X 2-inches

9 X 2¾-inches

ANTI-TIPPERS (3-INCH WHEELS):

CASTER FORKS:

Standard

Standard, Shock Fork (Optional)

FOOTRESTS:

Telescoping Front Rigging Supports,

Swing-Away (Std), Heavy Duty (Opt.),

2-in. and 4-in. longer Pivot Slide Tube (Opt)

ARMRESTS:

Flip Back, Fixed or Adjustable Height

(Desk and Full Length)

SEAT ANGLE ADJUSTMENT:

SEAT CUSHION:

Adjustable (0^oto 10^o)

Cushion (Optional)

Nylon

CHAIR UPHOLSTERY OPTIONS:

BATTERY REQUIREMENTS:

See chart on page 70

WEIGHT LIMITATIONS:

Arrow with gearless/brushless motor (after 1/25/04)

up to 400 lbs

up to 300 lbs

up to 400 lbs

Arrow with gearless/brushless motor (before 1/26/04)

Arrow with 4 pole motor

PERFORMANCE BEFORE 1/26/04

SPEED

RATING

RANGE

G/B MOTOR

4 POLE MOTOR

N/A

300 lbs

400 lbs

up to 8 mph

N/A

up to 29 miles

up to 19 miles

up to 4.5 mph

PERFORMANCE AFTER 1/25/04

SPEED

RATING

RANGE

G/B MOTOR

4 POLE MOTOR

400 lbs

up to 7 mph

N/A

up to 33 miles

Range will vary with battery conditions, surface, terrain and operators weight.

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TYPICAL PRODUCT PARAMETERS - TORQUE SP

TYPICAL PRODUCT PARAMETERS -

TORQUE SP

SEAT WIDTH RANGE:

Standard:

Recliner:

12 to 22-inches

14 to 22-inches

SEAT DEPTH RANGE:

Standard:

Recliner:

12 to 22-inches

16 to 22-inches

BACK HEIGHT RANGE:

Standard:

Recliner:

12 to 24-inches

18½ to 26-inches

BACK ANGLE RANGE:

Standard:

Recliner:

80^oto 100^o

90^oto 170^o

SEAT-TO-FLOOR

(approximate)

Standard:

17½-inches

19¾-inches or 21-inches

Optional:

OVERALL WIDTH OF BASE (w/o joystick):

25-inches

Overall Height:

Standard:

Minimum:

34¼-inches

44¼-inches

Maximum:

Recliner

Low Seat Frame:

Med. Seat Frame:

High Seat Frame:

51½-inches

53¾-inches

55½-inches

OVERALL LENGTH (without front riggings)

Standard:

Long Frame:

29½-inches

32½-inches

WEIGHT:

MODEL TRUTK (GEARLESS/BRUSHLESS MOTOR)

W/O GP24 Batteries:

With GP24Batteries:

166 lbs

270 lbs

206 lbs

Shipping (approx.):

MODEL 251-300TQ (4 POLE MOTOR)

Without Batteries:

With Batteries:

154 lbs

228 lbs

194 lbs

Shipping (approx.):

MODEL 301-400TQHD (4 POLE MOTOR)

Without Batteries:

With Batteries:

154 lbs

258 lbs

194 lbs

Shipping (approx.):

DRIVE AXLE (NON-RECLINERS ONLY):

Adjustable

DRIVE WHEELS/TIRES:

(Foam Filled or Pneumatic)

Standard:

Optional*:

*Note: Not available on gearless/brushless motors after 1/25/04.

14 X 3-inches

14 X 4-inches

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TYPICAL PRODUCT PARAMETERS - TORQUE SP

TYPICAL PRODUCT PARAMETERS -

TORQUE SP

PHYSICAL DIMENSIONS

CASTERS W/PRECISION SEALED BEARINGS

SEMI-PNEUMATIC:

Standard:

Option:

8 x 1¼-inches

6 x 2-inches (w/ shock fork)

PNEUMATIC OR FOAM FILLED:

Standard:

Option:

8 x 2-inches

9 x 2¾-inches

ANTI-TIPPERS (3-INCH WHEELS):

CASTER FORKS:

Standard

Standard, Shock Fork (Optional)

FOOTRESTS:

Telescoping Front Rigging Supports,

Swing-Away, Heavy Duty,

4-in. long Pivot Slide Tube (Opt)

ARMRESTS:

Flip Back, Fixed or Adjustable Height

(Desk and Full Length)

SEAT ANGLE ADJUSTMENT:

SEAT CUSHION:

Adjustable (0^oto 10^o)

Cushion (Optional)

CHAIR UPHOLSTERY OPTIONS:

Naugahyde and Nylon

BATTERY REQUIREMENTS:

See chart on page 70.

PERFORMANCE BEFORE 1/26/04

SPEED

4 POLE MOTOR

RATING

RANGE

G/B MOTOR

251-300 lbs

(24:1 ratio) up to 4.5 mph

(18:1 ratio) up to 6.5 mph

up to 19

up to 29

up to 19

251-300 lbs

301-350 lbs

up to 8 mph

N/A

up to 4.5 mph

PERFORMANCE AFTER 1/25/04

SPEED

RATING

251-300 lbs

301-400 lbs

RANGE

G/B MOTOR

4 POLE MOTOR

(24:1 ratio) up to 4.5 mph

(18:1 ratio) up to 6.5 mph

up to 19

up to 33

up to 19

up to 7 mph

up to 4.5 mph

Range will vary with battery conditions, surface, terrain and operator’s weight.

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TYPICAL PRODUCT PARAMETERS - RANGER X

TYPICAL PRODUCT PARAMETERS -

RANGER X

SEAT WIDTH RANGE:

Standard:

Recliner:

12 to 22-inches

14 to 22-inches

SEAT DEPTH RANGE:

Standard:

Recliner:

12 to 22-inches

14 to 22-inches

BACK HEIGHT RANGE:

Standard:

Recliner:

12 to 24-inches

18½ to 26-inches

BACK ANGLE RANGE:

Standard:

Recliner:

80^oto 100^o

90^oto 170^o

SEAT-TO-FLOOR

(approximate)

Standard:

17½-inches

19¾-inches

21-inches

Optional:

OVERALL WIDTH OF BASE (w/o joystick):

25-inches

Overall Height:

Standard:

Minimum:

34¼-inches

44¼-inches

Maximum:

Recliner

Low Seat Frame:

Med. Seat Frame:

High Seat Frame:

51½-inches

53¾-inches

55½ inches

OVERALL LENGTH

(without front riggings)

Standard:

29½-inches

32½-inches

Long Frame:

WEIGHT:

GEARLESS/BRUSHLESS MOTOR

W/O GP24 Batteries:

With GP24Batteries:

Shipping (approx.):

174 lbs

278 lbs

214 lbs

4 POLE MOTOR

Without Batteries:

With Batteries:

162 lbs

266 lbs

202 lbs

Shipping (approx.):

DRIVE AXLE:

ꢀ Non-Recliners ONLY.

ꢀAdjustable

DRIVE WHEELS/TIRES:

(Foam Filled or Pneumatic)

Standard:

Optional*:

*Note: Not available on gearless/brushless motors after 1/25/04.

14 X 3-inches

14 X 4-inches

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TYPICAL PRODUCT PARAMETERS - RANGER X

TYPICAL PRODUCT PARAMETERS -

RANGER X

PHYSICAL DIMENSIONS

CASTERS W/PRECISION SEALED BEARINGS

SEMI-PNEUMATIC:

Standard:

Option:

8 X 2-1/4-inches

6 X 2-inches (w/ shock fork)

PNEUMATIC OR FOAM FILLED:

Standard:

Option:

8 X 2-inches

9 X 2-3/4-inches

ANTI-TIPPERS (3-INCH WHEELS):

CASTER FORKS:

Standard

Standard, Shock Fork (Optional)

FOOTRESTS:

Telescoping Front Rigging Supports,

Swing-Away (Std.), Heavy Duty (Opt.),

4-in. longer Pivot Slide Tube (Opt.)

ARMRESTS:

Flip Back, Fixed or Adjustable Height

(Desk and Full Length)

SEAT ANGLE ADJUSTMENT:

SEAT CUSHION:

Adjustable (0^oto 10^o)

Cushion (Optional)

Naugahyde and Nylon

Group 24

CHAIR UPHOLSTERY OPTIONS:

BATTERY REQUIREMENTS:

WEIGHT LIMITATIONS:

up to 300 lbs

PERFORMANCE BEFORE 1/26/04

SPEED

RATING

RANGE

G/B MOTOR

300 lbs

4 POLE MOTOR

up to 6.5 mph

up to 19

up to 29

up to 8 mph

PERFORMANCE AFTER 1/25/04

SPEED

RATING

G/B MOTOR

300 lbs

RANGE

4 POLE MOTOR

up to 6.5 mph

up to 19

up to 33

400 lbs

up to 7 mph

Range will vary with battery conditions, surface, terrain and operators weight.

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SECTION 1

GENERAL GUIDELINES

This Section Includes the Following:

Repair or Service Information

Operating Information

Label Location

Warning/Caution Label Location

Shipping Tie Down Restraints

REPAIR OR SERVICE INFORMATION

Setup of the Electronic Control Unit is to be performed ONLY by individuals

certified by Invacare. The final tuning adjustments of the controller may

affect other activities of the wheelchair. Damage to the equipment could

occur under these circumstances. If non-certified individuals perform any

work on these units, the Limited Warranty is void.

OPERATING INFORMATION

GENERAL WARNINGS

Professionals of the healthcare field or other persons should only make

performance adjustments fully conversant with this process and the

wheelchair operator’s capabilities. Incorrect settings could cause injury to

the driver, bystanders, damage to the chair and to surrounding property.

After the wheelchair has been set up/adjusted, check to make sure that the

wheelchair performs to the specifications entered during the setup

procedure. If the wheelchair does NOT perform to specifications, turn the

wheelchair OFF immediately and reenter setup specifications. Repeat this

procedure until the wheelchair performs to specifications.

DO NOT leave the power button ON when entering or exiting your

wheelchair.

Avoid storage or use near external flames or combustible products.

ELECTRICAL

Grounding Instructions:

DO NOT, under any circumstances, cut or remove the round grounding

prong from any plug used with or for Invacare products. Some devices are

equipped with three-prong (grounding) plugs for protection against

possible shock hazards. Where a two-prong wall receptacle is encountered,

it is the personal responsibility and obligation of the customer to contact a

qualified electrician and have the two-prong receptacle replaced with a

properly grounded three-prong wall receptacle in accordance with the

National Electrical Code. If you must use an extension cord, use ONLY a

three-wire extension cord having the same or higher electrical rating as the

device being connected. In addition, Invacare has placed RED/ORANGE

WARNING TAGS on some equipment. DO NOT remove these tags.

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SECTION 1

GENERAL GUIDELINES

BATTERIES

The warranty and performance specifications contained in this manual are

based on the use of deep cycle gel cell batteries. Invacare strongly

recommends their use as the power source for this unit.

Carefully read battery/battery charger information prior to installing,

servicing or operating your wheelchair.

RAIN TEST

INVACARE has tested its power wheelchairs in accordance with ISO 7176

“Rain Test”. This provides the end user or his/her attendant sufficient time

to remove his/her power wheelchair from a rain storm and retain

wheelchair operation.

CAUTION

Failure to follow these instructions will void your limited warranty.

Do determine and establish your particular safety limits by practicing

bending, reaching and transferring activities in the presence of a qualified

healthcare professional BEFORE attempting active use of the wheelchair.

DO NOT attempt to reach objects if you have to move forward in your

seat.

DO NOT attempt to reach objects if you have pick them up from the floor

by reaching between your knees.

DO NOT lean over the top of the back upholstery to reach objects from

behind, as this may cause the wheelchair and/or seating system (if any) to

tip over.

DO NOT shift your weight or sitting position toward the direction you are

reaching as the wheelchair and/or seating system (if any) may tip over.

DO NOT use and escalator to move a wheelchair between floors. Serious

bodily injury may occur.

CAUTION

Wheel Locks are NOT brakes. DO NOT attempt to stop a moving

wheelchair with the wheel locks.

DO NOT service or adjust your wheelchair while occupied, unless

otherwise noted.

DO NOT operate on roads, streets or highways.

DO NOT climb, go up or down ramps or traverse slopes greater than 9°.

DO NOT attempt to move up or down an incline that has a water, ice or oil

film.

DO NOT use with broken or missing joystick knob.

DO NOT use if joystick does not spring back to the neutral position or

becomes sticky or sluggish.

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SECTION 1

GENERAL GUIDELINES

CAUTION

For safe product function, material compatibility, proper installation,

operation and maintenance, you must only use parts, accessories and

adapters manufactured or supplied by Invacare. DO NOT use any other

parts, accessories, or adapters. Otherwise, the warranty is void.

DO NOT stand on the frame of the wheelchair.

DO NOT use the footplates as a platform. When getting in or out of the

wheelchair, make sure that the footplates are in the upward position or

swing footplates toward the outside of the wheelchair.

DO NOT attempt to drive over curbs or obstacles, unless your wheelchair

has a climbing feature. Doing so may cause your wheelchair to turn over

and cause bodily harm or damage to the chair.

WARNING

Never leave an unoccupied wheelchair unattended at any time, especially

on an incline.

DO NOT attempt to lift the wheelchair by any removable (detachable)

parts. Lifting by means of any removable (detachable) parts of a wheelchair

may result in injury to the user or damage to the wheelchair.

DO NOT overtighten hardware attaching to the frame. This could cause

damage to the frame tubing.

ALWAYS DO keep hands and fingers clear of moving parts to avoid injury.

ALWAYS DO wear your seat positioning strap.

ALWAYS DO check foam grips for looseness before using the wheelchair.

If loose, contact a qualified technician for instructions.

ALWAYS DO engage both wheel locks AND reduce the gap distance

BEFORE transferring to and from the wheelchair. Turn all casters toward

the object you are transferring onto.

WEIGHT TRAINING WARNING

Invacare DOES NOT recommend the use of its wheelchairs and seating

systems as a apparatus for weight training. Invacare wheelchairs and seating

systems have NOT been designed or tested as a seat for any kind of weight

training. If you use the wheelchair or seating system for weight training,

INVACARE SHALL NOT BE LIABLE FOR BODILY INJURY AND THE

LIMITED WARRANTY IS VOID.

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GENERAL GUIDELINES

TIRE PRESSURE WARNING

SECTION 1

The recommended tire pressure is listed on the side wall of each tire. DO

NOT use your wheelchair unless it has the proper tire pressure. (P.S.I.).

DO NOT overinflate the tires. A qualified technician MUST perform

replacement of a pneumatic tire or tube. Failure to follow these warnings

may cause the tire to explode and cause bodily harm.

CAUTION: WEIGHT LIMITATION

Please refer to TYPICAL PRODUCT PARAMETERS to determine the

weight limit (total combined weight of user and any attachments) of your

wheelchair model. Do not exceed the limit- otherwise, injury or damage

may result.

LABEL LOCATION

LABEL USED BEFORE 2/13/2001

NOTE: These caution labels are only found on battery boxes used with the gearless/brushless

motor.

GROUP 24

BATTERIES

22NF BATTERIES

LABEL USED AFTER 2/13/2001

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SECTION 1

GENERAL GUIDELINES

WARNING/CAUTION LABEL LOCATION

SUSPENSION ARM

USED

WITH

CONVENTIONAL

MOTOR/GEARBOX

ASSEMBLY

SUSPENSION ARM

USED

NOTE: WARNING LABEL also

WITH GEARLESS/

found on side frame near the

rear of the chair.

BRUSHLESS MOTOR

MUST

1070497

SHIPPING TIE DOWN RESTRAINTS

Invacare recommends that wheelchair users NOT be transported in

vehicles of any kind while in wheelchairs. As of this date, the Department of

Transportation has not approved any tie-down systems for transportation

of a user while in a wheelchair, in a moving vehicle of any type.

Frame end cap can only be used as a shipping tie-down point for an

UNOCCUPIED wheelchair.

FRONT OF

WHEELCHAIR

REAR OF

WHEELCHAIR

Frame

End

Caps

Base Frame

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TROUBLESHOOTING

SECTION 2

This Section Includes the Following:

Field Load Test

Motor Testing

Motor Brush Inspection

Electro-Mechanical Parking Brake Testing

FIELD LOAD TEST (FIGURE 1)

NOTE: The following test can also be performed through the controller of the wheelchair along

with a remote programmer. Refer to the ELECTRONICS MANUAL supplied with each wheel-

chair.

Old batteries lose their ability to store and release power, due to increased internal

resistance. This means that as you try to take power from the battery, some of that

power is used up in the process of passing through the battery, resulting in less voltage

at the posts. The more power drawn, the lower the voltage available. When this lost

voltage drops the output 1.0 volts under load (2.0 for a pair), replace the batteries.

Testing under load is the only way to spot this problem. While special battery load

testing equipment is available, it is costly and difficult to transport.

Use a digital voltmeter to check battery charge level at the charger connector. It is located

on the base of the wheelchair frame.

Battery Charger

Connector

(-)

NOTE: READ the instructions CAREFULLY

before using the digital voltmeter.

(+)

NOTE: Invacare recommends that ONLY

qualified service personnel perform this test.

1. Ensure that power is OFF.

2. Make sure battery is fully charged. An

Digital Voltmeter

extremely discharged battery will exhibit

FIGURE 1 - FIELD LOAD TEST

the same symptoms as a bad one.

3. Remove the footrests from the wheelchair and place the CASTERS of the wheelchair

against a wall, workbench or other stationary object.

4. Place the voltmeter leads into the charger plug on the wheelchair. Most digital voltmeters

are not affected by polarity, however, analog meters (meters with swinging needles) can be

and should be used carefully. A good meter reading should be 25.5 to 26 VDC.

5. Have two (2) individuals (one [1] on each arm) apply as much downward pressure as

possible on the arms of the wheelchair.

6. Turn the wheelchair ON and push the joystick forward, trying to drive the wheelchair

through the stationary object. This puts a heavy load on the batteries as they try to

push through the stationary object. Read the meter while the motors are straining to

determine the voltage under load.

NOTE: If the voltage drops to less than 23.5 volts from a pair of fully charged batteries while

under load, they should be replaced regardless of the unloaded voltages.

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SECTION 2

TROUBLESHOOTING

MOTOR TESTING (FIGURE 2)

NOTE: This procedure should only be

performed on wheelchairs with the

conventional motor/gearbox assembly. For

gearless/brushless motors, there are no

serviceable parts. Return motor to

manufacturer for testing.

1. On the 4-pin motor connector, locate

the two (2) contacts in the red and

black housings.

2. Set the digital multimeter to measure

ohms (Ω).

3. Measure the resistance between the

two (2) motor contacts.

Ohmmeter

NOTE: A normal reading is between 1 and 5

ohms (Ω). A reading of 0 ohms (Ω) or in

excess of 15 ohms (Ω) indicates a problem.

High readings are generally caused by bad

connections and/or damaged brushes. Contact

authorized dealer or Invacare.

Motor Connector

FIGURE 2 - MOTOR TESTING

MOTOR BRUSH INSPECTION (FIGURE 3)

NOTE: This procedure should only be performed on wheelchairs with conventional motor/

gearbox assembly.

There are two (2) contact brushes on

Cap

STORM motors located under the brush

caps on the motor housing. If these caps

are hard to remove they are either

Motor

overtightened or the motor has become

very hot. Let motors cool. If caps still

cannot be removed, it is recommended

that the motor be sent to Invacare

4 Pin Motor Connector

Technical Services for inspection/repair.

FIGURE 3 - MOTOR BRUSH

INSPECTION

NOTE: It is very important to note which way

the brush comes out of the motor. The brush

MUST be placed into the motor exactly the

same way to ensure good contact with the

commutator.

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TROUBLESHOOTING

SECTION 2

Once the motor brush caps have been removed, pull the brushes out of the motor. The

end of the brushes should be smooth and shiny and the spring should not be damaged or

discolored. If one or both of the brushes are damaged, only the damaged or worn

brushes need be replaced. It is very important that any time a brush is replaced, it must

be “burned in”. This is accomplished by running the motor for one hour in each

direction with a half hour break in-between. This should also be done with little or no

load on the motor, i.e., put the wheelchair up on blocks so the drive (large) wheels do

not contact the ground and run the wheelchair. A motor with only one brush replaced

will only carry a small percentage of its rated load capacity until the NEW brush is

burned in.

ELECTRO-MECHANICAL PARKING BRAKE TESTING

(FIGURE 4)

NOTE: This procedure should only be performed on wheelchairs with conventional motor/

gearbox assembly.

1. On the four-pin motor connector, locate the side by side connectors in the black

housings.

2. Set the digital multimeter to read ohms (Ω).

3. Measure the resistance between the two (2) brake contacts. A normal reading is 100

ohms (Ω). A reading of 0 ohms (Ω) or a very high reading; i.e., MEG ohms or O.L.

(out of limit) indicates a shorted brake or an open connection respectively. If either

condition exists, send the motor to Invacare Technical Service for inspection/repair.

CAUTION

A shorted electro-mechanical brake

will damage the brake output section

in the controller. DO NOT connect a

shorted electro-mechanical brake to

a good controller module. A shorted

4 Pin Motor Connector

brake MUST be replaced.

Ohmmeter

NOTE: A bad motor can damage the

controller module but a bad controller will

NOT damage a motor.

FIGURE 4 - ELECTRO-

MECHANICAL PARKING BRAKE

TESTING

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 3

HARDWARE TORQUE SPECIFICATIONS

STANDARD SEAT FRAME

*Torque to

60 in-lbs

*Loctite and

Torque to

75 in-lbs

*Loctite^®and

Torque to

75 in-lbs

Torque to

156 in-lbs

**Torque to

156 in-lbs

**Torque to

156 in-lbs

NOTE:

* These torque specifications also apply to the ASBA assembly.

** These torque specifications also apply to the van seat and ASBA assemblies.

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HARDWARE TORQUE SPECIFICATIONS

SECTION 3

HARDWARE TORQUE SPECIFICATIONS

*VAN SEAT

Loctite and Torque to

75 in-lbs

Torque to

156 in-lbs

Torque to

156 in-lbs

* NOTE: For additional torque specifications, refer to the torque specifications drawing for the

standard seat frame assembly.

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SECTION 3

HARDWARE TORQUE SPECIFICATIONS

*ASBA

(ADJUSTABLE SEAT BACK ANGLE)

Torque to

156 in-lbs

Torque to

156 in-lbs

Torque to

75 in-lbs

Torque to

156 in-lbs

Torque to

156 in-lbs

* NOTE: For additional torque specifications, refer to the torque specifications drawing for the

standard seat frame assembly.

3G Storm Series Wheelchairs

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HARDWARE TORQUE SPECIFICATIONS

SECTION 3

HARDWARE TORQUE SPECIFICATIONS

BASE FRAME - CONVENTIONAL MOTOR/GEARBOX

Torque to

Loctite and torque to

156 in-lbs

Torque to

85 ft-lbs

REAR OF

WHEELCHAIR

Loctite and

Torque to

156 in-lbs

Torque to

156 in-lbs

(Torque to

156 in-lbs

and back

FRONT OF

WHEELCHAIR

off 1/4 turn)

Loctite and torque

to 75 in-lbs

8-inch Wheels -

Torque to 120 in-lbs

9-inch Wheels -

Torque to 156 in-lbs

Wheel Halves -

Torque to 156 in-lbs

Torque to

156 in-lbs

Wheel Halves

8-inch - Torque to 18 in-lbs

9-inch - Torque to 156 in-lbs

Torque to

540 in-lbs

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SECTION 3

HARDWARE TORQUE SPECIFICATIONS

BASE FRAME - STANDARD GEARLESS/BRUSHLESS MOTOR

(FOR WHEELCHAIRS BUILT BEFORE 1/26/04)

NOTE: All torque specifications called out for the conventional motor/gearbox assembly are

applicable to the gearless/brushless motor except for the specs called out below.

Adjustment

Screw

Torque

to 75 in-lbs

Torque to 13 ft-lbs

Torque to 25 in-lbs

Torque to 13 ft-lbs

BASE FRAME - HEAVY DUTY GEARLESS/BRUSHLESS MOTOR

Torque to 13 ft-lbs

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ARMS

SECTION 4

This Section Includes the Following:

Replacing Van Seat Armrest Pads

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that

all attaching hardware is tightened securely - otherwise injury or damage

may result.

REPLACING VAN SEAT ARMREST PADS (FIGURE 1)

1. Remove the locknut and washer from the outside of the armrest pad.

2. Remove the mounting screw securing the armrest pad to the armrest post.

3. Position the new armrest pad so the mounting holes align with the armrest post

mounting holes.

4. Secure the armrest pad to the armrest post with the mounting screw, washer and

locknut removed in steps 1-2.

NOTE: The mounting screw should be installed fromt he inside of the wheelchair frame.

Armrest Pad

Armrest Pad Mounting Hole

Mounting Screw

Locknut

Armrest Post

Mounting Hole

Washer

Armrest Post

FIGURE 1 - REPLACING VAN SEAT ARMREST PADS

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Part No. 1104849

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SECTION 5

UPHOLSTERY/POSITIONING STRAP

This Section Includes the Following:

Replacing Van Seat Positioning Strap

Replacing Back Upholstery

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that

all attaching hardware is tightened securely - otherwise injury or damage

may result.

REPLACING VAN SEAT POSITIONING STRAP

(FIGURE 1)

1. Remove the van style seat from the van seat frame. Refer to INSTALLING/REMOVING

VAN SEAT ASSEMBLY in SECTION 6 of this manual.

2. Remove the two (2) rear mounting screws, washers, and locknuts that secure the

seat positioning straps to the van seat frame.

NOTE: The washer is positioned between the seat positioning strap and the mounting screw.

3. Secure the NEW seat positioning strap halves with the mounting screws, washers

and locknuts to the van seat frame and torque to 75 in-lbs.

4. Reinstall the van style seat to the van seat frame. Refer to INSTALLING/REMOVING

VAN SEAT ASSEMBLY in SECTION 6 of this manual.

Van Seat Frame

Seat Positioning

Strap

REAR OF SEAT

FRAME

Mounting

Screw

Locknuts

Washer

FRONT OF

SEAT FRAME

FIGURE 1 - REPLACING VAN SEAT POSITIONING STRAP

3G Storm Series Wheelchairs

Part No. 1104849

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UPHOLSTERY/POSITIONING STRAP

SECTION 5

REPLACING BACK UPHOLSTERY (FIGURE 2)

1. Remove one (1) armrest from the wheelchair. Refer to INSTALLING/REMOVING

FLIP BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782

or 1123757.

2. If applicable, remove the two (2) mounting screws and locknuts that secure the

spreader bar to the back canes.

3. Remove the two (2) mounting screws and washers that secure the existing back

upholstery to the back canes.

4. Cut the tie-wraps that secure the bottom of the existing back upholstery to the back

canes.

NOTE: Note the back angle before disassembly for proper reinstallation.

5. On the side of the wheelchair that the armrest was removed, remove one (1) of the

mounting screws, washer, spacer, and locknut that secures the back cane to the seat

frame.

NOTE: To avoid losing the insert in each back cane, thread the mounting screw just removed

through the cane from the inside of the wheelchair to hold the insert in place.

6. Remove the other mounting screw, washer, spacer, and locknut that secures the

back cane to the seat frame.

7. Slide the back cane out of the spreader bar (if applicable) and the existing back

upholstery.

8. Remove other armrest from the chair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

9. Repeat STEPS 5-7 for the opposite side of the wheelchair.

10. Slide the other back cane out of the spreader bar (if applicable) and the existing back

upholstery.

11. Slide one (1) back cane into NEW back upholstery and through spreader bar (if

applicable).

12. Secure back cane to the seat frame from the outside of the wheelchair with the

existing two (2) mounting screws, washers, spacers, and locknuts. Use Loctite 242

and torque to 75 in-lbs.

13. Repeat STEPS 11-12 for opposite back cane.

14. Secure the top of the new back upholstery to the back canes with the two (2) existing

mounting screws.

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SECTION 5

UPHOLSTERY/POSITIONING STRAP

NOTE: When replacing the back upholstery, back assembly or changing back height, follow these

guidelines for spreader bar height:

STANDARD MODELS

BACK HEIGHT

16-inches*

17-inches*

18-19-inches*

20-24-inches

◆ SPREADER BAR HEIGHT

5-inches

7-inches

NOTE: Spreader Bar required on ALL back heights between 20-24-inches. *Spreader bar required

on back heights 16,17,18, or 19 ONLY if the width or depth of the chair exceeds 19-inches.

◆ Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp.

HEAVY DUTY MODELS

BACK HEIGHT

16-17-inches

18-24-inches

◆ SPREADER BAR HEIGHT

5-inches

7-inches

NOTE: Spreader bar required on all back heights.

◆Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp.

15. If applicable, reposition the spreader bar at the correct height for the corresponding

back height and torque the mounting hardware to 60 in-lbs.

16. Reinstall the armrest onto the wheelchair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

Locknuts

Back Cane

Spacers

Mounting

Screw

Locknut

Washer

Spreader

Bar

Back

Upholstery

Insert

Mounting

Screw

Torque

to 60 in-lbs

Mounting Screws

Torque to 75 in-lbs

Washers

FIGURE 2 - REPLACING BACK UPHOLSTERY

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SEAT FRAME

SECTION 6

This Section Includes the Following:

Preparation for Removing/Installing Seat Frame (Standard Frame,

ASBA, and Van Seat)

Replacing Same Size Standard Seat Frame

Removing/Installing Standard Seat Frame Subassembly

Changing Seat Depth

Changing Seat Width (Standard and ASBA)

Installing/Removing ASBA Subassembly and/or Component Replacement

Installing/Removing Van Seat Assembly

Replacing Van Seat and/or Van Seat Frame

Converting From Standard Seat Frame to ASBA or Vice Versa

Converting From ASBA to Van Seat or Vice Versa

Converting From Standard Seat Frame to Van Seat or Vice Versa

Removing/Installing Seat Pan

Seat Angle Adjustment

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that

all attaching hardware is tightened securely - otherwise injury or damage

may result.

NOTE: The procedures in this section of the manual refer to NON-RECLINER seat frames only,

EXCEPT Seat Angle Adjustment. For recliner seat frames, refer to SECTION 14 of this manual.

PREPARATION FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ASBA, AND VAN SEAT)

(FIGURE 1)

NOTE: When installing/replacing components of the wheelchair, refer to the individual procedure

for correct use of LOCTITE 242 and torque specifications or SECTION 3 of this manual.

NOTE: To reinstall these components, reverse the following steps.

1. Remove footrest assemblies. Refer to INSTALLING/REMOVING FOOTRESTS in

SECTION 3 of the Owner’s Manual, part number 1104782 or 1123757.

2. Remove battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

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SECTION 6

SEAT FRAME

3. Cut tie wraps and disconnect joystick from controller.

4. Turn the lever on the adjustment lock

to release the adjustment lock from

the joystick mounting tube.

Adjustment Lock

Lever for Joystick

(STEP 4)

Back Upholstery

(STEP 10)

5. Remove the joystick from the

wheelchair.

Flip Back Armrests

(STEP 6A)

Battery

Boxes

(STEP 2)

6. Perform one (1) of the following:

Footrest

Location

(STEP 1)

A. STANDARD OR

ASBA - Remove the flip-back

armrests from the wheelchair.

Refer to INSTALLING/REMOVING

FLIP BACK ARMRESTS in

SECTION 4 of the Owner’s

Manual, part number 1104782 or

1123757.

Joystick

(STEPS

3,5)

B. VAN SEAT - Remove the mount-

ing screw that secures the armrest

to the van seat frame. Repeat for

opposite side.

7. For standard and ASBA, remove the

seat pan (including seat positioning

straps). Refer to REMOVING/IN-

STALLING SEAT PAN in this section

of the manual.

Seat Pan

(Step 7)

Seat Positioning

Strap (STEP 7)

Controller, Left/Right Motor

Connectors (STEPS 8,9)

8. Disconnect battery and left/right motor

connectors from the controller. Refer

to REMOVING/INSTALLING WIRING

HARNESS in SECTION 10 of this

manual.

Height

Adjustment

Holes

9. Remove tie-wraps that secures the

wiring harness to the seat frame and

the charger cable from its mounting

bracket. Refer to REMOVING/

Van Seat

Base

Socket Screw

INSTALLING WIRING HARNESS in

SECTION 10 of this manual.

10. For standard and ASBA, remove the

back upholstery (including back canes

and spreader bar, if applicable). Refer

to REPLACING BACK UPHOLSTERY

in SECTION 5 of this manual.

FIGURE 1 - PREPARATION FOR

REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME,

ADJUSTABLE FRAME, AND VAN

SEAT)

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SEAT FRAME

SECTION 6

REPLACING SAME SIZE STANDARD SEAT FRAME

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in this section of the

manual.

2. Remove the existing standard seat frame subassembly and install the NEW standard

frame. Refer to REMOVING/INSTALLING STANDARD SEAT FRAME SUBASSEMBLY

in this section of the manual.

3. FOR 12 TO 15-INCH SEAT DEPTHS ONLY: Remove the CJ back brackets

from the existing standard seat frame and install onto the NEW standard seat frame.

Refer to REMOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this

manual.

4. Reinstall the components previously

removed in STEP 1. Perform the

Mounting Screws

(Torque to

156 in-lbs)

Mounting Screws

(Torque to

156 in-lbs)

instructions outlined in PREPARATION

FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME,

ADJUSTABLE FRAME, AND VAN

SEAT) in this section of the manual.

REMOVING/INSTALLING

STANDARD SEAT FRAME

SUBASSEMBLY (FIGURE 2)

Spacer

(16-inch

Wide Only)

Standard

Seat

Assembly

REMOVING

1. Remove the four (4) mounting screws,

locknuts and spacers, if applicable, that

secure the standard seat frame subassembly

to the seat mounting plates.

Spacer

(16-inch

Wide Only)

Seat

Mounting

Plate

2. Remove the existing standard seat frame.

INSTALLING

1. Position NEW standard seat frame

subassembly on seat mount plates.

2. Secure NEW standard seat frame

subassembly onto seat mounting plates

with the existing four (4) mounting

screws, locknuts and spacers, if

Locknuts

applicable. Torque to 156 in-lbs.

Base Frame

FIGURE 2 - REMOVING/

INSTALLING STANDARD SEAT

FRAME SUBASSEMBLY

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SECTION 6

SEAT FRAME

CHANGING SEAT DEPTH

STANDARD SEAT FRAME

NOTE: Review the chart below. This will determine the components needed to obtain the

desired seat depth.

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

1. Find current seat depth in left

hand column in the chart.

SEAT FRAME COMPONENTS

CJ BACK

BRACKETS

SEAT

FRAME

DEPTH

2. Follow that row to right under

seat frame components.

SEAT

DEPTH REQUIRED

SEAT

PAN

3. Verify and note the

components of the current seat

depth.

12-inches

15-inches

YES

17-inch

16-inch deep

16-inches

17-inches

18-inches

19-inches

20-inches

21-inches

22-inches

16-inch

17-inch

18-inch

19-inch

20-inch

21-inch

22-inch

16-inch deep

18-inch deep

20-inch deep

22-inch deep

4. Repeat STEPS 1-3 for your

desired seat depth.

5. Compare existing components

of the current seat depth and

the required components for

the desired seat depth.

6. Perform one (1) of the following:

A. If the current seat depth and

the desired seat depth is within the 12 to 15-inch seat depth range, this change

can be accomplished by repositioning the back canes on the CJ back brackets.

Refer to CHANGING SEAT DEPTH BETWEEN 12 AND15-INCHES in this

section of the manual.

B. If the desired change only requires a NEW seat pan, refer to REMOVING/

INSTALLING SEAT PAN in this section of the manual.

C. For all other seat depth changes, perform the following:

ꢀ

PREPARATION FOR REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ASBA, AND VAN SEAT) in this section of the manual.

Perform one (1), two (2), or all three (3) of the procedures listed below depending

on the components required for the desired seat depth determined from STEPS 1-5:

ꢀ

REMOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this

manual.

ꢀ

REMOVING/INSTALLING STANDARD SEAT SUBASSEMBLY in this

section of the manual.

ꢀ

REMOVING/INSTALLING SEAT PAN in this section of the manual.

After completing the procedure(s) listed above, perform the steps outlined in

PREPARATION FOR REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ADJUSTABLE FRAME, AND VAN SEAT) to complete the desired seat

depth change.

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SEAT FRAME

SECTION 6

ASBA (FIGURE 3)

NOTE: Review the chart below. This will determine the components needed to obtain your

desired seat depth.

COMPONENT IDENTIFICATION TABLE

FOR STANDARD SEAT FRAME

1. Find current seat depth in left

hand column in the chart.

SEAT FRAME COMPONENTS

CJ BACK

2. Follow that row to right under

seat frame components.

SEAT BRACKETS SEAT

DEPTH REQUIRED PAN

SIDE CENTER

FRAME FRAME

3. Verify and note the components

of the current seat depth.

12-inches

15-inches

YES

17-inch

Short

4. Repeat STEPS 1-3 for the

desired seat depth.

16-inches

17-inches

18-inches

19-inches

20-inches

21-inches

22-inches

16-inch

17-inch

Short

Long

5. Compare existing components

of the current seat depth and

the required components for

the desired seat depth.

18-inch Medium

19-inch Medium

20-inch

21-inch

Long

To adjust the depth of the seat on

the wheelchair, use the following

guidelines:

22-inch X-Long

NOTE: Note the four (4) different lengths of side frames

short, medium, long, and X-long, as well as the two different

center frames, short and long. These components are

interchanged to obtain the various different seat depths.

If the current seat depth is and the

desired seat depth are within the 12

to 15-inch seat depth range, this

change can be accomplished by

repositioning the back canes on the

CJ back brackets. Refer to CHANGING SEAT DEPTH BETWEEN 12 AND15-INCHES in

this section of the manual.

If the desired change only requires a new seat pan, refer to REMOVING/INSTALLING

SEAT PAN in this section of the manual.

If the desired change requires the removal/installation of CJ back brackets, refer to

REMOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this manual.

If the desired change requires a new side frame, and/or new center frame, perform the

following steps:

A. Perform the instructions outlined in SEAT FRAME REMOVING/INSTALLING

PREPARATION FOR STANDARD FRAME, ASBA, AND VAN SEAT in this

section of the manual.

NOTE: Note the mounting hole position of side frame for proper installation of NEW side frame.

B. Remove the two (2) mounting screws, coved washers, spacers, and locknuts that

secure the side frame to the center frame.

C. Remove the side frame from the center frame.

D. Repeat STEPS A and B for opposite side frame.

NOTE: If the desired seat depth requires a new center frame, determined in STEPS 1-5

perform STEPS E - G, otherwise proceed to STEP H.

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SECTION 6

SEAT FRAME

E. Remove the four (4) mounting screws that secure the EXISTING center frame to

support brackets.

F. Remove existing center frame from seat mount plates.

G. Secure NEW center frame to support brackets with the existing four (4) mounting

screws and locknuts. Torque to 156 in-lbs.

H. Secure NEW side frame to the center frame at the position noted previously.

Torque to 75 in-lbs.

NOTE: If seat width adjustment is also desired, refer to CHANGING SEAT WIDTH in this

section of the manual for mounting hole locations and allowable seat width/seat depth

combinations.

Mounting Screws

(Torque to

156 in-lbs)

Mounting Screws

(Torque to

75 in-lbs)

Side

Frame

Coved

Washers

Spacers

Locknuts

Side Frame

Center

Frame

Support

Brackets

FIGURE 3- CHANGING SEAT DEPTH - ASBA

3G Storm Series Wheelchairs

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SEAT FRAME

SECTION 6

CHANGING SEAT DEPTH BETWEEN 12 AND 15-INCHES

(FIGURE 4)

NOTE: There are two (2) sizes of CJ back brackets. Refer to the following chart to determine if

the seat depth required is obtainable by repositioning the back canes only, or if the CJ back

brackets must be replaced.

CJ BACK BRACKET (SEAT DEPTH) RANGES

12 and 13-inches

14 and 15-inches

If seat depth required is within seat depth range of the original CJ back brackets, only

the back canes need to be repositioned. Refer to the following procedure.

If the seat depth required is NOT within the seat depth range of the original CJ back

brackets, the CJ back brackets must be replaced before repositioning the back canes.

Refer to REMOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this manual.

1. Remove the armrests from the wheelchair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

2. Cut the tie wraps that secure the back upholstery to the CJ back brackets.

3. Pull the bottom of the back upholstery away from the rear of the seat pan.

4. Remove mounting screw, washer and coved washer from the top mounting hole of

the CJ back bracket and back cane.

NOTE: Before removing the back canes from the CJ back brackets, note the BACK ANGLE for

reinstallation.

NOTE: To avoid losing the insert in each back cane, line up the holes in the insert with the holes

in the back cane and start one of the screws through the cane from the inside of the wheelchair

to hold the insert in place.

5. Remove the mounting screw, washer and coved washer from the bottom mounting

hole of the CJ back bracket and the back cane.

6. Reposition the back cane to the desired

seat depth and angle. If changing the back

angle as well, refer to BACK ANGLE

ADJUSTMENT in SECTION 8 of this

manual.

Back Cane

Coved

Washers

CJ Back

Bracket

Threaded

Insert

7. Secure bottom of the back

upholstery to the seat pan.

8. Secure the bottom of the back

upholstery to the CJ back brackets

with new tie wraps.

Seat

Frame

9. Use Loctite 242 and torque the

mounting screws to 75 in-lbs.

Washers

Mounting Screws

10. Repeat the STEPS 1-9 for the opposite

back cane.

FIGURE 4 - ADJUSTING SEAT

DEPTH - CHANGING SEAT DEPTH

BETWEEN 12 AND 15-INCHES

11. Reinstall the armrests onto the

wheelchair. Refer to INSTALLING/

REMOVING FLIP BACK ARMRESTS in

SECTION 4 of the Owner’s Manual,

part number 1104782 or 1123757.

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SECTION 6

SEAT FRAME

CHANGING SEAT WIDTH (STANDARD AND ASBA)

STANDARD SEAT FRAME

NOTE: If changing seat width below 16-inches wide, you must convert to an ASBA. Refer to

CONVERTING FROM STANDARD TO ASBA OR VICE VERSA in this section of the manual. For all

changes above 16-inches wide, perform the outlined steps.

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in this section of the

manual.

2. Remove the existing standard seat frame subassembly and install the NEW standard frame.

Refer to REMOVING/INSTALLING STANDARD SEAT FRAME SUBASSEMBLY in this

section of the manual.

3. FOR 12 TO 15-INCH SEAT DEPTHS ONLY: Remove the CJ back brackets from

the existing standard seat frame and install onto the NEW standard seat frame. Refer to

REMOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this manual.

4. Reinstall the components previously removed in STEP 1. Perform the instructions outlined

in PREPARATION FOR REMOVING/INSTALLING SEAT FRAME (STANDARD FRAME,

ADJUSTABLE FRAME, AND VAN SEAT) in this section of the manual.

ASBA (FIGURE 5)

NOTE: If changing seat width above 16-inches wide, you must convert to a standard seat frame.

Refer to CONVERTING FROM STANDARD TO ASBA OR VICE VERSA in this section of the manual.

For all changes below 16-inches wide, perform the outlined steps.

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in this section of the

manual.

2. Review the following chart for the allowable seat width and seat depth combinations for

the ASBA.

NOTE: The seat widths and seat depths enclosed in the outlined box will require the use of CJ back

brackets and a 17-inch deep seat pan.

ALLOWABLE SEAT WIDTH AND

DEPTH COMBINATIONS FOR ASBA

3. Remove the two (2) mounting screws,

coved washers, spacers, and locknuts

that secure the side frame to the center

frame.

SEAT WIDTH

✓

4. Adjust side frame to desired width

determined from STEP 2. See DETAIL

“A” for proper mounting hole position.

✓

5. Secure side frame to center frame with

existing mounting screws, coved

17 N/A

18 N/A

19 N/A

20 N/A

21 N/A

22 N/A

N/A

washers, spacers, and locknuts. Torque

mounting screws to 75 in-lbs.

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SEAT FRAME

SECTION 6

WARNING

Both side frames MUST be adjusted to the same mounting hole position to

maintain proper weight balance of user and seat frame. If weight is not balanced,

injury to the assistant and/or user and damage to the wheelchair may result.

6. Repeat STEPS 3-5 for opposite side frame.

7. Perform one (1) of the following:

A. For adjusting the seat width only, perform the instructions outlined in

PREPARATION FOR REMOVING/INSTALLING SEAT FRAME (STANDARD

FRAME, ASBA, AND VAN SEAT) in this section of the manual.

NOTE: When performing the steps outlined in PREPARATION FOR REMOVING/INSTALLING SEAT

FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) the seat pan, seat cushion, back upholstery

and spreader bar (if applicable), will need to be replaced. Spreader bars are only required on seat

depths greater than 19-inches.

B. For all other changes regarding seat frame changes, refer back to the starting

procedure to complete the desired change.

DETAIL “A”

12-inches

13-inches

14-inches

15-inches

16-inches

STEPS 3-6

Mounting

Screws

Coved

Washers

Side Frame

Spacers

Locknut

Side

Frame

Center

Frame

FIGURE 5 - CHANGING SEAT WIDTH - ASBA

3G Storm Series Wheelchairs

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SECTION 6

SEAT FRAME

INSTALLING/REMOVING ASBA SUBASSEMBLY AND/OR

COMPONENT REPLACEMENT (FIGURE 6)

CONVERTING FROM ASBA TO STANDARD SEAT FRAME OR

VAN SEAT

NOTE: This section must be performed in conjunction with a starting procedure.

1. Remove the four (4) mounting screws that secure the two (2) support brackets of

the ASBA subassembly to the seat mounting plates.

2. To complete conversion, refer back to the starting procedure to complete the

desired change.

CONVERTING FROM STANDARD SEAT FRAME OR VAN SEAT

TO ASBA

NOTE: This section must be performed in conjunction with a starting procedure.

NOTE: When converting the seat frame, you will need a seat pan, seat cushion, back upholstery

and spreader bar (if applicable). Spreader bars are only required on seat depths of greater than

19-inches.

1. Secure both support brackets to the seat mounting plates with four (4) mounting

screws and locknuts. Torque mounting screws to 156 in-lbs.

2. Secure the center frame to the support brackets with four (4) mounting screws,

locknuts, and spacers. Torque to 156 in-lbs.

3. Insert the side frame into the center frame and secure with mounting screw, coved

spacer, spacer, and locknut. Torque to 75 in-lbs. Repeat for opposite side frame.

COMPONENT REPLACEMENT

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

NOTE: Note the mounting hole position of the current side frame(s) for proper installation of the

NEW side frame(s).

2. Remove the two (2) mounting screws, coved spacers, spacers, and locknuts that

secure the side frame to the center frame.

3. Perform one (1) of the following:

A. If center frame needs replaced, repeat STEP 2 for opposite side frame and

proceed to STEP 4.

B. If opposite side frame needs replaced, repeat STEP 2, then proceed to STEP 6.

Otherwise proceed to STEP 6.

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SEAT FRAME

SECTION 6

4. Remove the four (4) mounting screws and locknuts that secure the center frame to

the support brackets.

5. Secure NEW center frame to support brackets with existing four (4) mounting

screws and locknuts. Torque to 156 in-lbs.

WARNING

Both side frames MUST be adjusted to the same mounting hole position to

maintain proper weight balance of user and seat frame. If weight is not

balanced, injury to the assistant and/or user and damage to the wheelchair

may result.

6. Install new/existing side frame(s) into new/existing center frame at the mounting

position previously noted. Torque to 75 in-lbs.

7. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in this section of the

manual.

Mounting Screws

(Torque to

156 in-lbs)

Mounting Screws

(Torque to

156 in-lbs)

Mounting Screws

(Torque to

75 in-lbs)

Side Frame

Spacer

Coved Washer

Center Frame

Locknuts

Support

Bracket

Side Frame

Mounting Screws

(Torque to

156 in-lbs)

Support

Bracket

Mounting Screws

(Torque to

156 in-lbs)

Locknuts

Base

Frame

Mounting Plate

Locknuts

FIGURE 6 - INSTALLING/REMOVING ASBA SUBASSEMBLY AND/OR

COMPONENT REPLACEMENT

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SECTION 6

SEAT FRAME

INSTALLING/REMOVING

VAN SEAT ASSEMBLY

(FIGURE 7)

Van Seat

INSTALLING VAN SEAT

1. Position the van seat on the seat

mounting plates at the position shown

in FIGURE 7.

Seat

Mounting

Plate

Mounting Screws

(Torque to

156 in-lbs)

2. Line up mounting holes in the van seat

frame and the mounting holes in the

seat mounting plates.

Base

Frame

3. Secure the van seat to the seat mount-

ing plates with four (4) mounting

screws, and locknuts. Torque to

156 in-lbs.

Seat

Mounting

Plate

Locknuts

REMOVING VAN SEAT

FIGURE 7 - REMOVING/

INSTALLING VAN SEAT

ASSEMBLY

1. Remove the four (4) mounting screws

and locknuts that secure the van seat

to the seat mounting plates.

2. Remove van seat from seat mounting plates.

REPLACING VAN SEAT AND/OR VAN SEAT FRAME

(FIGURE 8)

1. Perform the instructions outlined in

PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD

Van Seat

FRAME, ADJUSTABLE FRAME, AND

VAN SEAT) in this section of the manual.

2. Remove the van seat assembly from

the wheelchair. Refer to

Van Seat

Frame

INSTALLING/REMOVING VAN

SEAT ASSEMBLY in this section

of the manual.

3. Remove the four (4) mounting

screws, two (2) washers, and

two (2) spacers that secure the

van seat to the seat frame.

Washer

Mounting Screw

(Torque to

75 in-lbs)

Spacer

FIGURE 8 - REPLACING VAN SEAT

AND/OR VAN SEAT FRAME

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SEAT FRAME

SECTION 6

4. Replace the van seat or the seat frame.

5. Secure new/existing van seat to the new/existing van seat frame with existing four (4)

mounting screws and spacers. Torque to 75 in-lbs.

6. Install new van seat assembly onto the wheelchair. Refer to INSTALLING/

REMOVING VAN SEAT ASSEMBLY in this section of the manual.

CONVERTING FROM STANDARD SEAT FRAME TO

ASBA OR VICE VERSA

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

2. Perform one (1) of the following:

A. Remove the existing standard seat frame subassembly. Refer to REMOVING/

INSTALLING STANDARD SEAT FRAME SUBASSEMBLY in this section of the

manual.

B. Remove the ASBA subassembly. Refer to REMOVING/INSTALLING ASBA

SUBASSEMBLY AND/OR COMPONENT REPLACEMENT in this section of the

manual.

3. Perform one (1) of the following:

A. Install the standard frame subassembly. Refer to INSTALLING/REMOVING

STANDARD SEAT FRAME SUBASSEMBLY in this section of the manual.

B. Install the ASBA subassembly. Refer to INSTALLING/REMOVING ASBA

SUBASSEMBLY AND/OR COMPONENT REPLACEMENT in this section of the

manual.

4. ASBA ONLY: Adjust side frame to desired seat width.

Refer to CHANGING SEAT WIDTH in this section of the manual for mounting hole

locations and allowable seat width/seat depth combinations.

5. STANDARD AND ASBA WITH 12 TO 15-INCH SEAT DEPTHS ONLY:

Remove the CJ back brackets from the existing standard seat frame and install onto the

NEW standard seat frame. Refer to REMOVING/INSTALLING CJ BACK BRACKETS

in SECTION 8 of this manual.

6. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 6

SEAT FRAME

CONVERTING FROM ASBA TO VAN SEAT OR VICE

VERSA

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

2. Perform one (1) of the following:

A. Remove the ASBA subassembly. Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this section of the manual.

B. Remove the van seat Assembly. Refer to INSTALLING/REMOVING VAN SEAT

ASSEMBLY in this section of the manual.

3. Perform one (1) of the following sections:

ASBA

A. Install the ASBA subassembly. Refer to INSTALLING/REMOVING ASBA SUBAS-

SEMBLY AND/OR COMPONENT

REPLACEMENT in this section of the manual.

B. Adjust side frames to desired seat width. Refer to CHANGING SEAT WIDTH in

this section of the manual for mounting hole locations and allowable seat width/

seat depth combinations.

C. 12 TO 15-INCH SEAT DEPTHS ONLY: Install the CJ back brackets, seat

positioning strap, and quick release pin from the onto the ASBA. Refer to RE-

MOVING/INSTALLING CJ BACK BRACKETS in SECTION 8 of this manual.

D. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

Van Seat

A. Install the van seat. Refer to INSTALLING/REMOVING VAN SEAT ASSEMBLY in

this section of the manual.

B. Adjust the van seat to the desired position. Refer to ADJUSTING VAN SEAT in

SECTION 6 of the Owner’s Manual, part number 1104782 or 1123757.

C. Perform the instructions outlined in PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in

this section of the manual.

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Part No. 1104849

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SEAT FRAME

SECTION 6

CONVERTING FROM STANDARD SEAT FRAME TO VAN

SEAT OR VICE VERSA

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in this

section of the manual.

2. Perform one (1) of the following:

A. Remove the standard seat frame subassembly. Refer to REMOVING/INSTALLING

STANDARD SEAT FRAME SUBASSEMBLY in this section of the manual.

B. Remove the van seat Assembly. Refer to INSTALLING/REMOVING VAN SEAT

ASSEMBLY in this section of the manual.

3. Perform one (1) of the following:

A. Install the van seat. Refer to INSTALLING/REMOVING VAN SEAT ASSEMBLY in

this section of the manual.

B. Install the standard seat frame. Refer to REMOVING/INSTALLING STANDARD

SEAT FRAME SUBASSEMBLY in this section of the manual.

4. STANDARD FRAMES ONLY ON 12 TO 15-INCH SEAT DEPTHS ONLY:

Install the CJ back brackets from the onto the ASBA. Refer to REMOVING/INSTALLING

CJ BACK BRACKETS in SECTION 8 of this manual.

5. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in this section of the

manual.

6. Adjust the van seat to the desired position. Refer to ADJUSTING VAN SEAT in

SECTION 6 of the Owner’s Manual, part number 1104782 or 1123757.

REMOVING/INSTALLING SEAT PAN (FIGURE 9)

REMOVING

1. Remove the seat cushion from the seat pan.

2. Remove the flip-back armrests from the wheelchair. Refer to INSTALLING/REMOVING

FLIP BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

3. Remove the six (6) mounting screws, locknuts, and spacers that secure the seat pan,

seat positioning strap, and quick release pin to the seat frame.

NOTE: When removing seat pan, note tab position of quick release pin to the seat positioning strap.

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SECTION 6

SEAT FRAME

INSTALLING

1. Position the NEW seat pan on the seat frame, aligning the mounting holes of the

seat pan and the mounting holes of the seat frame.

2. Position the seat positioning strap and

quick release pin tab onto the seat

frame and secure with mounting screw

Mounting

Screws

and locknut. See FIGURE 9 for proper

orientation. Repeat for other seat

positioning strap.

NOTE: Check seat positioning strap for proper

Seat

Pan

length. The width range for the four (4) seat

positioning straps are: 12 to 16-inches wide

(Junior), 16 to 19-inches wide, 20 to 22-inches

wide, and 23 to 24-inches wide.

Seat

Positioning

Strap

3. Reinstall the remaining mounting

screws, locknuts, and spacers. Torque

all mounting screws to 75 in-lbs.

Spacer

Seat Frame

4. Remove the protective strips from new

seat pan and reinstall the seat cushion

onto the seat pan.

Locknut

Tab

Locknut

Quick Release Pin

5. Perform one (1) of the following:

NOTE: Illustration shows standard frame only

for clarity. The seat pan removes/installs onto

the ASBA the way.

A. When changing the seat width or

depth, refer back to that procedure

to complete the desired change.

FIGURE 9 - REMOVING/

INSTALLING SEAT PAN

B. Reinstall the flip-back armrests

from the wheelchair. Refer to

INSTALLING/REMOVING FLIP BACK ARMRESTS in SECTION 4 of the

Owner’s Manual, part number 1104782 or 1123757.

3G Storm Series Wheelchairs

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SEAT FRAME

SECTION 6

SEAT ANGLE ADJUSTMENT (FIGURE 10)

NOTE: The angle of the seat is factory set providing the user with a 5^oseat dump. This angle

can be changed by adjusting either the front or back of the seat mount plate to obtain any

angle between 0^oor 10^oseat dump.

NOTE: There are three (3) heights of seat mounting plates; low, medium, and high.

LOW HEIGHT

MEDIUM HEIGHT

HIGH HEIGHT

1. To obtain a 0^oseat dump (DETAIL “A”):

A. Loosen the two (2) mounting screws that secures the seat mount plate to the

seat support bracket.

B. Loosen the two (2) mounting screws that secures the remaining seat mount plate

to the seat support bracket.

C. Adjust the seat mount plates so that the rear mounting screws are positioned at

the bottom of the rear slots.

D. Adjust the seat mount plates so

that the front mounting screws are

positioned at the top of the front

slots.

Rear of Seat Frame

DETAIL “A”

Mounting

Screw

E. Securely tighten all four (4) mounting

screws. Torque to 156 in-lbs.

2. To obtain a 10^oseat dump (DETAIL “A”):

A. Loosen the two (2) mounting

screws that secure the front of the

seat frame to the seat mount plate.

Front of

Seat Frame

Medium Height

Seat Mount Plate

B. Position the mounting screws at

the bottom of the front slot.

Mounting Screw

FIGURE 10 - SEAT ANGLE

ADJUSTMENT

C. Securely tighten both mounting

screws. Torque to 156 in-lbs.

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SECTION 7

BASE FRAME

This Section Includes the Following:

Replacing Seat Mounting Plates

Replacing Seat Support Brackets

Replacing Seat Support Bracket T-Nuts

Replacing Battery Charger Bracket and T-Nut

Removing/Installing Seat Stop Screws

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that

all attaching hardware is tightened securely - otherwise injury or damage

may result.

REPLACING SEAT MOUNTING PLATES (FIGURE 1)

NOTE: When replacing components of the wheelchair, refer to the individual procedure for

correct use of LOCTITE 242 and torque specifications or SECTION 3 of this Manual.

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in

SECTION 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer to REMOVING/INSTALLING

STANDARD SEAT FRAME SUBASSEMBLY in SECTION 6 of this manual.

B. Remove ASBA subassembly. Refer to INSTALLING/REMOVING ASBA ASSEMBLY

AND OR COMPONENT REPLACEMENT in SECTION 6 of this manual.

C. Remove van seat. Refer to INSTALLING/REMOVING VAN SEAT ASSEMBLY in

SECTION 6 of this manual.

NOTE: Before removing seat mounting plates, note the position of the washers.

Washer

3. Remove the two (2) mounting screws,

washers and bolt strap bracket that

Bolt Strap

secure the seat mounting plate to the

seat support bracket.

Seat

Mounting

Plate

Mounting

Screws

4. Secure NEW seat mounting plate with

existing two (2) mounting screws,

washers, and bolt straps to seat

support bracket using Loctite 242 and

torque to 156 in-lbs.

Seat

Support

Bracket

Washer

Mounting

Screws

FIGURE 1 - REPLACING SEAT

MOUNTING PLATES

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BASE FRAME

SECTION 7

5. Repeat STEPS 1-2 for opposite side, if necessary.

NOTE: For illustrations of the three (3) different seat mounting plates, refer to SEAT ANGLE

ADJUSTMENT in SECTION 6 of this manual.

6. Adjust seat mounting plates to desired angle. Refer to SEAT ANGLE ADJUSTMENT

in SECTION 6 of this manual.

7. Reverse STEP 2.

8. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in

SECTION 6 of this manual.

REPLACING SEAT SUPPORT BRACKETS (FIGURE 2)

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in

SECTION 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer to REMOVING/INSTALLING

STANDARD SEAT FRAME SUBASSEMBLY in SECTION 6 of this manual.

B. Remove ASBA subassembly. Refer to INSTALLING/REMOVING ASBA ASSEM-

BLY AND OR COMPONENT

REPLACEMENT in SECTION 6 of this manual.

C. Remove van seat. Refer to INSTALLING/REMOVING VAN SEAT ASSEMBLY in

SECTION 6 of this manual.

3. Remove seat mount plates. Refer to REPLACING SEAT MOUNTING PLATES in this

section of the manual.

NOTE: Note the position of the seat support brackets before removing to ensure proper reinstallation.

WARNING

Do not adjust the position of the seat support bracket in this procedure.

If an adjustment is desired, refer to ADJUSTING WEIGHT DISTRIBUTION

in SECTION 15 of this manual.

4. Remove the two (2) mounting screws and washers that secure the seat support

bracket to the base frame.

WARNING

When installing seat support bracket, ensure the mounting screws are

threaded into the T-Nuts located inside the channel of the base frame.

5. Secure the NEW seat support bracket to base frame with the existing two (2)

mounting screws and washers. Torque to 156 in-lbs.

6. Reinstall seat mount plates. Refer to REPLACING SEAT MOUNTING PLATES in

this section of the manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 7

BASE FRAME

Mounting Screws

7. Adjust seat mount plates to desired

angle. Refer to SEAT ANGLE

ADJUSTMENT in SECTION 6 of

this manual.

Washer

Seat Support

Bracket

8. Reverse STEP 2.

9. Perform the instructions

outlined in PREPARATION

FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD

FRAME, ASBA, AND VAN

SEAT) in SECTION 6 of this

manual.

Base

Frame

T-Nut

FIGURE 2 - REPLACING SEAT SUPPORT

BRACKETS

REPLACING SEAT SUPPORT BRACKET T-NUTS (FIGURE 3)

1. Perform the instructions outlined in PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in

SECTION 6 of this manual.

2. Perform one (1) of the following:

A. Remove standard seat frame subassembly. Refer to REMOVING/INSTALLING

STANDARD SEAT FRAME SUBASSEMBLY in SECTION 6 of this manual.

B. Remove ASBA subassembly. Refer to INSTALLING/REMOVING ASBA ASSEM-

BLY AND OR COMPONENT

REPLACEMENT in SECTION 6 of this manual.

C. Remove van seat. Refer to

INSTALLING/REMOVING VAN

Seat

Support Bracket

SEAT ASSEMBLY in SECTION 6

of this manual.

Channel

Cover

3. Remove the seat mount plates.

Refer to REPLACING SEAT

MOUNTING PLATES in this

section of the manual.

Base

Frame

End Cap

T-Nut

FIGURE 3 - REPLACING SEAT

SUPPORT BRACKET T-NUTS

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BASE FRAME

SECTION 7

NOTE: Before removing seat mounting plates, note the position of the washers.

4. Remove the seat support brackets. Refer to REPLACING SEAT SUPPORT BRACKETS

in this section of the manual.

5. Remove the seat stop screw that is closest to the end cap. Refer to REMOVING/

INSTALLING SEAT STOP SCREWS in this section of the manual.

6. Remove the end cap and channel cover.

7. Slide existing T-Nut(s) out of channel.

8. Insert NEW T-Nut(s) into channel in correct orientation.

9. Replace channel cover and end cap.

WARNING

The seat stop screws must be in place before operation of your power wheelchair.

Ensure the T-Nut(s) are positioned between both seat stop screws.

10. Use Loctite 242and reinstall seat stop screw into base frame.

11. Reinstall the seat seat support brackets. Refer to REPLACING SEAT SUPPORT

BRACKETS in this section of the manual.

12. Reinstall the seat mount plates. Refer to REPLACING SEAT MOUNTING PLATES in

this section of the manual.

13. Adjust seat mounting plates to desired angle. Refer to SEAT ANGLE ADJUSTMENT

in SECTION 6 of this manual.

14. Reverse STEP 2.

15. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in SECTION 6 of this

manual.

REPLACING BATTERY CHARGER BRACKET AND

T-NUT (FIGURE 4)

NOTE: For 3G wheelchairs equipped with 2G powered seating systems only.

1. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

THE SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in SECTION 6 of

this manual.

2. Remove one (1) of the following (Refer to SECTION 6):

A. Standard seat frame subassembly.

B. ASBA subassembly.

C. Van seat.

3. Remove the seat support brackets. Refer to REPLACING SEAT SUPPORT BRACKETS

in this section of this manual.

3G Storm Series Wheelchairs

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SECTION 7

BASE FRAME

4. Remove the two (2) mounting screws that secure the battery charger connector to

the mount bracket.

5. Remove battery charger connector from mount bracket.

6. Remove the mounting screw which secures the battery charger mount bracket to

the T-nut located in the channel of the base frame.

7. Replace battery charger mount

bracket and secure to base

frame with existing mounting

screw.

Mounting Screw

Battery

Charger

Connector

Battery

Charger

Mount

Bracket

NOTE: To replace the Battery Charger

Bracket T-Nut, perform STEPS 3-13 in

REPLACING SEAT SUPPORT BRACKET

T-NUTS in this section of the manual.

T-Nut

Base

Frame

8. Secure the battery charger

connector to the mount

bracket with the EXISTING

two (2) mounting screws.

Tighten securely.

FIGURE 4 - REPLACING BATTERY

CHARGER BRACKET AND T-NUT

9. Reverse STEP 2.

10. Perform the instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ASBA, AND VAN SEAT) in SECTION 6 of this

manual.

REMOVING/INSTALLING SEAT STOP SCREWS (FIGURE 5)

NOTE: The front seat stop screw should only be removed if replacing a T-nut for either the seat support

bracket or the battery charger mount bracket. The rear seat stop screw should never be removed.

1. Unthread seat stop screw from base frame.

WARNING

The seat stop screws must be in place before operation of your power

wheelchair. Ensure the seat support bracket is positioned between both

seat stop screws.

2. When reinstalling the front seat stop screw, ensure the seat support bracket is

located in-between both seat stop screws. Use loctite 242 and tighten securely.

Seat Support Bracket

Base

Frame

Rear Seat

Stop Screw

Front Seat Stop Screw

FIGURE 5 - REMOVING/INSTALLING SEAT STOP SCREWS

3G Storm Series Wheelchairs

Part No. 1104849

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BACK FRAME

SECTION 8

This Section Includes the Following:

Removing/Installing CJ Back Brackets

Changing Back Height

Back Angle Adjustment

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all

attachinghardwareistightenedsecurely-otherwiseinjuryordamagemayresult.

NOTE: The procedures in this section of the manual refer to NON-RECLINER seat frames only.

For recliner seat frames, refer to SECTION 14 of this manual.

REMOVING/INSTALLING CJ BACK BRACKETS (FIGURE 1)

NOTE: The following procedure is for Jr. wheelchairs only.

REMOVING CJ BACK BRACKETS

1. If necessary, perform the instructions outlined in PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND

VAN SEAT) in SECTION 6 of this manual.

2. Remove the locknuts and washers that secure the CJ back bracket to the back angle plate.

3. Remove the mounting screw and locknut that secures the quick release pin and CJ

back bracket and seat positioning strap to the seat frame.

4. Remove the existing CJ back bracket.

5. Repeat STEPS 2-4 for the opposite CJ back bracket.

6. For replacement of CJ back brackets, proceed to INSTALLING CJ BACK BRACK-

ETS in this section of the manual.

INSTALLING CJ BACK BRACKETS

1. If necessary, perform the instructions outlined in PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND

VAN SEAT) in SECTION 6 of this manual.

2. Install the threaded studs of the CJ back bracket through the back angle plates as

shown in FIGURE 1.

NOTE: Ensure the CJ back bracket is mounted in the front holes of the back angle plates as

shown in DETAIL “A” of FIGURE 1.

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SECTION 8

BACK FRAME

WARNING

Always wear your seat positioning

strap.

CJ Bracket

mounts in Front

Holes on Back

Angle Plates.

DETAIL “A”

3. Position the seat positioning strap and

quick release pin under the CJ back

bracket.

Toward Front of

Wheelchair

4. Secure the quick release pin, seat

positioning strap, and CJ back bracket

to the seat frame. Torque to 75 in-lbs.

Seat

Positioning

Strap

CJ Back

Bracket

Back

Angle

Plate

Mounting

Screw

Threaded

Studs

5. Install washers and locknuts onto the

threaded studs of the CJ back bracket.

Torque to 75 in-lbs.

Washers

6. For replacing CJ back brackets only,

perform the instructions outlined in

PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME

(STANDARD FRAME, ADJUSTABLE

FRAME, AND VAN SEAT) in

SECTION 6 of this manual.

Quick

Release

Locknuts

Locknut

Seat

Pan

Seat Frame

FIGURE 1 - REMOVING/

INSTALLING CJ BACK BRACKETS

3G Storm Series Wheelchairs

Part No. 1104849

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BACK FRAME

SECTION 8

CHANGING BACK HEIGHT (FIGURE 2)

NOTE: If changing the back height, new back upholstery may be needed as well. Read the

following to determine if new back upholstery is needed:

Back upholsery height ranges are 16 to 17-inches, 18 to 19-inches, 20-inches,

21 to 22-inches, 23 to 24-inches

●

If back height required is within the range of the original back height, only

new back canes will be needed.

●

If the back height required is NOT within the range of the original back

height, new back upholstery, as well as new back canes will be needed.

NOTE: Existing hardware and inserts will be reused.

1. Remove the armrests from the wheelchair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

NOTE: Note the correct mounting screw mounting positions to ensure the proper back angle for

reinstallation.

2. Remove the two (2) mounting screws and washers that secure the existing back

upholstery to the back canes.

3. Remove the four (4) mounting screws, washers, spacers, and locknuts that secure

the existing back canes to the seat frame.

4. Remove the inserts from the existing back canes.

5. Remove the back assembly from the wheelchair.

6. If applicable, loosen, but do not remove the mounting screws and locknuts that

secure the spreader bar to the existing back canes.

7. Remove existing back canes from the back assembly.

8. Slide the inserts into the bottom of the new back canes.

9. Line up the mounting holes of the inserts with the mounting holes in the back canes.

NOTE: To keep the inserts lined up for reinstallation onto the wheelchair, start one (1) of the mounting

screws through the back cane from inside of the wheelchair to hold the insert in place.

10. Slide new back canes through the existing/new back upholstery and spreader bar.

11. If applicable, loosely tighten the mounting screws that secure the spreader bar to the

new back canes.

12. Line up mounting holes in the back canes with the mounting holes in the seat frame.

NOTE: If needing a reference for proper mounting holes for the back angle required, or if changing

the original back angle, refer to BACK ANGLE ADJUSTMENT in this section of the manual.

WARNING

The back canes MUST be fastened securely to the seat frame BEFORE

using the wheelchair. Torque to 75 in-lbs.

13. Secure the two (2) NEW back canes to the seat frame with the existing four (4) mounting

screws, washers, spacers, and locknuts. Use Loctite 242 and torque to 75 in-lbs.

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SECTION 8

BACK FRAME

14. Secure the top of the existing/new back upholstery to the back canes with the two

(2) existing mounting screws and washers.

15. Secure bottom of the existing/NEW back upholstery to rear of the seat pan.

16. Secure the bottom of the existing/NEW back upholstery to the back canes with new

tie-wraps.

NOTE: Clean upholstery with warm DAMP cloth and mild detergent to remove superficial soil.

WARNING

Laundering or moisture will reduce flame retardancy of the upholstery.

NOTE: When replacing the back upholstery, back assembly or changing back height, follow

these guidelines for spreader bar height (where applicable):

BACK HEIGHT

16-inches*

17-inches*

18 to 19-inches*

20 to 24-inches

◆ SPREADER BAR HEIGHT

5-inches

7-inches

NOTE: Spreader Bar required on back heights 20 to 24-inches. *Spreader bar ONLY required

on these back heights if the width or depth of the chair exceeds 19-inches.

◆Height of Spreader Bar from Bottom of Back Canes to Top of Spreader Bar Clamp.

HEAVY DUTY MODELS

Locknuts

BACK HEIGHT

◆ SPREADER BAR

HEIGHT

5-inches

Back Cane

16 to 17-inches

18 to 24-inches

Spacers

7-inches

Mounting

Screw

◆Height of Spreader Bar from Bottom

of Back Canes to Top of Spreader Bar

Clamp.

Locknut

Washer

NOTE: Spreader bar required on all Heavy

Duty models.

Spreader

Bar

Back

Upholstery

17. If necessary, reposition the spreader bar at

the correct height for the corresponding

back height and torque the mounting

hardware to 60 in-lbs.

Mounting

Screw

Torque to

60 in-lbs

Insert

18. Reinstall the armrest onto the wheelchair.

Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the

Owner’s Manual, part number 1104782

or 1123757.

Mounting Screws

Torque to 75 in-lbs

Washers

FIGURE 2 - CHANGING BACK

HEIGHT

3G Storm Series Wheelchairs

Part No. 1104849

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BACK FRAME

SECTION 8

BACK ANGLE ADJUSTMENT (FIGURE 3)

1. Remove armrests from the wheelchair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

2. Remove the mounting screw and washer from the top mounting hole of back angle

plate and back cane.

NOTE: To avoid losing the insert in each back cane, thread the mounting screw through the

cane from the inside of wheelchair to hold the insert in place.

3. Remove the mounting screw and washer from the bottom mounting hole of the back

angle plate and back cane.

4. Reposition the back canes into the correct mounting holes of the back angle plate to

obtain a back angle between 80^oand 100^oin 5^oincrements.

5. Torque mounting screws to 75 in-lbs.

6. Reinstall the armrests onto the wheelchair. Refer to INSTALLING/REMOVING FLIP

BACK ARMRESTS in SECTION 4 of the Owner’s Manual, part number 1104782 or

1123757.

Top Front

Top

Bottom

Bottom Rear

80°

Top

Top Front

Bottom Center

2nd From

Bottom

85°

Top

Front

Top

Bottom

Front

90 ^o

Bottom

Top

Top Center

2nd From

Bottom

Bottom Front

95°

Top

Top Rear

Bottom

Front

100°

FIGURE 3 - BACK ANGLE ADJUSTMENT

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 9

BATTERIES

This Section Includes the Following:

Warnings for Handling and Replacing Batteries

Using the Proper Batteries

Installing/Removing Batteries Into/From Battery Boxes

Disconnecting/Connecting Battery Cables

When to Charge Batteries

Charging Batteries

Replacing Batteries

Removing/Installing Battery Boxes

WARNINGS FOR HANDLING AND REPLACING BATTERIES

WARNING

Make sure power to the wheelchair is OFF before performing this procedure.

The use of rubber gloves and chemical goggles or face shield is recommended

when working with batteries.

Invacare strongly recommends that battery installation and battery

replacement always be done by a qualified technician.

After ANY adjustments, repair or service and BEFORE use, make sure all

attaching hardware is tightened securely - otherwise injury or damage may

result.

22NF batteries weigh 37 pounds each. GP24 batteries weigh 51 pounds

each. Use proper lifting techniques (lift with your legs) to avoid injury.

Failure to use the correct battery size and/or voltage may cause damage to

your wheelchair and give you unsatisfactory performance.

ALWAYS use a battery lifting strap when lifting a battery. It is the most

convenient method and assures that the battery acid will not spill. It also

helps to prolong the life of the battery.

DO NOT tip the batteries. Keep the batteries in an upright position.

NEVER allow any of your tools and/or battery cable(s) to contact BOTH

battery post(s) at the same time. An electrical short may occur and serious

personal injury or damage may occur.

When tightening the clamps, always use a box wrench. Pliers will “round

off” the nuts. NEVER wiggle the battery terminal(s)/post(s) when

tightening. The battery may become damaged.

The POSITIVE (+) RED battery cable MUST connect to the POSITIVE (+)

battery terminal(s)/post(s), otherwise serious damage will occur to the

electrical system.

The warranty and performance specifications contained in this manual are

based on the use of deep cycle gel cell batteries. Invacare strongly

recommends their use as the power source for this unit.

NOTE: If there is battery acid in the bottom of the battery tray or on the sides of the battery(ies),

apply baking soda to these areas to neutralize the battery acid. Before reinstalling the NEW or

existing battery(ies), clean the baking soda from the battery tray or battery(ies).

3G Storm Series Wheelchairs

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BATTERIES

SECTION 9

USING THE PROPER BATTERIES (FIGURES 1 AND 2)

1. Place battery on ground/flat surface.

2. Visually draw a horizontal and vertical centerline through the middle of battery.

3. Position the battery so that the terminals are above the horizontal centerline.

4. Visually inspect the battery to ensure the correct position of the positive and nega-

tive terminals, as shown in FIGURES 1 AND 2:

WARNING

FOR 3G STORM WHEELCHAIRS THAT USE 22NF BATTERIES: Batteries

with terminal configuration (positive on the left and negative on the right) as

shown below MUST be used. Batteries that have the reverse terminal

configuration MUST NOT be used - otherwise injury and damage may occur.

Terminals must have a cross hole in them as shown in DETAIL “A” below.

PROPER BATTERY TO BE USED

NEGATIVE (-) Battery

Terminal/Post

POSITIVE (+) Battery

Terminal/Post

NEGATIVE (-) Battery

Terminal/Post

POSITIVE (+) Battery

Terminal/Post

Centerline

22NF

DO NOT USE

DETAIL “A” - TERMINAL CROSS HOLES

Terminal Cross Holes

FIGURE 1 - USING THE PROPER BATTERIES - 22NF

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 9

BATTERIES

WARNING

FOR 3G STORM WHEELCHAIRS THAT USE GP24 BATTERIES: Batteries

with terminal configuration (positive on the right and negative on the left) as

shown below MUST be used. Batteries that have the reverse terminal

configuration MUST not be used - otherwise injury and damage may occur.

Terminals must have a cross hole in them as shown in DETAIL “A” below.

POSITIVE (+) Battery

Terminal/Post

POSITIVE (+) Battery

Terminal/Post

NEGATIVE (-) Battery

Terminal/Post

NEGATIVE (-)

Battery Terminal/Post

GP24

DO NOT USE

DETAIL “A” - TERMINAL CROSS HOLES

Terminal Cross Holes

FIGURE 2 - USING THE PROPER BATTERIES - GP24

3G Storm Series Wheelchairs

Part No. 1104849

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BATTERIES

SECTION 9

INSTALLING/REMOVING BATTERIES INTO/FROM

BATTERY BOXES (FIGURE 3)

NOTE: To remove the battery(ies) from the battery box(es), reverse the following procedure.

NOTE: Have the following tools available:

TOOL

QTY

COMMENTS

Supplied

Battery Lifting Strap

1/2-inch (6 pt) Box Wrench

Not Supplied

NOTE: If there is battery acid in the bottom or on the sides of the battery box(es) or battery(ies),

apply baking soda to these areas to neutralize the battery acid. Before reinstalling the NEW or

existing battery(ies), clean the baking soda from the battery box(es) or battery(ies).

NOTE: When securing battery lifting strap to battery, observe polarity markings located on the

ends of the battery lifting strap, (+) side to POSITIVE (+) battery post and (-) side to NEGATIVE

(-) battery post.

1. If necessary, remove the battery boxes from the wheelchair. Refer to REMOVING/

INSTALLING BATTERY BOXES in this section of the manual.

2. Disconnect battery cables. Refer to DISCONNECTING/CONNECTING BATTERY

CABLES for one (1) of the following:

A. Group 24 Batteries

B. 22NF batteries in single battery box

3. Secure battery lifting strap to battery terminal(s)/post(s) (FIGURE 3).

CAUTION

Some battery

Battery Lifting

Strap

Molded Carrying Straps (These

batteries must NOT be used.)

manufacturers mold a

carrying strap and/or hold

down flanges directly into

the battery case. Batteries

which interfere with the

battery box cannot be used

for these applications.

Attempting to “wedge” a

battery into a battery box

may damage the box and/or

the battery.

Group 24

Battery Box Bottom

4. Remove batteries from

battery box(es).

22NF Battery Box

Bottom

FIGURE 3 - INSTALLING/REMOVING

BATTERIES INTO/FROM BATTERY BOXES

3G Storm Series Wheelchairs

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SECTION 9

BATTERIES

DISCONNECTING/CONNECTING BATTERY CABLES

WARNING

NEVER allow any of your tools and/or battery cable(s) to contact BOTH

battery post(s) at the same time. An electrical short may occur and serious

personal injury or damage may occur.

The use of rubber gloves and chemical goggles or face shields is

recommended when working with batteries.

When tightening the clamps, always use a box wrench. Pliers will “round off”

the nuts. NEVER wiggle the battery terminal(s)/post(s) when tightening. The

battery may become damaged.

The POSITIVE (+) RED battery cable MUST connect to the POSITIVE (+)

battery terminal(s)/post(s), otherwise serious damage will occur to the

electrical system.

GROUP 24 BATTERIES ON WHEELCHAIR MANUFACTURED

BEFORE 1/26/04 (FIGURE 4)

Disconnecting.

NOTE: Perform this procedure on one (1) battery and battery box at a time. Repeat procedure

for other battery box.

1. Lift up on battery box lid to expose underlying cables.

2. Peel back battery clamp covers to expose battery clamp on each battery cable as follows:

A. RED battery clamp cover from RED battery cable.

B. BLACK battery clamp cover from BLACK battery cable.

3. Disconnect NEGATIVE

battery cable clamp from NEGATIVE(-) battery post

4. Disconnect POSITIVE

battery cable clamp from POSITIVE (+) battery post (FIGURE 4).

Connecting.

NOTE: Perform this procedure on one (1) battery and battery box at a time. Repeat procedure

for other battery box.

1. Position battery box top next to battery box bottom as shown in FIGURE 4.

2. Peel back battery clamp covers to expose battery clamp on each battery cable as follows:

A. RED battery clamp cover from RED battery cable.

B. BLACK battery clamp cover from BLACK battery cable.

3. Connect NEGATIVE

battery cable clamp to NEGATIVE(-) battery post and connect

battery cable clamp to POSITIVE (+) battery post (FIGURE 4).

POSITIVE

4. Secure the battery cable clamp(s) to the battery post(s) with provided hex screws and

nuts. Securely tighten.

3G Storm Series Wheelchairs

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BATTERIES

SECTION 9

5. Verify battery cable clamps(s) are correctly installed and securely tightened.

6. Reposition battery clamp covers over battery post(s).

7. Install the battery box top(s).

8. Install the battery box(es) into the wheelchair. Refer to REMOVING/INSTALLING

BATTERY BOXES in this section of this manual.

NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the

battery(ies) will be reduced.

9. If necessary, charge the battery(ies). Refer to CHARGING BATTERIES in this section of

the manual.

NEGATIVE (-)

POSITIVE (+)

Battery

Terminal/Post

Battery

Terminal/Post

Battery

Battery Box Bottom

TWO (2) CONNECTOR

BATTERY BOX

ONE (1) CONNECTOR

BATTERY BOX

One (1) Connector

Battery Box Top

Black NEGATIVE

(-)

Battery Cable

BLACK

Battery

Clamp

Cover

RED POSITIVE (+)

Battery Cable

Two (2)

Connector

Battery

BLACK

Battery

Clamp

Cover

BLACK

RED POSITIVE

(+)

NEGATIVE (-)

Battery

Cable

Box Top

Battery

Cable

Black

NEGATIVE (-)

Battery

Cable

Black NEGATIVE

(-)

Battery Cable

Clamp

RED

Battery

Clamp

Cover

Clamp

RED

POSITIVE

(+) Battery

Cable

Battery

Box

Bottom

RED

Battery

Clamp

Cover

Clamp

NEGATIVE (-)

Battery Terminal/

Post

NEGATIVE (-)

Battery

Terminal/Post

POSITIVE (+)

Battery Terminal/Post

POSITIVE (+)

Battery

Terminal/Post

Red POSITIVE (+)

Battery Cable

Clamp

Battery Box

Bottom

FIGURE 4 - DISCONNECTING/CONNECTING BATTERY CABLE(S) -

GROUP 24 BATTERIES

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 9

BATTERIES

GROUP 24 BATTERIES ON WHEELCHAIRS BUILT

AFTER 1/25/04 (FIGURE 5)

Disconnecting.

NOTE: Perform this section on one (1) battery and battery box at a time. Repeat section for

other battery box.

1. Lift up on battery box lid to expose underlying cables.

2. Peel back battery terminal caps to expose battery cable ends as follows:

A. RED battery terminal cap from RED battery cable.

B. BLACK battery terminal cap from BLACK battery cable.

3. Remove the locknut and mounting screw to disconnect BLACK battery cable from

the NEGATIVE(-) battery terminal/post (DETAIL “A” of FIGURE 5)

4. Remove the locknut and fuse mounting screw to disconnect RED battery cable from

the POSITIVE (+) battery post (DETAIL “A” of FIGURE 5).

Connecting.

NOTE: Perform this section on one (1) battery and battery box at a time. Repeat section for

other battery box.

1. Position battery box top above battery as shown in FIGURE 5.

2. Peel back battery terminal caps to expose battery cable ends as follows:

A. RED battery terminal cap from RED battery cable.

B. BLACK battery terminal cap from BLACK battery cable.

3. Install the locknut and mounting screw to connect the BLACK battery cable to the

NEGATIVE(-) battery terminal/post (DETAIL “A” of FIGURE 5).

4. Install the locknut and fuse mounting screw to connect the RED battery cable to the

POSITIVE (+) battery post (DETAIL “A” of FIGURE 5).

5. Verify battery cables are correctly installed and securely tightened.

NOTE: Cables will be crossed on one (1) connector battery box top.

6. Reposition terminal caps over battery post(s).

7. Install the battery box top(s).

8. Install the battery boxes into the wheelchair. Refer to REMOVING/INSTALLING

BATTERY BOXES in this section of the manual.

NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the

battery(ies) will be reduced.

9. If necessary, charge the battery(ies). Refer to CHARGING BATTERIES in this section

of the manual.

3G Storm Series Wheelchairs

Part No. 1104849

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BATTERIES

SECTION 9

DETAIL “A” - CONNECTING CABLES TO TERMINALS

Mounting Screw

Top View of Battery

Locknut

POSITIVE (+)

Battery

Terminal/Post

Locknut

NEGATIVE (-)

Battery

Terminal/Post

Fuse Mounting Screw

Black NEGATIVE

(-)

Battery Cable

RED POSITIVE (+) Battery Cable

TWO (2) CONNECTOR

BATTERY BOX

ONE (1) CONNECTOR

BATTERY BOX

Black

One (1) Connector

Battery Box Top

NEGATIVE (-)

Battery

Cable

Two (2) Connector

Battery Box Top

Black NEGATIVE

(-)

Battery Cable

RED

BLACK Battery

Terminal Cap

RED Battery

Terminal Cap

Red POSITIVE

(+)

Battery Cable

BLACK

Battery

Terminal Cap

Battery

Terminal

Cap

RED POSITIVE (+)

Battery Cable

NEGATIVE (-)

Battery

Terminal/Post

POSITIVE (+)

Battery

Terminal/Post

NEGATIVE (-)

Battery

Terminal/Post

POSITIVE (+)

Battery

Terminal/Post

Top View of Battery

FIGURE 5 - DISCONNECTING/CONNECTING BATTERY CABLE(S) -

GROUP 24 BATTERIES

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 9

BATTERIES

22NF BATTERIES IN SINGLE BATTERY BOX (FIGURE 5)

NOTE: Note polarity of white battery cable (jumper) battery terminal ends.

Disconnecting.

1. Remove battery terminal cap(s) from battery terminal(s) ends. Refer to DETAIL “A”

in FIGURE 5.

2. Disconnect WHITE battery cable (jumper) NEGATIVE

terminal end from

NEGATIVE (-) battery terminal/post of front battery and disconnect POSITIVE

terminal end from POSITIVE (+) battery terminal/post of rear battery.

3. Disonnect NEGATIVE (-) BLACK battery cable of the battery box top from NEGATIVE

(-) battery terminal/post of rear battery.

4. Disonnect POSITIVE (+) RED battery cable on battery box top from POSITIVE (+)

battery terminal/post of front battery.

Connecting.

1. Remove battery terminal cap(s) from battery terminal(s) ends. Refer to DETAIL “A”

in FIGURE 5.

2. Connect WHITE battery cable (jumper) NEGATIVE

(-) battery terminal/post of front battery and connect POSITIVE

POSITIVE (+) battery terminal/post of rear battery.

terminal end to NEGATIVE

terminal end to

3. Place battery top upside down on top of rear battery.

4. Connect NEGATIVE (-) BLACK battery cable of the battery box top to NEGATIVE

(-) battery terminal/post of rear battery.

5. Position battery box top right side up and rotate outward toward right to expose

POSITIVE (+) battery terminal/post of front battery.

6. Connect POSITIVE (+) RED battery cable on battery box top to POSITIVE (+)

battery terminal/post of front battery.

7. Replace battery terminal cap(s) onto battery cable terminal end(s).

8. Rotate top toward left into position. Secure in place.

9. Install the battery box into the wheelchair. Refer to REMOVING/INSTALLING

BATTERY BOXES in this section of the manual.

NOTE: New Battery(ies) MUST be fully charged BEFORE using, otherwise the life of the

battery(ies) will be reduced.

10. If necessary, charge the battery(ies). Refer to CHARGING BATTERIES in this section of

the manual.

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BATTERIES

SECTION 9

STEPS 3 AND 4

Battery

Box Bottom

Front

Battery

FRONT

NEGATIVE (-)

Battery

Terminal/Post

STEP 2

Rear

Battery

Front

Battery

FRONT

NEGATIVE (-)

BLACK

Battery Cable

Single

Battery

Box

WHITE

Battery

Cable

Bottom

Battery

Box Top

(Under Side

shown)

POSITIVE (+)

RED Battery

Cable

Rear

Battery

(Jumper)

REAR

Fuse

Block

STEPS 5 AND 6

POSITIVE (+) RED Battery Cable

POSITIVE (+)

Battery

DETAIL “A”

Terminal Cap

Terminal/Post

Front

Battery

Rear

Battery

Box Top

Battery Box Bottom

Terminal End

NOTE: Battery box top cut away for clarification

purposes only.

FIGURE 5 - CONNECTING BATTERY CABLES -

SINGLE 22NF BATTERY BOX

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SECTION 9

BATTERIES

WHEN TO CHARGE BATTERIES (FIGURE 6)

MKIV-A AND MKIV-RII

JOYSTICKS

The Battery Discharge Indicator (BDI) is a

bar graph display located on the MKIV

joystick. It will keep you informed as to

power availability. A visual warning is

Battery Discharge Indicator

(BDI) (in LCD Readout)

Battery Discharge

given before the power becomes too low

Indicator (BDI)

to operate the wheelchair. At full charge

the two (2) LEFT segments and the farthest

RIGHT segment of the bar graph will be

illuminated. As the battery becomes

discharged, the farthest RIGHT segment

MKIV- A

JOYSTICK

MKIV- A+

JOYSTICK

Battery Discharge

Indicator (BDI)

will progressively move to the LEFT until

only the last two (2) bars (LEFT) are

illuminated. At this level the last two (2)

bars (LEFT) will start to Flash ON and OFF

to indicate that the end user should charge

the batteries as soon as possible.

MKIV- RII JOYSTICK

(TORQUE SP ONLY)

FIGURE 6 - WHEN TO CHARGE

BATTERIES

MKIV-A+ JOYSTICKS

The left half of the second line on the LCD is the Battery Discharge Indicator (BDI). It

provides information on the remaining charge in the batteries. At full charge solid blocks

fill in all ten (10) segments between E (Empty) and F (Full). As the battery becomes

discharged, the farthest right segments will progressively disappear a half bar at a time

until no segments appear between E and F. At this level the word RECHARGE will

appear on the second line to indicate that the user should charge the batteries as soon

as possible.

CHARGING BATTERIES (FIGURE 7)

NOTE: New batteries MUST be fully charged prior to initial use of the wheelchair.

WARNING

Never attempt to recharge the batteries by attaching cables directly to the

battery terminals or clamps. Always use the recharging plug located on the

side of the wheelchair frame.

DO NOT attempt to recharge the batteries and operate the power wheelchair

at the same time.

During use and charging, unsealed batteries will vent hydrogen gas which is

explosive in the right concentration with air.

DO NOT sit in wheelchair while charging batteries.

CAUTION

Always charge new batteries before initial use or battery life will be reduced.

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BATTERIES

SECTION 9

NOTE: As a general rule, batteries should be recharged daily to assure the longest possible life

and minimize the required charging time. Plan to recharge the batteries when it is anticipated

the wheelchair will not be used for a long period of time.

The range per battery charge using recommended batteries should be approximately 5

to 9 hours of typical operation. Extensive use on inclines may substantially reduce per

charge mileage.

DESCRIPTION OF BATTERY CHARGERS

The charger automatically reduces the charge from an initially high rate to a zero

reading at a fully charged condition. If left unattended, the charger should automatically

shut-off when full charge is obtained.

There are some basic concepts which will help you understand this automatic

process. They are:

The amount of electrical current drawn within a given time to charge a battery is called

the “charge rate”. If, due to usage, the charge stored in the battery is low, the charge

rate is high, as indicated by the green light on the charger. Initially, the green light will

stay illuminated for a short period of time followed by a longer period of off time. As a

charge builds up, the charge rate is reduced, and the green light will stay illuminated for

a longer period of time followed by a shorter off time.

WARNING

NEVER leave the charger unattended when the charger circuit breaker is

tripping ON and OFF. A condition between the battery charger and batteries

exists. Contact an Invacare dealer.

NOTE: If performing the charging procedures independently, READ and CAREFULLY follow the

individual instructions for each charger (supplied or purchased).

NOTE: If charging instructions are not supplied, consult a qualified service technician for proper

procedures.

REQUIRED ITEMS:

TOOL

Battery Charger

ꢀExtension Cord

QUANTITY COMMENTS

Supplied

Not Supplied

ꢀ(3-prong plug, 15 ampere current rating; industrial type)

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SECTION 9

BATTERIES

USING BATTERY CHARGERS

1. Perform one (1) of the following:

A. WHEELCHAIRS EQUIPPED WITH MCC-MARK IV JOYSTICK - Attach

the battery charger connector to the charger cable/battery harness.

NOTE: The battery charger connector is factory installed on the RIGHT side of the wheelchair.

It can be positioned on either side of the wheelchair for user convenience.

NOTE FOR RECLINERS ONLY: If the wheelchair is a recliner, the battery charger connector as

well as the limit switch, are factory set on the RIGHT side of the wheelchair. However, they can

be positioned on either side for user convenience. The limit switch MUST BE positioned on the

same side as the battery charger connector.

B. TORQUE SP EQUIPPED WITH MARK IV RII JOYSTICK - Attach the

battery charger connector to the charger port on the FRONT of the joystick.

2. Plug the charger’s AC power cord, or extension, into the grounded 120 VAC wall outlet.

3. Wait until charging is complete.

NOTE: It is advantageous to recharge frequently rather than only when necessary. In fact, a

battery’s life is extended if the charge level is maintained well above a low condition.

NOTE: If the batteries need to be charged more often or take longer to charge than normal,

they may need to be replaced. Contact an Invacare dealer for service.

WHEELCHAIRS EQUIPPED WITH

MCC-MARK IV JOYSTICK

WHEELCHAIRS EQUIPPED WITH

MARK IV RII JOYSTICK

Three (3) Pronged Plug

FRONT VIEW OF

JOYSTICK

Battery Charger Connector

Battery Charger

Charger Cable

From Battery

Charger

From Battery

Charger

Three (3)

Pronged Plug

Charger

Port

Joystick

Charger Port

Battery Boxes

Battery

Boxes

Battery Charger

NOTE: This joystick is available only on the

Torque SP.

Support

Plate

Battery Charger Mount Bracket

From

Battery

Base Frame

Charger

Battery Charger

Port

FIGURE 7 - CHARGING BATTERIES

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BATTERIES

SECTION 9

REPLACING BATTERIES

NOTE: Invacare recommends that both batteries be replaced if one (1) battery is defective.

RECOMMENDED BATTERY TYPES

WARNING

Failure to use the correct battery size and/or voltage may cause damage to

your wheelchair and give you unsatisfactory performance.

The warranty and performance specifications contained in this manual are

based on the use of deep cycle gel cell or sealed lead acid batteries.

Invacare strongly recommends their use as the power source for this unit.

NOTE: GB denotes gearless/brushless. Both battery sizes are deep cycle batteries.

NOTE: Charge batteries daily. It is critical not to let them run low at any time.

1. Remove the battery boxes from the wheelchair. Refer to REMOVING/INSTALLING

BATTERY BOXES in this section of the manual.

2. Remove existing batteries from the battery box(es). Refer to INSTALLING/

REMOVING BATTERIES INTO/FROM BATTERY BOXES in this section of manual.

3. Clean the new battery terminals. Refer to CLEANING BATTERY TERMINALS in

this section of the manual.

4. Install the new batteries into the battery box(es). Refer to INSTALLING/REMOVING

BATTERIES INTO/FROM BATTERY BOXES in this section of the manual.

5. Install the battery boxes into the wheelchair. Refer to REMOVING/INSTALLING

BATTERY BOXES in this section of the manual.

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SECTION 9

BATTERIES

BATTERY REQUIREMENTS AND WEIGHT LIMITATIONS

(FOR WHEELCHAIRS BUILT BEFORE 1/26/04)

MODEL

WEIGHT

LIMITATION

MOTOR

BATTERY

ARROW

Up to 300 lbs

Up to 400 lbs

Up to 250 lbs

251-300 lbs

Gearless/Brushless

4 Pole Motor

Group 24

*22NF

TORQUE SP

RANGER X

4 Pole Motor

*22NF

Gearless/Brushless

4 Pole Motor

Group 24

301-350 lbs

Up to 300 lbs

4 Pole Motor

Gearless/Brushless

* Two batteries inside one battery box.

BATTERY REQUIREMENTS AND WEIGHT LIMITATIONS

(FOR WHEELCHAIRS BUILT AFTER 1/25/04)

MODEL

WEIGHT

LIMITATION

MOTOR

BATTERY

ARROW

Up to 400 lbs

251-300 lbs

301-350 lbs

Up to 400 lbs

Gearless/Brushless

4 Pole Motor

Group 24

*22NF

TORQUE SP

4 Pole Motor

Group 24

Gearless/Brushless

RANGER

* Two batteries inside one battery box.

NOTE: Weight limitation is total weight: user weight plus any additional items that the user may

require (back pack, etc.). Example: If weight limitation of the chair is 300 lbs and additional

items equal 25 lbs, subtract 25 lbs from 300 lbs This gives the maximum weight limitation of

the user to be 275 lbs

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BATTERIES

SECTION 9

CLEANING BATTERY TERMINALS

WARNING

Most batteries are not sold with instructions. However, warnings are

frequently noted on the cell caps. Read them carefully.

DO NOT allow the liquid in the battery to come in contact with skin,

clothes or other possessions. It is a form of acid and harmful or damaging

burns may result. Should the liquid touch your skin, wash the area

IMMEDIATELY and thoroughly with cool water. In serious cases or if eye

contact is made, seek medical attention IMMEDIATELY.

1. Examine battery clamps and terminals for corrosion.

2. Verify the plastic caps are in place over battery cell holes.

3. Clean terminals and inside battery clamps by using a battery cleaning tool, wire

brush, or medium grade sand paper.

NOTE: Upon completion, areas should be shiny, not dull.

4. Carefully dust off all metal particles.

REMOVING/INSTALLING BATTERY BOXES

GROUP 24 BATTERY BOXES FOR WHEELCHAIRS WITHOUT

VENT TRAY (FIGURE 8)

WARNING

Each battery weighs 51 pounds. Use proper lifting techniques (lift with your

legs) to avoid injury.

Removing.

1. Place the wheelchair in a well ventilated area where work can be performed without

risking damage to carpeting or floor covering.

2. Verify the joystick ON/OFF switch is in the OFF position.

3. Rotate the levers of the battery retainer assembly to the unlocked position.

4. Lift battery retainer assembly up off the mounting screws that secure the shocks to

the base frame.

NOTE: For gearless/brushless motors, ensure that the motor lock levers are in the engaged

(drive) position. Refer to SECTION 9.

5. Slide one (1) connector battery box along the sub-frame and remove from the

wheelchair.

6. Slide the two (2) connector battery box along the sub-frame and remove from the

wheelchair.

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SECTION 9

BATTERIES

Installing.

1. Place the wheelchair in a well ventilated area where work can be performed without

risking damage to carpeting or floor covering.

2. Verify the joystick ON/OFF switch is in the OFF position.

3. Secure the battery box carrying strap to the lid of the two (2) connector battery box.

4. Place two (2) connector battery box onto the battery sub-frame assembly with guide

pins facing the inside of the wheelchair.

5. Slide the two (2) connector battery box along the sub-frame until its guide pins are

engaged in the sub-frame connector.

NOTE: Visually inspect to ensure the connection is properly made. Connectors MUST be fully engaged.

NOTE: Make certain that the battery box carrying strap is positioned on top of the battery box

and will not interfere with the one (1) battery box guide pins when engaging the connector on

the one (1) battery box lid.

6. Secure the battery box carrying strap to the lid of the one (1) connector battery box.

7. Place one (1) connector battery box onto battery sub-frame.

8. Slide one (1) connector battery box along the sub-frame until its guide pins are

engaged in the connector of the two (2) connector battery box.

NOTE: Visually inspect to ensure the connection is properly made. Connectors MUST be fully engaged.

9. Place the battery retainer assembly on head portion of the mounting screws that

secure the shocks to the base frame.

CAUTION

The battery retainer assembly MUST be locked securely to hold the

battery boxes firmly in place or battery box connectors may be damaged

causing erratic wheelchair operation.

10. Rotate the levers of the battery retainer assembly to the locked position.

FRONT OF

BASE FRAME

Locked

Position

Unlocked

Position

Battery Retainer

Assembly

REAR OF

BASE FRAME

Levers

FIGURE 8 - REMOVING/INSTALLING BATTERY BOXES - GROUP 24

BATTERY BOXES FOR WHEELCHAIRS WITHOUT VENT TRAY

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BATTERIES

SECTION 9

GROUP 24 BATTERY BOXES FOR WHEELCHAIRS EQUIPPED

WITH VENT TRAY (FIGURE 9)

WARNING

Each battery weighs 51 pounds. Use proper lifting techniques (lift with your

legs) to avoid injury.

Removing.

1. Place the wheelchair in a well ventilated area where work can be performed without

risking damage to carpeting or floor covering.

2. Verify the joystick ON/OFF switch is in the OFF position.

3. Pull the battery box retainer UP over the end of the one (1) connector battery box.

4. Slide one (1) connector battery box along the sub-frame and remove from the wheelchair.

5. Slide the two (2) connector battery box along the sub-frame and remove from the wheelchair.

Installing.

1. Place the wheelchair in a well ventilated

Battery Box

area where work can be performed

without risking damage to carpeting or

floor covering.

Sub-Frame

Retainer Bar

Two (2)

Connector

Battery Box

2. Verify the joystick ON/OFF switch is in

the OFF position.

3. Secure the battery box carrying strap

to the lid of the two (2) connector

battery box.

Base

Frame

4. Place two (2) connector battery box

onto the battery sub-frame assembly

with guide pins facing the inside of the

wheelchair.

One (1) Connector Battery Box

Two (2) Connector

Battery Box

5. Slide the two (2) connector battery

box along the sub-frame until its guide

pins are engaged in the sub-frame

connector.

Battery Box

Sub-Frame

NOTE: Visually inspect to ensure the

connection is properly made. Connectors

MUST be fully engaged.

Base

Frame

Battery Box

Retainer Bar

NOTE: Make certain that the battery box

carrying strap is positioned on top of the

battery box and will not interfere with the one

(1) battery box guide pins when engaging the

connector on the one (1) battery box lid.

One (1) Connector Battery Box

FIGURE 9 - REMOVING/

INSTALLING BATTERY BOXES -

GROUP 24 BATTERY BOXES FOR

WHEELCHAIRS EQUIPPED WITH

VENT TRAY

6. Secure the battery box carrying strap

to the lid of the one (1) connector

battery box.

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SECTION 9

BATTERIES

7. Place one (1) connector battery box onto battery sub-frame.

8. Slide one (1) connector battery box along the sub-frame until its guide pins are

engaged in the connector of the two (2) connector battery box.

NOTE: Visually inspect to ensure the connection is properly made. Connectors MUST be fully engaged.

CAUTION

The battery box retainer MUST be locked securely to hold the battery

boxes firmly in place or battery box connectors may be damaged causing

erratic wheelchair operation.

9. Pull the battery box retainer down over the end of the one (1) connector battery

box until it is securely clipped (locked) into place.

22NF BATTERY BOXES (FIGURE 10)

NOTE: To install the battery box onto the wheelchair, reverse the following procedure.

1. Place the wheelchair in a well ventilated area where work can be performed

without risking damage to carpeting or floor covering.

2. Verify the joystick ON/OFF switch is in the OFF position.

3. Disconnect the battery cable from the outside of the battery box.

4. Disconnect the battery box retention strap.

5. Remove the battery box.

6. Slide the four (4) clips that secure the battery box cover to the battery box to the

OPEN position.

NOTE: Arrows on the battery box cover point to the open position.

7. Remove battery box cover from the battery box.

Arrows

Battery Box

Retention Strap

FIGURE 10 - REMOVING/INSTALLING BATTERY BOXES -

22NF BATTERY BOXES

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WIRING HARNESS

SECTION 10

This Section Includes the Following:

Removing/Installing the Wiring Harness

Adjusting Limit Switch

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all

attaching hardware is tightened securely - otherwise injury or damage may result.

REMOVING/INSTALLING THE WIRING HARNESS

GROUP 24 BATTERIES (FIGURE 1)

Removing.

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

2. Remove the two mounting screws and locknuts that secure the wiring harness

bracket to the base frame (DETAIL “A” of FIGURE 1).

3. Perform one (1) of the following sections:

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

A. Cut TIE-WRAPS A and B that secure the two (2) motor/controller

connections and the controller/wiring harness connection (BLUE connectors)

together (DETAIL “B” of FIGURE 1).

B. Cut TIE-WRAP C that secures the battery charger cable, motor connector

cable, controller connector cable, and wiring harness cable to the base frame

(DETAIL “B” of FIGURE 1).

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR

A. Cut TIE-WRAP A that secures the battery charger cable to the base frame

(DETAIL “C” of FIGURE 1).

NOTE: For STEPS 4-6 refer to DETAIL “B” or “C” of FIGURE 1.

4. Disconnect the battery harness/charger cable (BLUE) from the controller connector (BLUE).

5. Remove the two mounting screws that secure the charger cable to the mounting bracket.

6. Remove the wiring harness.

Installing.

1. Install NEW wiring harness w/bracket to the rear of the sub-frame and torque

mounting screws to 160 in-lbs (DETAIL “A” of FIGURE 1).

2. Secure the charger cable to the mounting bracket with the two (2) mounting

screws. Securely tighten (DETAIL “B” OR “C” of FIGURE 1).

3. Connect the battery harness/charger cable (BLUE) to the controller connector

(BLUE) (DETAIL “B” or “C” of FIGURE 1).

4. Perform one (1) of the following sections:

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

A. Group the two (2) motor/controller connections together along with the controller/wiring

harness connection (BLUE) and secure with TIE-WRAPS A and B (DETAIL “B” of

FIGURE 1).

B. Secure the Wiring Harness Cable, Battery Charger Cable, Controller Connector Cable,

and Motor Connector Cable to the suspension arm with TIE-WRAP C (DETAIL “B”

of FIGURE 1).

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SECTION 10

WIRING HARNESS

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR OPTION:

A. Secures the battery charger cable to the base frame with TIE-WRAP A

(DETAIL “C”).

5. Reinstall the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

DETAIL A - GROUP 24 BATTERIES

Wire Harness

Mounting

Bracket

Screws

Battery Box

Sub-Frame

REAR OF

CHAIR

Base Frame

Locknuts

DETAIL “B” - WHEELCHAIRS

WITH MOTOR/GEARBOX

ASSEMBLY

DETAIL “C” - WHEELCHAIRS

WITH GEARLESS/BRUSHLESS

MOTOR

Battery

Mounting

Screws (not shown)

Charger

Cable

Wiring

Controller

Connector

(BLUE)

Mounting

Screws

Harness

Connector

(BLUE)

Tie-Wrap C

Controller

Connector

Charger

Cable

Motor

Connector

Wiring

Harness

Cable

Motor

Connector

Cable

Tie-Wrap

NOTE: There is no

need to cut this tie-wrap.

Tie-Wraps

A and B

Controller

Connector

Motor

Connector

Wiring Harness

Connector (BLUE)

Controller

Connector (BLUE)

FIGURE 1 - REMOVING/INSTALLING THE WIRING HARNESS -

GROUP 24 BATTERIES

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WIRING HARNESS

SECTION 10

22NF BATTERIES (FIGURE 2)

Removing.

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

2. Cut the tie wrap that secures the rear portion of the wiring harness and joystick

cable to the rear of the seat frame (DETAIL “A”).

3. Perform one (1) of the following sections:

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

A. Cut TIE-WRAPS A and B that secure the two (2) motor/controller

connections and the controller/wiring harness connection (BLUE connectors)

together (DETAIL “B”).

B. Cut TIE-WRAP C that secures the battery charger cable, motor connector

cable, controller connector cable, and wiring harness cable to the base frame

(DETAIL “B”).

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR

A. Cut TIE-WRAP A that secures the battery charger cable to the base frame

(DETAIL “C”).

NOTE: For STEPS 4-6 refer to Detail “B” or “C”.

4. Disconnect the battery harness/charger cable (BLUE) from the controller connector (BLUE).

5. Remove the two mounting screws that secure the charger cable to the mounting bracket.

6. Remove the wiring harness.

Installing.

1. Secure the charger cable to the mounting bracket with the two (2) mounting

screws. Securely tighten (DETAIL “B” or “C”).

2. Connect the battery harness/charger cable (BLUE) to the controller connector

(BLUE) (DETAIL “B” or “C”).

3. Perform one (1) of the following sections:

WHEELCHAIRS WITH MOTOR/GEARBOX ASSEMBLY

A. Group the two (2) motor/controller connections together along with the

controller/wiring harness connection (BLUE) and secure with TIE-WRAPS A

and B (DETAIL “B”).

B. Secure the Wiring Harness Cable, Battery Charger Cable, Controller Connector

Cable, and Motor Connector Cable to the suspension arm with TIE-WRAP C

(DETAIL “B”).

WHEELCHAIRS WITH GEARLESS/BRUSHLESS MOTOR OPTION:

A. Secures the battery charger cable to the base frame with TIE-WRAP A

(DETAIL “C”).

4. Tie-wrap NEW wiring harness and joystick cable to the rear of the seat frame (DETAIL “A”).

5. Reinstall the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

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SECTION 10

WIRING HARNESS

DETAIL “A” - 22NF BATTERIES

Joystick

Cable

Wiring

Harness

NOTE: Illustration depicts gearless/brushless motor. Wiring harness is

secured to the rear of the seat frame in the same manner for

wheelchairs with conventional motor/gearbox assembly.

DETAIL “B” - WHEELCHAIRS

WITH GEARLESS/BRUSHLESS

DETAIL “C” - WHEELCHAIRS

WITH GEARLESS/BRUSHLESS

MOTOR

Mounting

Screws

Wiring

Controller

Connector

Battery

Charger

Cable

Harness

Controller

Connector

Mounting

Screws

Connector

(BLUE)

Motor

Connector

Charger

Mount

Bracket

Motor

Connector

Charger

Cable

NOTE: There is no

need to cut this tie-wrap.

Tie-Wraps

A and B

Controller

Connector

Controller

Connector

(BLUE)

Wiring Harness

Connector

(BLUE)

FIGURE 2 - REMOVING/INSTALLING THE WIRING HARNESS -

22NF BATTERIES

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WIRING HARNESS

SECTION 10

ADJUSTING LIMIT SWITCH (FIGURE 3)

NOTE: The following section is for high back van seat model wheelchairs only.

WARNING

NEVER operate the wheelchair while in any recline position over 114^°RELATIVE

TO THE SEAT FRAME. If the limit switch does not stop the wheelchair from

operating in a recline position greater than 114^°RELATIVE TO THE SEAT

FRAME, DO NOT operate the wheelchair. Adjust the limit switch BEFORE using

the wheelchair, otherwise injury or damage can occur.

1. Place the wheelchair on a level surface.

2. Recline the van seat back to a 24^oto achieve the 114^oangle relative to the seat

frame. Refer to ADJUSTING VAN SEAT in SECTION 6 of the Owner’s Manual, part

number 1104782 or 1123757.

NOTE: The van seat frame is at a 5^oangle relative to the ground. When the back angle is

adjusted to 114^orelative to the seat, it will measure 61^orelative to the ground.

NOTE: To determine 114^oback angle relative to the seat frame, place a magnetic protractor

(available at any hardware store) on the back as shown in FIGURE 2 and adjust the back until

the magnetic protractor reads 61^o.

3. Turn the wheelchair power switch on the joystick to the ON position.

NOTE: The wheelchair should not operate.

4. IF wheelchair operates, proceed to the following steps to adjust the actuator on the

upper limit switch bracket:

A. Fully recline the back. Refer to ADJUSTING VAN SEAT in SECTION 6 of the Owner’s

Manual, part number 1104782 or 1123757.

NOTE: This will make access to the limit switch easier.

114^o

24^oBack

Recline Angle

Upper

Limit

Switch

Bracket

5-3/4-inches

Phillips

Screws,

Washers

and

61^o

5^oSeat Angle

Locknuts

Magnetic Protractor - (Will read 61^o

when back recline angle is at 114^o

relative to the seat frame)

FIGURE 3 - ADJUSTING LIMIT SWITCH

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 10

WIRING HARNESS

B. Loosen, but do not remove, the two (2) phillips screws, washers and locknuts

that secure the actuator to the upper limit switch bracket.

C. Slide the actuator UP (towards the top of the wheelchair).

CAUTION

DO NOT over tighten the phillips screws that secure the actuator to the

upper limit switch bracket. Damage to the actuator can occur.

D. Only tighten the two (2) phillips screws, washers and locknuts that secure the

actuator to the upper limit switch bracket until the actuator does not move.

E. Repeat STEPS 1-3 until the wheelchair does not operate when the van seat back

is at a 24^oangle.

3G Storm Series Wheelchairs

Part No. 1104849

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RETENTION STRAP/RETAINER

SECTION 11

This Section Includes the Following:

Replacing Battery Box Retainer Bar/Retainer Clip

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure that all

attaching hardware is tightened securely - otherwise injury or damage may result.

REPLACING BATTERY BOX RETAINER BAR/RETAINER

CLIP (FIGURE 1)

1. Remove the battery box. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

REPLACING RETAINER CLIP

1. Remove the mounting screw that secures the retainer clip and shock (or rubber

element) to the base frame.

2. Remove the existing retainer clip.

3. Position the NEW retainer clip between the shock (or rubber element) and the

battery box sub-frame as shown in FIGURE 1. Make sure the angled end of the

retainer clip is facing up.

WARNING

The Battery Box Retainer Bar/Retainer Clip MUST be fastened securely in place

before using the wheelchair. Use Loctite 242 and torque to 160 in-lbs.

4. Reinstall the mounting screw that secures the retainer clip and shock (or rubber

element) to the base frame. Use Loctite 242 and torque to 160 in-lbs.

5. Reinstall the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

REPLACING RETAINER BAR

1. Remove the two (2) mounting screws and spacers that secure the battery box

retainer bar to the base frame.

2. Pull up on the battery box retainer bar to remove it from the base frame.

3. Install the two (2) existing spacers through the mounting holes in the NEW battery

box retainer bar.

WARNING

The Battery Box Retainer Bar/Retainer Clip MUST be fastened securely in place

before using the wheelchair. Use Loctite 242 and torque to 160 in-lbs.

4. Line up the NEW battery box retainer bar and spacers with the mounting holes in

the battery box sub frame and the base frame.

5. Reinstall the mounting screws that secure the battery box retainer bar between battery

box sub frame and the base frame. Use Loctite 242 and torque to 160 in-lbs.

6. Reinstall both battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 11

RETENTION STRAP/RETAINER

Rubber

Element

Mounting

Screws

Retainer

Bar

Retainer

Clip

Battery Box

Sub-frame

Spacer

Shock

Assembly

Base Frame

FIGURE 1 - REPLACING BATTERY BOX RETAINER BAR/RETAINER CLIP

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

This Section Includes the Following:

Replacing Pneumatic Tires/Tubes - Drive Wheels/Casters

Removing/Installing Drive Wheels

Removing/Installing Drive Wheel Hub

Removing/Installing GB Motor Spacer

Removing/Installing Adapter Plate with Studs

Installing Wheel Lock Bracket onto Wheelchair

Removing/Installing the Rim and/or Tire

Removing/Installing Casters

Replacing Forks

Removing/Installing the Motor

Installing/Removing Fenders

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure all

attaching hardware is tightened securely - otherwise injury or damage

may result.

CAUTION

As with any vehicle, the wheels and tires should be checked periodically

for cracks and wear and should be replaced.

REPLACING PNEUMATIC TIRES/TUBES - DRIVE WHEELS/

CASTERS

WARNING

DO NOT use your wheelchair unless it has the proper tire pressure

(p.s.i.). DO NOT overinflate the tires. Failure to follow these suggestions

may cause the tire to explode and cause bodily harm.

If tires are pneumatic, replacement of tire or tube MUST be performed

by an authorized Invacare dealer or qualified technician.

NOTE: If drive wheels or casters are pneumatic, under-inflation causes excessive wear which

results in poor performance of the tires.

REMOVING/INSTALLING DRIVE WHEELS (FIGURE 1)

CAUTION

Perform the following SECTION in a designated work area to prevent

damage to flooring (carpeting, tile, etc.).

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

REMOVING

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

2. Remove the four (4) beveled hex nuts that secures the drive wheel assembly to one

of the following: drive wheel hub, GB motor spacer or adapter plate with studs.

3. Remove existing drive wheel assembly from wheel hub.

INSTALLING

1. Reinstall new/existing drive wheel assembly to one (1) of the following: drive wheel

hub, GB motor spacer or adapter plate with studs and torque the four (4) beveled

hex nuts to 160-inch pounds.

2. Repeat procedure for opposite side of wheelchair, if necessary.

3. Reinstall the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

14 X 3-INCH WHEEL

CONVENTIONAL MOTOR

WITH GEARBOX

GEARLESS/BRUSHLESS MOTOR

G/B Motor

Drive Wheel

Assembly

Drive Wheel

Assembly

Motor/Gearbox

Assembly

Drive Wheel

Hub

GB Motor

Spacer

Drive Wheel

Hub

Four (4) Beveled Hex Nuts

14 X 4-INCH WHEEL

WHEELCHAIRS BUILT

BEFORE 1/26/04 ONLY

G/B Motor

Motor/Gearbox

Assembly

Drive Wheel

Assembly

Drive Wheel

Assembly

Adapter Plate

With Studs

Drive Wheel

Hub

Four (4) Beveled Hex Nuts

FIGURE 1 - REMOVING/INSTALLING DRIVE WHEELS

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

REMOVING/INSTALLING DRIVE WHEEL HUB (FIGURE 2)

REMOVING

1. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

2. Remove the locknut, washer, keystock and existing drive wheel hub from the drive

shaft of the motor/gearbox assembly.

INSTALLING

1. Position the keystock on the drive shaft of the motor/gearbox assembly.

CAUTION

DO NOT apply more than a 1-inch (in length) thin film of anti-seize

compound to the drive shaft. Applying more than 1-inch (in length) can

cause the anti-seize compound to leak resulting in damage to flooring

(carpet, tile, etc.).

2. Apply a thin film of anti-seize compound 1-inch in length to the end of the drive shaft.

3. Reinstall drive wheel hub onto the drive shaft of the motor/gearbox assembly.

NOTE: While installing the drive wheel hub onto the drive shaft, spin the drive wheel hub to

evenly distribute the anti-seize compound over the entire drive shaft.

4. Reinstall the washer and locknut and torque locknut to 45 ft-lbs (540 in-lbs).

5. Reinstall the drive wheel assembly to the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

6. Repeat procedure for the opposite side of the wheelchair, if necessary.

14 X 4-INCH WHEEL

14 X 3-INCH WHEEL

Motor/Gearbox

Assembly

Motor

Gearbox

Keystock

Drive Wheel

Hub

Drive Wheel

Hub

Washer

Locknut

Washer

Locknut

FIGURE 2 - REMOVING/INSTALLING DRIVE WHEEL HUB

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

REMOVING/INSTALLING GB MOTOR SPACER (FIGURE 3)

REMOVING

1. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

2. Remove the four (4) locknuts that secure the GB motor spacer to the GB motor.

INSTALLING

GB Motor

1. Secure the new/existing GB motor

spacer to the GB motor with the

existing four (4) locknuts. Tighten

locknuts to 160 in-lbs.

Four (4)

Locknuts

2. Reinstall the drive wheel onto the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in this

section of the manual.

GB Motor

Spacer

FIGURE 3 - REMOVING/

INSTALLING GB MOTOR SPACER

REMOVING/INSTALLING THE ADAPTER PLATE WITH

STUDS (FIGURE 4)

REMOVING

1. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

2. Remove the four (4) locknuts that secures the adapter plate with studs to the GB

motor.

GB Motor

INSTALLING

Four (4) Beveled

Hex Nuts

1. Secure the new/existing adapter plate

with studs to the GB motor with the

existing four (4) locknuts. Tighten

locknuts to 160 in-lbs.

2. Reinstall the drive wheel onto the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in this

section of the manual.

Adapter Plate

With Studs

FIGURE 4 - REMOVING/

INSTALLING THE ADAPTER

PLATE WITH STUDS

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

INSTALLING WHEEL LOCK BRACKET ONTO WHEELCHAIR

(FIGURE 5)

NOTE: This SECTION only pertains to wheelchairs with the conventional motor and gearbox.

On wheelchairs with the gearless/brushless motor, the wheel lock bracket is not required.

1. Remove the two (2) mounting screws closest to the large wheel that secure the

gearbox to the suspension arm.

2. Line up mounting holes in the wheel lock mounting bracket with the gearbox

mounting holes in the suspension arm.

3. Apply Loctite 242 to the two (2) mounting screws.

4. Reinstall the two (2) mounting screws into the mounting holes of the wheel lock

mounting bracket and gear box and torque to 75 in-lbs.

5. Repeat STEPS 1-4 for opposite wheel lock bracket.

6. Adjust the wheel locks. Refer to ADJUSTING WHEEL LOCKS in SECTION 9 of the

Owner’s Manual, part number 1104782 or 1123757.

Mounting

Screws

Wheel Lock

Mounting

Bracket

Gearbox

Suspension

Arm

FIGURE 5 - INSTALLING WHEEL LOCK BRACKET ONTO WHEELCHAIR

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

REMOVING/INSTALLING THE RIM AND/OR TIRE (FIGURE 6)

NOTE: This procedure is for wheelchairs equipped with heavy duty gearless/brushless motors

before 1/26/04 and standard gearless/brushless motors after 1/25/04.

REMOVING

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES

in SECTION 9 of this manual.

WARNING

If wheelchair is equipped with pneumatic tires, deflate tire BEFORE

removing rim - otherwise serious personal injury and damage will result.

2. If the wheelchair is equipped with pneumatic tires, deflate the tire.

3. Remove the five (5) mounting screws that secure the rim to the gearless/brushless

motor.

4. Remove the rim and tire from the gearless/brushless motor.

INSTALLING

1. Perform one (1) of the following:

A. Pneumatic Tires - Secure new/existing rim and new/existing pneumatic tire

[w/ new tube (if applicable)] to the gearless/brushless motor and torque the five

(5) mounting screws to 160 in-lbs.

B. Flat Free Tires

NOTE: In order to install the tire with flat free properly, the tire must be compressed to a

certain point to allow the use of the 16 mm length mounting screws. This is accomplished by

first using three (3) 25 mm length mounting screws threaded in every other mounting hole. The

longer mounting screws are not to be threaded completely into the GB motor. They are to be

threaded 1/4-inch only to provide compression of the tire.

Gearless/

Brushless

Motor

Tire

DETAIL “A”

M8-1-1/4-25mm

Mounting Screw

Five (5)

M8-1-1/4-16mm

Mounting Screws

Rim

FIGURE 6 - REMOVING/INSTALLING THE RIM AND/OR TIRE

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

B. Secure new/existing rim and new/existing tire with flat free to gearless/brushless

motor with the three (3) M8 x 1-1/4 x 25 mm mounting screws (not provided).

See DETAIL “A” in FIGURE 6.

NOTE: Once all three (3) mounting screws are in place, install one (1) shorter mounting screw

in each of the two (2) remaining mounting holes. Remove one (1) longer mounting screw at a

time and replace with the existing M8 x 1-1/4 x 16 mm length mounting screws. Torque all

five (5) mounting screws to 160 in-lbs.

2. Reinstall battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

3. If wheelchair is equipped with pneumatic tires, inflate tire to proper tire pressure

located on the side wall of the tire.

REMOVING/INSTALLING CASTERS (FIGURE 7)

WARNING

DO NOT use your power wheelchair unless it has the proper tire

pressure (p.s.i.). DO NOT over-inflate the tires. Failure to follow these

suggestions may cause the tire to explode and cause bodily harm. The

recommended tire pressure is listed on the side wall of the tire.

Periodically, the tires will need to be replaced due to wear or puncture.

REMOVING CASTERS

1. Remove the mounting screw, washers, spacers and locknut that secure the caster to

the fork.

2. Remove the existing caster from the fork.

8-inch Caster

Mounting Hole

SHOCK FORK

HARDWARE ORIENTATION

8-INCH FORK

Fork

(Reference)

Locknut

Washer

Spacer

Washer

Locknut

Mounting

Screw

Mounting

Screw

Spacer

Washer

Spacer

FIGURE 7 - REMOVING/INSTALLING CASTERS

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

INSTALLING CASTERS

1. Position the caster into the fork.

2. Reinstall the mounting screw, washers, spacers and locknut that secure the caster to the

fork.

3. Torque locknut to 10 ft-lbs (120 in-lbs).

4. Loosen the locknut 1/8 of a turn.

5. Move the caster side to side.

NOTE: If the caster moves side to side, tighten the locknut slightly.

REPLACING FORKS (FIGURE 8)

1. Remove the caster from the existing fork. Refer to REMOVING/INSTALLING

CASTERS in this section of the manual.

2. Remove the dust cover.

3. Remove the locknut, nylon washer, and spacer.

4. Drop the existing fork out of the caster head tube and spacer.

5. Slide the new fork into the spacer and caster head tube.

NOTE: Check bearing assemblies. Replace if necessary.

6. Ensure new fork slides completely into caster headtube.

7. Install spacer, nylon washer and secure with locknut.

WARNING

Improper positioning of the washer will prohibit the free movement of

the forks.

Dust Cover

Locknut

8. Install the caster onto the new fork.

Refer to REMOVING/INSTALLING

CASTERS in this section of the manual.

9. Adjust the forks. Refer to ADJUSTING

FORKS in SECTION 9 of the Owner’s

Manual, part number 1104782 or

1123757.

Washer

Spacer

Caster

Headtube

Spacer

Fork

FIGURE 8 - REPLACING FORKS

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

REMOVING/INSTALLING THE MOTOR

CONVENTIONAL MOTOR WITH GEARBOX (FIGURE 9)

Removing.

1. Disconnect the right and/or left motor connector from the controller.

2. Remove the two (2) allen screws and washers that secure the motor to the gearbox.

CAUTION

DO NOT damage the motor/gearbox coupling.

3. Carefully pull the motor away from the gearbox.

Installing.

1. Perform the following:

Motor

Connector

A. Inspect the coupling for wear and

damage. If damage is evident,

replace coupling.

B. Install coupling onto gearbox input

shaft inserting coupling drive plate

onto slot on shaft.

Motor Connector

Motor

C. Carefully align motor and coupling

and place motor against gearbox.

Coupling

D. With motor against gearbox, turn

gearbox drive shaft until the

coupler seats into gearbox.

Gearbox

Allen

Screw

Washer

NOTE: When properly aligned, motor will be

seated into gearbox.

Slots*

E. Install two (2) allen screws.

Use Loctite 242, tighten allen

screws evenly and then torque to

75 in-lbs.

*NOTE: The slots on coupling of motor, the

slots on the coupling and the slots on the

gearbox must line up for proper installation

2. Reconnect right/left motor connector

to controller.

FIGURE 9 - REMOVING/

INSTALLING THE MOTOR -

CONVENTIONAL MOTOR/

GEARBOX

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

STANDARD GEARLESS/BRUSHLESS MOTOR BEFORE 1/26/04

(FIGURE 10)

Removing.

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

2. Unthread the mounting screws that secure the wiring harness connector to the motor.

3. Unplug the wiring harness connector from the motor.

4. If necessary, remove the 22NF battery box tray. Refer to REMOVING/INSTALLING

22NF BATTERY BOX TRAY in SECTION 15 of this manual.

5. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

6. Note the mounting position of the motor on the suspension arm before removing the motor.

7. Loosen adjustment screw that secures the motor lock lever in place on the brake release shaft.

NOTE: Alignment pin is located inside of bushing guide on the suspension arm.

8. Remove the mounting screw and washer that secure the alignment pin in place.

9. Slide the alignment pin back out of the end of the motor lock lever.

10. Remove the four (4) mounting screws and washers that secure the motor to the

suspension arm.

11. Remove motor with motor lock lever from suspension arm.

12. If replacing motor, remove the motor lock lever from the brake release shaft of the

existing motor.

Installing.

NOTE: Do not tighten adjustment screw of motor lock lever until motor is secured in place on

the suspension arm.

1. If necessary, install motor lock lever onto new brake release shaft of motor.

2. Position the new/existing motor with motor lock lever onto the suspension arm in

the mounting position noted from STEP 5 of REMOVING THE STANDARD

GEARLESS/BRUSHLESS MOTOR in this section of the manual.

3. Secure motor to the suspension arm with existing four (4) mounting screws.

Torque to 13 ft-lbs.

4. Slide the motor lock lever along brake release shaft until the end is flush with the

bushing guide.

5. Slide alignment pin, located inside of bushing guide, into the end of the motor lock

lever and secure in place with existing mounting screw and washer. Securely tighten.

6. Secure motor lock lever in place on the brake release shaft with existing mounting screw.

7. Install the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in this section of the manual.

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

8. If necessary, install the 22NF battery box tray. Refer to REMOVING/INSTALLING

22NF BATTERY BOX TRAY in SECTION 15 of this manual.

9. Plug the wiring harness connector into the motor.

10. Secure the wiring harness connector to the motor with the existing two (2)

mounting screws.

11. Install the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

Brake Release Shaft

Guide Bushing

*Alignment Pin

Washer

Mounting

Screw

Motor

Lock

Lever

Motor

Suspension

Arm

Adjustment

Screw

Wiring Harness

Connector

Mounting

Screws

Washer

Mounting

Screws

Washer

Mounting Screws

*NOTE: Alignment pin exploded away suspension arm for clarification purposes only.

FIGURE 10 - REMOVING/INSTALLING THE MOTOR - STANDARD

GEARLESS/BRUSHLESS MOTOR BEFORE 1/26/04

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

HEAVY DUTY GEARLESS/BRUSHLESS MOTOR (FIGURE 11)

Removing.

1. Remove the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

2. Unthread the mounting screws that secure the wiring harness connector (not

shown) to the motor.

3. Unplug the wiring harness connector (not shown) from the motor.

4. Remove the drive wheel from the wheelchair. Refer to REMOVING/INSTALLING

THE RIM AND/OR TIRES in this section of the manual.

5. Note the mounting position of the motor on the suspension arm before removing

the motor.

6. Remove the cotter pin from the motor lock lever rod.

7. Disengage motor lock lever rod from the brake release lever located on the

gearless/brushless motor.

8. Remove the two (2) upper mounting screws that secure the gearless/brushless

motor, fender bracket and spacer to the suspension arm.

9. Remove the two (2) lower mounting screws and washers that secure the gearless/

brushless motor and spacer motor to the suspension arm.

10. Remove the gearless/brushless motor and fender bracket from the suspension arm.

Installing.

1. Position the new/existing motor onto the suspension arm in the mounting position

noted in STEP 5 of REMOVING THE MOTOR in the procedure above.

2. Re-position the fender bracket on the suspension arm.

3. Secure the gearless/brushless motor, spacer and fender bracket to the suspension

arm with existing two (2) upper mounting screws, two (2) lower mounting screws

and two (2) washers. Torque all four (4) mounting screws to 13 ft-lbs.

4. Engage the motor lock lever rod to the brake release lever on the motor and secure

with the existing cotter pin.

5. Install the drive wheel to the wheelchair. Refer to REMOVING/INSTALLING THE

RIM AND/OR TIRES in this section of the manual.

6. Plug the wiring harness connector (not shown) to the motor.

7. Re-thread the mounting screws that secure the wiring harness connector (not

shown) to the motor.

8. Install the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

Upper Mounting

Screws

Gearless/Brushless

Fender Bracket

Motor Lock

Lever Rod

Cotter Pin

Gearless/

Brushless

Motor

Lower Mounting

Screws

Washers

Suspension

Arm

Motor Lock

Lever

Brake

Release

Lever

Spacers

WIRING HARNESS FROM CONTROLLER

CONNECTS TO THE MOTOR HERE

FIGURE 11 - REMOVING/INSTALLING THE MOTOR - HEAVY-DUTY

GEARLESS/BRUSHLESS MOTOR

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

INSTALLING/REMOVING FENDERS

4 POLE MOTORS (FIGURE 12)

Installing.

1. Remove the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

NOTE: When performing STEPS 2 and 3, only the two (2) mounting screws on the side of the

suspension arm where the drive wheel mounts need to be removed in order to install the fender.

2. Remove the LONGER mounting screw that secures the rear of motor/gearbox to

the suspension arm.

3. Remove the SHORTER mounting screw and lock washer (if applicable) that secures

the rear of motor/gearbox to the suspension arm.

CAUTION

The longer mounting screws MUST be used to secure the REAR of the

gearbox to the suspension arm and the SHORTER mounting screws

MUST be used to secure the FRONT of the gearbox to the suspension

arm - otherwise, damage to the gearbox casting can result.

4. Secure the rear of 4 pole fender bracket to the suspension arm and motor/gearbox,

in the orientation shown, using the LONGER mounting screw removed in STEP 2.

Torque mounting screw to 160 in-lbs.

5. Secure the front of 4 pole fender bracket to the suspension arm and motor/gearbox,

in the orientation shown, using the SHORTER mounting screw and lock washer (if

applicable) removed in STEP 3. Torque mounting screw to 160 in-lbs.

6. Secure the fender and spacer to the 4 pole fender bracket, in the orientation shown,

with two (2) pan head tap screws provided. Securely tighten.

7. Reinstall the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

LONGER

Mounting Screw

SHORTER

Mounting Screw

Fender

Lock Washer

(if applicable)

4 pole

Fender Bracket

Suspension

Arm

Spacer

Pan Head

Tap Screws

FIGURE 12 - INSTALLING/REMOVING FENDERS -

4 POLE MOTORS

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

Removing.

1. Remove the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

NOTE: When performing STEPS 2 and 3, only the two (2) mounting screws on the side of the

suspension arm where the drive wheel mounts need to be removed in order to remove the fender.

2. Remove the LONGER mounting screw that secures the rear of motor/gearbox to

the suspension arm.

3. Remove the SHORTER mounting screw and lock washer (if applicable) that secures

the rear of motor/gearbox to the suspension arm.

CAUTION

The longer mounting screws MUST be used to secure the REAR of the

gearbox to the suspension arm and the SHORTER mounting screws

MUST be used to secure the FRONT of the gearbox to the suspension

arm - otherwise, damage to the gearbox casting can result.

4. Secure the rear of the suspension arm to the motor/gearbox using the LONGER

mounting screw removed in STEP 2. Torque mounting screw to 160 in-lbs.

5. Secure the front of the suspension arm to the motor/gearbox using the SHORTER

mounting screw and lock washer (if applicable) removed in STEP 3. Torque mounting

screw to 160 in-lbs.

6. Reinstall the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 12

WHEELS/MOTORS

STANDARD GEARLESS/BRUSHLESS MOTORS BEFORE 1/26/04

(FIGURE 13)

Installing.

1. Remove the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

2. Remove two (2) top mounting screws and flat washers (not shown) that secure the

gearless/brushless motor to the suspension arm. Discard flat washers.

3. Secure the gearless/brushless fender bracket to the suspension arm, in the

orientation shown, using the two (2) mounting screws removed in STEP 2. Torque

mounting screws to 160 in-lbs.

4. Secure the fender and spacer to the gearless/brushless fender bracket, in the orien-

tation shown, with the two (2) pan head tap screws provided. Securely tighten.

5. Reinstall the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

Removing.

1. Remove the drive wheel. Refer to REMOVING/INSTALLING THE DRIVE WHEELS

in this section of the manual.

2. Remove two (2) top mounting screws that secure the fender bracket and gearless/

brushless motor to the suspension arm.

3. Secure the gearless/

brushless motor and two

(2) flat washer to the

Two (2) Top

Mounting Screws

Gearless/Brushless

Fender Bracket

suspension arm using the

two (2) exisiting mounting

screws. Torque mounting

screws to 160 in-lbs.

Fender

4. Reinstall the drive wheel.

Refer to REMOVING/

INSTALLING THE DRIVE

WHEELS in this section of

the manual.

Pan Head

Tap Screws

Spacer

Suspension Arm

FIGURE 13 - INSTALLING/REMOVING

FENDERS - STANDARD GEARLESS/

BRUSHLESS MOTORS BEFORE 1/26/04

3G Storm Series Wheelchairs

Part No. 1104849

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WHEELS/MOTORS

SECTION 12

HEAVY DUTY GEARLESS/BRUSHLESS MOTORS (FIGURE 14)

Installing.

1. Remove the rim and tire from the heavy duty gearless/brushless motor. Refer to

REMOVING/INSTALLING THE RIM AND/OR TIRE in this section of the manual.

2. Remove two (2) top mounting screws and flat washers (not shown) that secure the

gearless/brushless motor to the suspension arm. Discard flat washers.

3. Secure the fender bracket to the suspension arm, in the orientation shown, using the

two (2) mounting screws removed in STEP 2. Torque mounting screws to 160 in-lbs.

4. Secure the fender and spacer to the fender bracket, in the orientation shown, with the

two (2) pan head tap screws provided. Securely tighten.

5. Reinstall rim and tire to the gearless/brushless motor. Refer to REMOVING/

INSTALLING THE RIM AND/OR TIRE in this section of the manual.

Removing.

1. Remove the rim and tire from the heavy duty gearless/brushless motor. Refer to

REMOVING/INSTALLING THE RIM AND/OR TIRE in this section of the manual.

2. Remove two (2) top mounting screws that secure the fender bracket and gearless/

brushless motor to the suspension arm.

3. Remove the fender bracket.

4. Secure the gearless/brushless motor to the suspension arm with two (2) flat washers and

two (2) existing mounting screws. Torque

mounting screws to 160 in-lbs.

Two (2) Top

Mounting Screws

Gearless/Brushless

Fender Bracket

5. Reinstall rim and tire to the gearless/

brushless motor. Refer to REMOVING/

INSTALLING THE RIM AND/

OR TIRE in this section of

the manual.

Fender

Suspension

Arm

Fender

Spacer

Pan Head

Tap Screws

FIGURE 14 - INSTALLING/REMOVING FENDERS -

HEAVY DUTY GEARLESS/BRUSHLESS MOTORS

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 13

ELECTRONICS

This Section Includes the Following:

Repositioning MKIV Joystick - Van Seat Models

Removing/Installing the MKIV Controller

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure

that all attaching hardware is tightened securely - otherwise injury or

damage may result.

REPOSITIONING MKIV JOYSTICK - VAN SEAT MODELS

(FIGURE 1)

1. Turn the lever on the adjustment lock to release the adjustment lock from joystick

mounting tube.

2. Remove the joystick mounting tube from wheelchair.

3. Remove the three (3) hex bolts, spacers and locknuts that secure joystick mounting

bracket to armrest plate.

4. Remove the phillips screws that secures the front of the armrest pad to the armrest plate.

5. Remove the phillips screw that secures the rear of the armrest pad and armrest

insert to the armrest plate.

6. Remove the armrest pad from the armrest plate.

7. Remove the lug bolt, washers and locknut that secure the existing armrest plate to

the armrest weldment.

8. Repeat STEPS 4-7 for opposite

side of the wheelchair.

Armrest Plate

Armrest Insert

Lug Bolt (STEPS 7, 9)

Locknuts

(STEPS 3,16)

9. Position armrest plate with

joystick mounting holes on

Phillips Screw

(STEPS 5, 13)

desired side of armrest weldment

and secure with lug bolt, washers

and locknut. Refer to FIGURE 1

for correct hardware orientation.

Locknut

(STEPS 7, 9)

Armrest Pad

Washer

(STEPS 7, 9)

Hex Bolts

(STEPS 3, 16)

10. Position armrest plate without

joystick mounting holes on

opposite side of the armrest

weldment and secure with lug

bolt, washers and locknut.

Refer to FIGURE 1 for correct

hardware orientation.

Phillips

Screws

(STEPS 4,

14)

Armrest

Weldment

Joystick Mounting

Bracket

(STEPS 3, 16)

Spacers

(STEPS 3, 16)

Washers

(STEPS 7, 9)

FIGURE 1 - REPOSITIONING MKIV

JOYSTICK - VAN SEAT MODELS

3G Storm Series Wheelchairs

100

Part No. 1104849

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ELECTRONICS

SECTION 13

REMOVING/INSTALLING THE MKIV CONTROLLER

REMOVING MKIV CONTROLLER (WHEELCHAIRS EQUIPPED

WITH NON-POWERED SEATING SYSTEMS) (FIGURE 2)

1. Remove the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the controller shroud (if applicable).

3. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket and jumper cable to the base frame.

4. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket to the base frame.

5. Remove the 8-32 x 1/2-inch mounting screw and lockwasher that secures the front

of the MKIV controller and jumper cable to the controller bracket.

6. Remove the two (2) 8-32 x 1/2-inch mounting screws that secure the rear of the

MKIV controller to the controller bracket.

INSTALLING MKIV CONTROLLER (WHEELCHAIRS EQUIPPED

WITH NON-POWERED SEATING SYSTEMS) (FIGURE 2)

1. Secure the rear of the MKIV controller to the controller bracket with two (2) of

the NEW 8-32 x 1/2-inch mounting screws. Securely tighten.

2. Secure the front of the MKIV controller and one end of the jumper cable to the

controller bracket with one (1) of the NEW 8-32 x 1/2-inch mounting screw and

lockwasher. Securely tighten.

3. Secure one side of the controller bracket to the base frame as shown in FIGURE 2

with one (1) of the NEW 5/16-18 x 1-inch hex head cap screw. Securely tighten.

4. Secure the other side of the controller bracket and opposite end of jumper cable to

the base frame as shown in FIGURE 2 with the remaining NEW 5/16-18 x 1-inch hex

head cap screw. Securely tighten.

5. Reinstall the controller shroud (if applicable).

6. Reinstall the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

101

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SECTION 13

ELECTRONICS

8-32 x 1/2-inch

Mounting Screws

Jumper Cable

5/16-18 x 1-inch

Hex Head

Cap Screw

Lockwasher

5/16-18 x 1-inch

Hex Head

Cap Screw

8-32 x 1/2-inch

Mounting Screws

Controller

Bracket

MKIV Controller

FIGURE 2 - REMOVING/INSTALLING THE MKIV CONTROLLER

(WHEELCHAIRS EQUIPPED WITH

NON-POWERED SEATING SYSTEMS)

3G Storm Series Wheelchairs

102

Part No. 1104849

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ELECTRONICS

SECTION 13

REMOVING GB CONTROLLER (WHEELCHAIRS EQUIPPED

WITH NON-POWERED SEATING SYSTEMS) (FIGURE 3)

1. Remove the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the controller shroud (if applicable).

3. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket and jumper cable to the base frame.

4. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket to the base frame.

5. Remove the 10-32 x 1/2-inch mounting screw and two (2) lockwashers that secure

the front of the GB controller and jumper cable to the controller bracket.

6. Remove the two (2) 10-32 x 1/2-inch mounting screws that secure the rear of the

GB controller to the controller bracket.

INSTALLING GB CONTROLLER (WHEELCHAIRS EQUIPPED

WITH NON-POWERED SEATING SYSTEMS) (FIGURE 3)

1. Secure the rear of the GB controller to the controller bracket with two (2) of the

NEW 10-32 x 1/2-inch mounting screws. Securely tighten.

2. Secure the front of the GB controller and one end of the jumper cable to the

controller bracket with one (1) of the NEW 10-32 x 1/2-inch mounting screw and

two (2) lockwashers. Securely tighten.

3. Secure one side of the controller bracket to the base frame as shown in FIGURE 3

with one (1) of the NEW 5/16-18 x 1-inch hex head cap screws. Securely tighten.

4. Secure the other side of the controller bracket and opposite end of jumper cable to

the base frame as shown in FIGURE 3 of the remaining NEW 5/16-18 x 1-inch hex

head cap screws. Securely tighten.

5. Reinstall the controller shroud (if applicable).

6. Reinstall the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

103

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SECTION 13

ELECTRONICS

8-32 x 1/2-inch

Mounting Screws

Jumper

Cable

5/16-18 x 1-inch

Hex Head

Cap Screw

Lockwashers

10-32 x 1/2-inch

Mounting Screw

5/16-18 x 1-inch

Hex Head

Cap Screw

Controller

Bracket

GB Controller

FIGURE 3 - REMOVING/INSTALLING THE GB CONTROLLER

(WHEELCHAIRS EQUIPPED WITH

NON-POWERED SEATING SYSTEMS)

3G Storm Series Wheelchairs

104

Part No. 1104849

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ELECTRONICS

SECTION 13

REMOVING MKIV CONTROLLER (WHEELCHAIRS EQUIPPED

WITH 2ND GENERATION POWERED SEATING SYSTEMS)

(FIGURE 4)

1. Remove the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the controller shroud (if applicable).

3. Remove the TRCM controller (if applicable). Refer to REPLACING THE TILT AND

RECLINE CONTROL MODULE (TRCM) in Tilt and Recline Service Manual, part

number 1090208.

4. Remove the 5/16-18 x 1-inch hex head cap screw that secures the jumper cable and

controller bracket to the base frame.

5. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket to the base frame.

6. Remove the 8-32 x 1/2-inch mounting screw and lockwasher that secures the front

of the MKIV controller and jumper cable to the controller bracket.

7. Remove the two (2) 8-32 x 1/2-inch mounting screws that secure the rear of the

MKIV controller to the controller bracket.

INSTALLING MKIV CONTROLLER (WHEELCHAIRS EQUIPPED

WITH 2ND GENERATION POWERED SEATING SYSTEMS)

(FIGURE 4)

1. Secure the rear of the MKIV controller to the controller bracket with two (2) of

the NEW 8-32 x 1/2-inch mounting screws. Securely tighten.

2. Secure the front of the MKIV controller and one end of the jumper cable to the

controller bracket with one (1) of the NEW 8-32 x 1/2-inch mounting screw and

lockwasher. Securely tighten.

3. Secure one side of the controller bracket to the base frame as shown in FIGURE 6

with one (1) of the NEW 5/16-18 x 1-inch hex head cap screw. Securely tighten.

4. Secure the other side of the controller bracket and opposite end of jumper cable to

the base frame as shown in FIGURE 4 with one (1) of the NEW 5/16-18 x 1-inch

hex head cap screw. Securely tighten.

5. Reinstall the TRCM controller (if applicable). Refer to REPLACING THE TILT AND

RECLINE CONTROL MODULE (TRCM) in Tilt and Recline Service Manual, part

number 1090208.

6. Reinstall the controller shroud (if applicable).

7. Reinstall the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

105

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SECTION 13

ELECTRONICS

5/16-18 x 1-inch Hex

Head Cap Screw

Jumper

Cable

8-32

x 1/2-inch

Mounting

Screws

8-32

x 1/2-inch

Mounting

Screw

Controller

Bracket

Lockwasher

MKIV

Controller

5/16-18 x 1-inch hex

Head Cap Screw

FIGURE 4 - REMOVING/INSTALLING THE MKIV CONTROLLER

(WHEELCHAIRS EQUIPPED WITH 2ND GENERATION

POWERED SEATING SYSTEM)

3G Storm Series Wheelchairs

106

Part No. 1104849

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ELECTRONICS

SECTION 13

REMOVING GB CONTROLLER (WHEELCHAIRS EQUIPPED

WITH 2ND GENERATION POWERED SEATING SYSTEMS)

(FIGURE 5)

1. Remove the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the controller shroud (if applicable).

3. Remove the TRCM controller (if applicable). Refer to REPLACING THE TILT AND

RECLINE CONTROL MODULE (TRCM) in Tilt and Recline Service Manual, part

number 1090208.

4. Remove the 5/16-18 x 1-inch hex head cap screw that secures the jumper cable and

controller bracket to the base frame.

5. Remove the 5/16-18 x 1-inch hex head cap screw that secures the controller

bracket to the base frame.

6. Remove the 10-32 x 1/2-inch mounting screw and two (2) lockwashers that secures

the front of the GB controller and jumper cable to the controller bracket.

7. Remove the two (2) 8-32 x 1/2-inch mounting screws that secure the rear of the GB

controller to the controller bracket.

INSTALLING GB CONTROLLER (WHEELCHAIRS EQUIPPED

WITH 2ND GENERATION POWERED SEATING SYSTEMS)

(FIGURE 5)

1. Secure the rear of the GB controller to the controller bracket with two (2) of the

NEW 10-32 x 1/2-inch mounting screws. Securely tighten.

2. Secure the front of the GB controller and one end of the jumper cable to the

controller bracket with one (1) of the NEW 10-32 x 1/2-inch mounting screw and

lockwasher. Securely tighten.

3. Secure one side of the controller bracket to the base frame with one (1) of the

NEW 5/16-18 x 1-inch hex head cap screws. Securely tighten.

4. Secure the other side of the controller bracket and opposite end of jumper cable to the

base frame one (1) of the NEW 5/16-18 x 1-inch hex head cap screws. Securely tighten.

5. Reinstall the TRCM controller (if applicable). Refer to REPLACING THE TILT AND

RECLINE CONTROL MODULE (TRCM) in Tilt and Recline Service Manual, part

number 1090208.

6. Reinstall the controller shroud (if applicable).

7. Reinstall the battery boxes. Refer to REMOVING/INSTALLING THE BATTERY

BOXES in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

107

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SECTION 13

ELECTRONICS

5/16-18 x 1-inch

Hex Head

Cap Screw

10-32 x 1/2-inch

Mounting Screws

(STEP 1)

Jumper

Cable

10-32 x

1/2-inch

Mounting

Screw

Controller

Bracket

Lockwashers

5/16-18 x 1-inch Hex

Head Cap Screw

GB Controller

FIGURE 5 - REMOVING/INSTALLING THE GB CONTROLLER

(WHEELCHAIRS EQUIPPED WITH 2ND GENERATION POWERED

SEATING SYSTEM)

3G Storm Series Wheelchairs

108

Part No. 1104849

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RECLINER

SECTION 14

This Section Includes the Following:

Positioning Limit Switch

Adjusting Limit Switch

Replacing Recliner Cable Assemblies

Replacing/Adjusting Gas Cylinders

Changing Back Height

Changing Seat Depth

Changing Seat Width

Installing/Replacing Adjustable 16 to 19-inch Deep Recliner

Seat Frame onto Arrow or X Base

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure

that all attaching hardware is tightened securely - otherwise injury or

damage may result.

POSITIONING LIMIT SWITCH (FIGURE 1)

NOTE: The battery charger connector, as well as, the limit switch are factory set on the RIGHT

side of the wheelchair. However, they can be positioned on either side for user convenience.

The limit switch MUST BE positioned on the same side as the battery charger connector.

1. Cut the two (2) tie wraps that secure the limit switch wire to the seat frame.

2. Remove the two (2) mounting screws and washers that secure the actuator to the

gas cylinder pivot block.

3. Position actuator on opposite gas cylinder pivot block.

CAUTION

DO NOT over tighten the mounting screws that secure the actuator to

the pivot block. Damage to actuator will occur.

4. Secure the actuator to the pivot block with the two (2) mounting screws and washers.

DO NOT overtighten.

5. Remove the mounting screw that secures the wire retainer to the inside of the seat frame.

6. Remove the two (2) mounting screws and washers that secure the limit switch

sensor to the seat frame.

7. Turn limit switch sensor over so opposite side is facing up and the wire is on the

INSIDE of the seat frame.

8. Position the limit switch sensor onto the opposite side of the seat frame.

CAUTION

DO NOT over tighten the mounting screws that secure the limit switch

sensor to the seat frame. Damage to the limit switch sensor will occur.

3G Storm Series Wheelchairs

Part No. 1104849

109

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SECTION 14

RECLINER

9. Secure limit switch sensor to the seat frame with the two (2) mounting screws and washers.

10. Secure the wire retainer onto the INSIDE of the seat frame with the mounting screw.

11. Tie wrap the limit switch wire to the seat frame.

12. Adjust the limit switch. Refer to ADJUSTING LIMIT SWITCH in this section of the

manual.

Mounting Screws

(DO NOT Over Tighten)

Limit Switch

Sensor

Actuator

Washers

Tie Wraps

Mounting Screws

(DO NOT Overtighten)

Mounting

Screws

Wire

Retainer

Seat

Frame

Gas Cylinder

Pivot Block

Limit Switch

Sensor

Mounting Screw

(DO NOT Overtighten)

Actuator

Washers

FIGURE 1 - POSITIONING LIMIT SWITCH

ADJUSTING LIMIT SWITCH (FIGURE 2)

WARNING

NEVER operate the wheelchair while in any recline position over 105^oRELATIVE

TO THE SEAT FRAME. If the limit switch does not stop the wheelchair from

operating in a recline position greater than 105^oRELATIVE TO THE SEAT

FRAME, do not operate the wheelchair. Adjust the limit switch BEFORE using the

wheelchair, otherwise injury or damage can occur.

1. Recline the back of the wheelchair until the gas cylinder rod measures 3-21/32 of an inch.

2. Turn the power of the joystick to the ON position.

NOTE: ALL segments of the bar graph on the joystick should start to flash on and off and the

wheelchair should not operate.

3. IF the wheelchair operates, proceed to the following steps to adjust the actuator on

the gas cylinder pivot block:

A. Loosen, but do not remove, the two (2) mounting screws and washers that

secure the actuator to the gas cylinder pivot block.

B. Slide actuator UP (towards top of the wheelchair).

CAUTION

DO NOT over tighten the mounting screws that secure the actuator to

the pivot block. Damage to the actuator will occur.

3G Storm Series Wheelchairs

110

Part No. 1104849

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RECLINER

SECTION 14

C. Only tighten the two (2) mounting screws and washers that secure the actuator

to the gas cylinder pivot block until the actuator does not move.

D. Repeat STEPS 1 and 2 until the wheelchair does not operate when the gas

cylinder rod is 3-21/32-inch long.

POSITION OVER

105° RELATIVE TO

THE SEAT FRAME

Gas Cylinder Rod

Measures 3-21/32-inches

Mounting Screws and Washers

(DO NOT Over-Tighten)

Actuator

Gas Cylinder Pivot

Block

FIGURE 2 - ADJUSTING LIMIT SWITCH

REPLACING RECLINER CABLE ASSEMBLIES (FIGURE 3)

NOTE: There are three (3) different cable lengths depending on back height:

CABLE LENGTH

Short

Medium

BACK HEIGHT

18-1/2 and 20-inches

22 and 24-inches

26-inches

Long

WARNING

Replace ONE (1) recliner cable assembly at a time to avoid injury.

1. Cut the tie wraps that secure the existing recliner cable assembly to the back cane.

2. Remove the pan screw that secures the handle of the existing recliner cable assembly

to the back cane.

3. Loosen the jam nut on the gas cylinder rod.

4. Remove the mounting screw, washer, nylon washers and locknut that secure the

TOP of the gas cylinder to the mounting bracket on the back cane.

5. Unscrew the gas cylinder from the operator of the existing recliner cable assembly

but do not remove the gas cylinder from the pivot block.

6. Remove the operator of the existing recliner cable assembly from the pivot block.

7. Make sure the threads of the gas cylinder rod are flush with the inside of the pivot block.

8. With the operator of the NEW recliner cable assembly on the inside of the recliner

seat frame, line up the mounting hole in the operator of the new recliner cable

assembly with the gas cylinder rod.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 14

RECLINER

CAUTION

DO NOT force the gas cylinder rod into the operator of the recliner

cable assembly.

DO NOT cross thread the operator of the recliner cable assembly with

the gas cylinder.

If slack in the recliner cable or movement in the operator of the cable

assembly can not be eliminated, DO NOT use the recliner cable assembly.

9. Screw the NEW gas cylinder into the

operator of the cable assembly until the

jam nut sits on the pivot block, there is

Mounting Bracket

Pan Screw

Mounting

Screw

no slack in the recliner cable and there

is no movement in the operator of the

recliner cable assembly.

Handle

Washer

Nylon

Washers

10. Visually inspect the handle to make

sure that the cable is snapped

completely into slot in handle and

cable fitting is seat properly in the

handle.

Locknut

Gas Cylinder

Tie

Wraps

Back Cane

Cable

Operator

11. Reinstall the mounting screw through

the mounting bracket of the back cane,

nylon washer, gas cylinder, nylon

Gas

Cylinder

Rod

washer, mounting bracket and washer

and securely tighten with the existing

locknut. Torque to 75 in-lbs.

No Slack in

Cable

Jam

Nut

12. Line up the mounting hole in the handle

of the recliner cable assembly with the

mounting hole in the back cane.

Cable Snapped

into Slot

13. Insert the pan screw through the handle

of the recliner cable assembly and the

back cane and torque to 9 in-lbs.

Pivot

Block

Handle

NO Movement in

Operator of the Recliner

Cable Assembly

14. Tie wrap the recliner cable assembly

to the recliner back cane.

Cable Fitting

Seated Properly

15. Adjust the gas cylinder. Refer to

ADJUSTING GAS CYLINDERS in this

section of the manual.

FIGURE 3 - REPLACING RECLINER

CABLE ASSEMBLIES

3G Storm Series Wheelchairs

112

Part No. 1104849

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RECLINER

SECTION 14

REPLACING/ADJUSTING GAS CYLINDERS (FIGURE 4)

WARNING

Replace ONE (1) gas cylinder at a time to avoid injury.

Both gas cylinders MUST be operational and adjusted properly BEFORE

using the recliner. DO NOT operate the recliner if only one (1) of the gas

cylinders is operational or adjusted properly.

REPLACING GAS CYLINDER

Mounting Bracket

Mounting Screw

Nylon Washer

1. Remove the mounting screw, washer,

nylon washers and locknut that secure

Handle

the TOP of the gas cylinder to

Washer

Lock Nut

mounting bracket on back cane.

2. Loosen the jam nut on existing gas

cylinder rod.

Gas Cylinder

Rod

No Slack

in Cable

Jam Nut

3. Unscrew the existing gas cylinder

from the operator of the recliner

cable assembly and the pivot block

and remove the existing gas cylinder

from the wheelchair.

Gas Cylinder

Rod Threads

Gas

Cylinder

4. Screw cylinder rod of the NEW gas

cylinder into the pivot block until the

threads of the cylinder rod are flush

with inside of pivot block (FIGURE 4).

Pivot Block

NO Movement in

Operator of the Recliner

Cable Assembly

Cable Snapped

into Slot

5. With the operator of the recliner

cable assembly on the inside of the

recliner seat frame, line up the

mounting hole in the operator of the

recliner cable assembly with the new

gas cylinder rod.

Handle

Cable Fitting

Seated Properly

FIGURE 4 - REPLACING/

ADJUSTING GAS CYLINDERS

CAUTION

DO NOT force the gas cylinder rod into the operator of the recliner

cable assembly.

DO NOT cross thread the operator of the recliner cable assembly with

the gas cylinder.

If slack in the recliner cable or movement in the operator of the cable assembly can not

be eliminated, DO NOT use the recliner cable assembly.

6. Screw the NEW gas cylinder into the operator of the cable assembly until the jam nut

sits on the pivot block, there is no slack in recliner cable and there is no movement in

the operator of the recliner cable assembly.

7. Visually inspect the handle to make sure that the cable is snapped completely into

slot in handle and cable fitting is seat properly in the handle.

8. Press the operator of the recliner cable assembly to extend the NEW gas cylinder.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 14

RECLINER

9. Line up the mounting holes of the NEW gas cylinder and the bracket of the back cane.

10. Reinstall the mounting screw through the mounting bracket of the back cane, nylon

washer, NEW gas cylinder, nylon washer, mounting bracket and washer and

securely tighten with the existing locknut. Torque to 75 in-lbs.

11. Adjust the NEW gas cylinders. Refer to ADJUSTING GAS CYLINDERS in this

section of the manual.

ADJUSTING GAS CYLINDER

1. To adjust the LEFT gas cylinder: Squeeze the handle of the RIGHT recliner cable

assembly and try to recline the back. The back should not recline.

2. If the LEFT side of the back releases without squeezing the handle of the LEFT

recliner cable assembly, perform the following steps:

A. Finger tighten the jam nut on the rod of the gas cylinder until it bottoms out on

the rod of the cylinder (FIGURE 4).

B. Turn the jam nut on the LEFT gas cylinder COUNTERCLOCKWISE

approximately half (1/2) revolution.

NOTE: The gas cylinder rod will turn.

C. Repeat STEP 1.

D. Repeat STEP B until the LEFT side of the back DOES NOT recline.

3. To adjust the RIGHT gas cylinder: Repeat STEPS 1 and 2 for the LEFT handle of the

cable assembly.

CAUTION

Damage to the gas cylinder rod WILL occur if the following steps are

NOT followed when the jam nut is torqued against the pivot block.

4. Using NO LARGER than 1/4-inch wide, fine toothed pliers, wrap masking tape

around the teeth of the pliers two (2) or three (3) revolutions.

5. Using NO excessive force, hold the gas cylinder rod just above the jam nut.

6. While holding the gas cylinder rod and using a 17 mm wrench, turn the jam nut

CLOCKWISE and torque the RIGHT and LEFT jam nuts against the RIGHT

and LEFT pivot blocks to 156 in-lbs.

CHANGING BACK HEIGHT (FIGURE 5)

1. Press the push pins on the headrest extension tubes in and remove headrest

extension from back canes.

2. Remove the recliner cables from the back canes. Refer to REPLACING RECLINER

CABLE ASSEMBLIES in this section of the manual.

3. Remove the mounting screws, washers and locknuts that secure the TOP of the gas

cylinders to the mounting bracket on the back canes.

4. Remove the mounting screws, washers and locknuts that secure the back canes to

the seat frame.

5. Remove the existing recliner back assembly from the wheelchair.

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RECLINER

SECTION 14

6. Turn the spreader bar on the existing back canes CLOCKWISE (toward back

upholstery) and remove the spreader bar from the existing back canes.

7. Loosely install the spreader bar onto the NEW back cane handles by rotating the

spreader bar COUNTERCLOCKWISE (away from the back canes).

NOTE: If the spreader bar does not thread onto the back canes, do not force. Turn the

spreader bar around and repeat STEP 7.

8. Line up two (2) bottom mounting holes of back canes with the two (2) mounting

holes in the seat frame.

WARNING

The back canes MUST be fastened securely to the seat frame BEFORE

using the wheelchair. Torque mounting screws to 156 in-lbs.

9. Reinstall the mounting screw, washer

Headrest

Extension Tube

Back Cane

and locknut through the back cane and

seat frame mounting holes and torque

to 156 in-lbs.

Spreader

Bar

10. Reinstall the mounting screw through

the mounting bracket of the back cane,

nylon washer, mounting hole in the

TOP of the gas cylinder, nylon washer,

mounting bracket and washer and

securely tighten with the existing

locknut. Torque to 75 in-lbs.

Mounting

Screw

Mounting

Bracket

Washers

Locknut

Push

11. Reinstall the recliner cable assemblies

onto the back canes. Refer to

Mounting

Screw

REPLACING RECLINER CABLES in

this section of the manual.

Seat Frame

NOTE: There are three (3) different cable

lengths depending on back height:

BACK HEIGHT (in inches) 18-1/2, 20 22, 24 26

CABLE LENGTH

Short Medium Long

NOTE: Upholstery not shown for clarity.

NOTE: New recliner cables will be needed if

back height is changed to a height not within

the length of the original cable.

FIGURE 5 - CHANGING BACK

HEIGHT

12. Install the NEW back upholstery onto the back canes.

13. Install the ten (10) or twelve (12) mounting screws (depending on back height) that

secure the back upholstery to the recliner back canes.

14. Reinstall headrest extension onto recliner back canes.

15. Adjust the tautness of the back and headrest upholstery. Refer to ADJUSTING

BACK OR HEADREST UPHOLSTERY in the Owner’s Manual, part number

l104782.

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SECTION 14

RECLINER

CHANGING SEAT DEPTH (FIGURE 6)

NOTE: 16-inch, 17-inch, 18-inch or 19-inch seat depths CAN NOT be increased to 20-inches

or deeper. If needing to increase to a seat depth of 20-inches or deeper, the base frame MUST

be converted from a STANDARD base frame to a LONG base frame as well.

NOTE: 20-inch, 21-inch or 22-inch seat depths CAN NOT be decreased to 19-inches or less.

If needing to decrease to a seat depth of 19-inches or less, the base frame MUST be converted

from a LONG base frame to a STANDARD base frame.

To adjust seat depth of wheelchair, use following guidelines:

If the current seat depth is an ODD number, i.e., 17-inches, 19-inches or 21-inches, the

seat depth CANNOT be INCREASED without changing the seat frame. Refer to

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT

FRAME ONTO ARROW OR X BASE FRAMES in this section of the manual.

If the current seat depth is an ODD number, i.e., 17-inches, 19-inches or 21-inches, the

seat depth can be DECREASED by 1-inch by installing a 1-inch shorter seat pan. Refer

to REMOVING/INSTALLING THE SEAT PAN in this procedure.

If the current seat depth is an EVEN number, i.e., *16-inches, 18-inches, 20-inches or

22-inches, the seat depth CANNOT be DECREASED without changing the seat frame.

Refer to INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP RECLINER

SEAT FRAME ONTO ARROW OR X BASE FRAME in this section of the manual.

*NOTE: 16-inch seat depth is the smallest seat depth available on recliner seat frames.

If the current seat depth is an EVEN number, i.e., 16-inches, 18-inches, 20-inches or

*22-inches, the seat depth can be

INCREASED by 1-inch by installing a

1-inch deeper seat pan. Refer to

REMOVING/INSTALLING THE SEAT

PAN in this procedure.

Hex Screws

*NOTE: 22-inch seat depth is the deepest

seat depth available on recliner seat frames.

Seat Pan

Seat

Positioning

Strap

REMOVING/INSTALLING THE

SEAT PAN

Seat Frame

1. Remove the seat cushion from the

wheelchair.

2. Remove the six (6) mounting screws

and locknuts that secure seat pan, seat

positioning strap to the seat frame.

Locknuts

FIGURE 6 - CHANGING SEAT

DEPTH

3. Install new 1-inch deeper/shorter seat

pan onto seat frame.

4. Reinstall the mounting screws, spacers and locknuts and torque to 75 in-lbs.

5. Remove the protective strips on the seat pan and reinstall the seat cushion onto the seat

pan.

NOTE: Clean upholstery with a warm damp cloth and mild detergent to remove superficial soil.

WARNING

Laundering or moisture will reduce the flame retardation of the upholstery.

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RECLINER

SECTION 14

CHANGING SEAT WIDTH

To change seat width, the seat frame must be changed to the desired width. Refer to

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH DEEP RECLINER SEAT

FRAME ONTO ARROW OR X BASE FRAME in this section of the manual.

NOTE: If changing the seat width of the wheelchair, the back and headrest upholstery, seat

pan and cushion also need to be changed.

NOTE: If changing the seat width of the wheelchair, the back canes, spreader bar and headrest

pillow may also need to be changed. Refer to the following charts:

BACK CANES AND SPREADER BAR SEAT WIDTH RANGES

14 to 17-INCHES

18 to 24-INCHES

HEADREST PILLOWS SEAT WIDTH RANGES (in inches)

14 to 15, 16 to 18, 19 to 20 OR 21 to 24

If the seat width required is within the range of the original back canes, spreader bar

and headrest pillow, the original components can still be used.

If the seat width required is NOT within the range of the original back canes, spreader

bar and headrest pillow, the original components can not be used.

INSTALLING/REPLACING ADJUSTABLE 16 TO 19-INCH

DEEP RECLINER SEAT FRAME ONTO ARROW OR

RANGER X BASE FRAME (FIGURE 7)

1. Perform instructions outlined in PREPARATION FOR REMOVING/INSTALLING

SEAT FRAME (STANDARD FRAME, ADJUSTABLE FRAME, AND VAN SEAT) in

SECTION 6 of this manual:

2. Perform one (1) of the following in SECTION 7 of this manual:

A. Remove standard seat frame subassembly. Refer to REMOVING/INSTALLING

STANDARD SEAT FRAME SUBASSEMBLY.

B. Remove adjustable seat frame subassembly. Refer to INSTALLING/REMOVING

ADJUSTABLE SEAT FRAME ASSEMBLY AND OR COMPONENT REPLACEMENT.

C. Remove van seat. Refer to INSTALLING/REMOVING VAN SEAT ASSEMBLY.

3. Remove seat pan on recliner.

4. Install new recliner seat assembly onto seat mount plates.

5. Secure recliner seat assembly to seat mount plates with the mounting screws,

spacers and locknuts. Torque the mounting screws to 156 in-lbs.

NOTE: There are three (3) types of seat mount plates; low, medium, and high heights. The

seat mount plate shown in this illustration represents the medium height. Refer to SEAT ANGLE

ADJUSTMENT in SECTION 6 of this manual for illustrations of the low and high heights.

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SECTION 14

RECLINER

6. Position limit switch onto wheelchair.

Refer to POSITIONING LIMIT

SWITCH in this section of the manual.

Recliner

Seat Assembly

Mounting

Screws

7. Reinstall recliner seat pan with existing

six (6) mounting screws.

8. Install the two (2) warnings labels onto

the two (2) suspension arm assemblies.

Refer to FIGURE 7 for correct label

placement.

9. Install battery boxes. Refer to

REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

Spacer

10. Perform instructions outlined in

PREPARATION FOR REMOVING/

INSTALLING SEAT FRAME (STAN-

DARD FRAME, ADJUSTABLE FRAME,

AND VAN SEAT) in SECTION 6 of

this manual:

Base

Frame

Seat Mount

Plate

Locknuts

Warning Label

Inside of

Suspension Arm

Assembly

FIGURE 7 - INSTALLING/

REPLACING ADJUSTABLE 16 TO

19-INCH DEEP RECLINER SEAT

FRAME ONTO ARROW

OR X BASE

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RWD WHEELCHAIRS

SECTION 15

This Section Includes the Following:

Removing/Installing Group 24 Battery Box Sub-Frame

Removing/Installing 22NF Battery Box Tray

Converting 22NF Battery Box Tray to Group 24 Battery Box Sub-Frame

Shock or Rubber Element Replacement

Shock Spring Replacement

Removing/Installing Gearbox

Adjusting Weight Distribution

Repositioning the Motor

Replacing Suspension Arm for Wheelchairs with Motor/Gearbox Assembly

Replacing Suspension Arm for Wheelchairs with Gearless/Brushless Motor

Anti-Tipper Wheel Replacement

Removing/Installing the 3-inch Anti-tip Assembly

WARNING

After ANY adjustments, repair or service and BEFORE use, make sure

that all attaching hardware is tightened securely - otherwise injury or

damage may result.

REMOVING/INSTALLING GROUP 24 BATTERY BOX

SUB-FRAME (FIGURE 1)

REMOVING

1. Remove the battery boxes. Refer to REMOVINg/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

2. Remove the two (2) mounting screws and locknuts that secure the wiring harness

w/bracket and the sub-frame to the base frame.

3. Perform one (1) of the following:

A. WHEELCHAIRS EQUIPPED WITH VENT TRAY - Remove the four (4) mounting

screws that secure the shocks, retainer bar, spacers and retainer clips to the base

frame.

B. WHEELCHAIRS WITHOUT VENT TRAY - Remove the four (4) mounting

screws that secure the shocks and spacers to the base frame.

4. Remove the existing sub-frame assembly.

INSTALLING

1. Install the two (2) mounting screws and locknuts that secure the wiring harness

with bracket and the NEW sub-frame to the base frame. Use Loctite 242 and torque

mounting screws to 160 in-lbs.

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SECTION 15

RWD WHEELCHAIRS

2. Perform one (1) of the following:

A. WHEELCHAIRS EQUIPPED WITH VENT TRAY - Reinstall the four (4) mounting

screws that secure the shocks, retainer bar, spacers and retainer clips to the base

frame. Use Loctite 242 and torque mounting screws to 160 in-lbs.

B. WHEELCHAIRS WITHOUT VENT TRAY - Reinstall the four (4) mounting

screws that secure the shocks and spacers to the base frame.

3. Reinstall the battery boxes. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual. Use Loctite 242 and torque mounting screws to 160 in-lbs.

Mounting

Screws

Wiring Harness

w/Bracket

REAR OF

CHAIR

Sub-Frame

Locknuts

FRONT OF

CHAIR

WHEELCHAIRS EQUIPPED

WITHOUT VENT TRAY

WHEELCHAIRS EQUIPPED WITH

VENT TRAY

REAR OF CHAIR

Spacer

Retainer Clip

Spacer

Mounting

Screws

Retainer Bar

Battery Box

Sub-frame

Mounting Screws

Spacer

Battery Box

Sub-frame

Base Frame

Shock

Base Frame

Shock

FRONT OF CHAIR

FIGURE 1 - REMOVING/INSTALLING GROUP 24

BATTERY BOX SUB-FRAME

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RWD WHEELCHAIRS

SECTION 15

REMOVING/INSTALLING 22NF BATTERY BOX TRAY

(FIGURE 2)

REMOVING

Battery Mount

Bracket

1. Remove the battery box. Refer to

REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

Locknuts

Bolts

2. Remove the two (2) rear locknuts

that secure the battery box tray to

battery mount brackets.

3. Remove the two (2) front bolts and

locknuts that secure the battery box

tray to the base frame.

Base

Frame

*Rubber

Element

4. Remove the battery tray from the

base frame.

Battery Tray

Locknuts

*NOTE: Illustration depicts the rubber

element. Battery Box Tray removes in the

same manner for shock assembly.

INSTALLING

1. Install battery tray onto base frame.

2. Secure the rear of the battery tray to

battery mount brackets with existing

locknuts. Torque to 160 in-lbs.

FIGURE 2 - REMOVING/

INSTALLING 22NF BATTERY

BOX TRAY

3. Secure the front of the battery tray to

the base frame with existing mounting screws and locknuts. Torque to 160 in-lbs.

4. Reinstall the battery box. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

CONVERTING 22NF BATTERY BOX TRAY TO GROUP 24

BATTERY BOX SUB-FRAME ASSEMBLY

REMOVING 22NF COMPONENTS (FIGURE 3)

1. Remove the battery box. Refer to REMOVING/INSTALLING BATTERY BOXES in

SECTION 9 of this manual.

2. Remove the battery box tray. Refer to REMOVING/INSTALLING THE 22NF

BATTERY BOX TRAY in this section of the manual.

3. Remove the wiring harness. Refer to REMOVING/INSTALLING THE WIRING

HARNESS in SECTION 10 of this manual.

NOTE: The battery box tray and the battery mount brackets will not be reused. Mounting

screws and spacers will be reused.

4. Remove the four (4) mounting screws that secure the battery mount brackets to the

base frame.

5. Remove the battery mount brackets.

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SECTION 15

RWD WHEELCHAIRS

Washer

Locknut

Battery Mount

Bracket

Spacer

Mounting Screws

*Rubber Element

(or Shock Assembly)

Base Frame

*NOTE: Illustration depicts rubber element. Battery Mount

Brackets remove in the same manner for the shock assembly.

FIGURE 3 - REMOVING 22NF COMPONENTS

INSTALLING GROUP 24 COMPONENTS (FIGURE 4)

1. Line up the mounting holes in the front of the NEW battery box sub-frame and the

NEW wiring harness w/bracket with the mounting holes in the base frame.

2. Install the two (2) mounting screws through the wiring harness w/bracket, battery

box sub-frame, and base frame.

3. Install the locknuts onto mounting screws. Torque to 160 in-lbs.

4. Perform one (1) of the following:

A. WHEELCHAIRS EQUIPPED WITH VENT TRAY

WARNING

The Battery Box Retainer/Retainer Clip MUST be fastened securely in

place before using the wheelchair. Use Loctite 242 and torque to 160 in-lbs.

ꢀ

Position the retainer clip between the NEW battery box sub-frame and the

top of the rubber element or shock assembly making sure the retainer clip

mounting hole is towards the bottom and the closed end of the clip is against

the battery box retainer bar.

NOTE: Make sure the closed end of the battery box retainer clip is pointing up.

ꢀ

Install the mounting screw that secures the retainer clip to the battery box

sub-frame. Use Loctite^®242 and torque to 160 in-lbs.

Line up the NEW battery box retainer bar and spacers with mounting holes

in the base frame (FIGURE 5).

Reinstall the mounting screws that secure the battery box retainer bar to the

base frame. Use Loctite 242 and torque to 160 in-lbs (FIGURE 5).

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RWD WHEELCHAIRS

SECTION 15

B. WHEELCHAIRS EQUIPPED WITHOUT VENT TRAY - Reinstall the four (4)

mounting screws that secure the shocks and spacers to the base frame.

5. Perform STEPS 2-7 of REMOVING/INSTALLING THE WIRING HARNESS in

SECTION 10 of this manual to complete the wiring harness installation.

6. Install the group 24 battery boxes. Refer to REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

STEPS 1 - 3

Mounting

Screws

REAR OF CHAIR

Wiring Harness

w/Bracket

Battery Box

Sub-Frame

Locknuts

Base

Frame

FRONT OF CHAIR

STEPS 4 - 7

WHEELCHAIRS EQUIPPED

WITHOUT VENT TRAY

WHEELCHAIRS EQUIPPED

WITH VENT TRAY

REAR OF CHAIR

Spacer

Retainer Clip

Mounting

Screws

Battery Box

Sub-frame

Mounting

Screws

Retainer Bar

Spacer

Battery Box

Sub-frame

Base Frame

Shock

Base Frame

Shock

FRONT OF CHAIR

FIGURE 4 - INSTALLING GROUP 24 COMPONENTS

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SECTION 15

RWD WHEELCHAIRS

SHOCK OR RUBBER ELEMENT REPLACEMENT

GROUP 24 BATTERIES (FIGURES 5 AND 6)

1. Remove the group 24 battery boxes. Refer to REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the drive wheel from the wheel hub. Refer to REMOVING/INSTALLING

THE DRIVE WHEELS in SECTION 12 of this manual.

3. Perform one (1) of the following:

A. Wheelchairs equipped with vent tray - Loosen the hex screw that secures

the battery box retainer bar to the base frame.

B. Wheelchairs without vent tray - Loosen the rearmost hex screw that

secures the battery box sub-frame and spacer to the base frame.

4. Perform one (1) of the following:

A. Wheelchairs equipped with vent tray - Remove the mounting screw that

secures the top of the shock and retainer clip to the base frame.

B. Wheelchairs without vent tray - Remove the mounting screw that secures

the top of the shock to the base frame.

5. Perform one (1) of the following:

A. FOR SHOCKS - Remove the mounting screw, two (2) short spacers, two (2)

large washers and locknut that secure the shock to the anti-tip bracket and

suspension arm.

B. FOR RUBBER ELEMENTS - Remove the mounting screw, two (2) short spacers,

two (2) large washers, two (2) small washers, one (1) 2-inch spacer and locknut

that secure the rubber element to the anti-tip bracket and suspension arm.

6. Remove the shock or rubber element.

7. Perform one (1) of the following sections:

A. Wheelchairs equipped with vent tray -

WARNING

The Battery Box Retainer/Retainer Clip MUST be fastened securely in

place before using the wheelchair. Use Loctite 242 and torque to 160 in-lbs.

ꢀ

Position retainer clip between shock and battery box sub-frame making sure

the retainer clip mounting hole is towards the bottom and the closed end of

clip is against battery box retainer bar.

ꢀ

Secure the top of shock and retainer clip to base frame. Apply Loctite 242

and torque to 160 in-lbs.

Apply Loctite 242 and torque the hex screw that secures the battery box

retainer bar to the base frame to 160 in-lbs.

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RWD WHEELCHAIRS

SECTION 15

B. Wheelchairs without vent tray - Secure the top of shock to base frame.

Apply Loctite 242 and torque to 160 in-lbs.

8. Perform one (1) of the following sections:

A. FOR SHOCKS - Secure the NEW shock to the anti-tip bracket and suspension

arm with the existing mounting screw, two (2) large washers, two (2) short

spacers, and locknut. Torque to 13 ft-lbs.

B. FOR RUBBER ELEMENTS - Secure the NEW rubber element to the anti-tip

bracket and suspension arm with the existing mounting screw, two (2) large

washers, two (2) small washers, two (2) short spacers, one (1) 2-inch spacer and

locknut. Torque to 13 ft-lbs.

9. Reinstall the drive wheel from the wheel hub. Refer to REMOVING/INSTALLING

THE DRIVE WHEELS in SECTION 12 of this manual.

10. Reinstall the group 24 battery boxes. Refer to REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

TOP OF SHOCK OR RUBBER ELEMENT

WHEELCHAIRS EQUIPPED WITH

VENT TRAY

WHEELCHAIRS WITHOUT

VENT TRAY

Battery Box

Sub-frame

FRONT

CHAIR

Rearmost Mounting

Screws (LOOSEN)

Spacer

Battery Box

Sub-frame

REAR

CHAIR

Base

Frame

Mounting Screw

(LOOSEN)

Spacer

Retainer Clip

(Closed End)

Top of

Shock

Battery Box Retainer Bar

FIGURE 5 - SHOCK OR RUBBER ELEMENT REPLACEMENT - GROUP 24

BATTERIES

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SECTION 15

RWD WHEELCHAIRS

BOTTOM OF SHOCK or RUBBER ELEMENT

Shock or

Rubber Element

RUBBER ELEMENT

Short

Spacer

Locknuts

Suspension Arm

for Gearless/

Brushless Motors

Anti-tip

Bracket

Long

Spacer

Washers

2-inch

Spacer

NOTE: Hardware

is mounted inside

of the anti-tip bracket

Large

Washer

Small

Washer

5/16-18 x 3-1/2-inch

Hex Head Cap Screw

Suspension Arm

for 4 Pole Motors

FIGURE 6 - SHOCK OR RUBBER ELEMENT REPLACEMENT - GROUP 24

BATTERIES OR 22NF BATTERIES

22NF BATTERIES (FIGURES 6 AND 7)

1. Remove the 22NF battery box. Refer to REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

2. Remove the drive wheel from the wheel hub. Refer to REMOVING/INSTALLING

THE DRIVE WHEELS in SECTION 12 of this manual.

3. Remove the mounting screw that secures the top of the shock to the base frame.

(FIGURE 7)

4. For 3-inch anti-tip assemblies (FIGURE 6) - Remove the mounting screw, two

(2) short spacers, two (2) large washers and lcoknut that secure the shock to the

anti-tip bracket and suspension arm.

5. Remove the shock from the base frame.

6. Secure the top of the NEW shock to base frame. Apply Loctite 242 and torque to

160 in-lbs. (FIGURE 7).

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RWD WHEELCHAIRS

SECTION 15

Shock or

Rubber Element

7. Secure the bottom of the NEW shock

to the suspension arm with the existing

mounting screw and locknut. Apply

Loctite 242 and torque to 160 in-lbs.

(FIGURE 6).

Mounting

Screw

Base

Frame

8. Install the drive wheel from the wheel

hub. Refer to REMOVING/INSTALLING

THE DRIVE WHEELS in SECTION 12 of

this manual.

9. Install the 22NF battery box. Refer to

REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

FIGURE 7 - SHOCK OR RUBBER

ELEMENT REPLACEMENT - 22NF

BATTERIES

SHOCK SPRING REPLACEMENT (FIGURE 8)

1. Remove the 22NF battery box or group 24 battery boxes. Refer to REMOVING/

INSTALLING BATTERY BOXES in SECTION 9 of this manual.

2. GROUP 24 BATTERIES ONLY - Loosen the mounting screw that secures the

battery box retainer bar to the base frame.

3. Remove the mounting screw that secures the top of the shock to the suspension arm.

4. Swing the top of the shock rearward.

5. Hold the spring retainer and turn the shock eyelet assembly counterclockwise to

unthread it from the shock.

6. Remove the spring retainer and spring.

7. Place the NEW spring onto the shock.

8. Reinstall the shock eyelet assembly and the spring retainer onto the NEW spring.

9. While holding the spring retainer, torque the shock eyelet assembly to 245 in-lbs.

10. Position the retainer clip between the shock and the battery box sub-frame making

sure the retainer clip mounting hole is towards the bottom and the closed end of

the clip is against the battery box retainer.

11. Secure top of shock and retainer clip to base frame. Apply Loctite 242 and torque to

160 in-lbs.

12. GROUP 24 BATTERIES ONLY - Apply Loctite 242 and torque the hex screw

that secures the battery box retainer bar to the base frame to 160 in-lbs.

13. Reinstall the 22NF battery box or group 24 battery boxes. Refer to REMOVING/

INSTALLING BATTERY BOXES in SECTION 9 of this manual.

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SECTION 15

RWD WHEELCHAIRS

GROUP 22 BATTERIES

GROUP 24 BATTERIES

Shock

Hex

Screws

Spacer

Battery Box

Retainer Bar

Mounting

Screw

Shock Eyelet

Assembly

Retainer Clip

Suspension

Arm

NOTE: Shock exploded away for clarity.

There is no need to remove shock from

suspension arm.

Shock Eyelet

Assembly

Spring

Retainer

Shock

Spring

Base

Shock

FIGURE 8 - SHOCK SPRING REPLACEMENT

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RWD WHEELCHAIRS

SECTION 15

REMOVING/INSTALLING GEARBOX (FIGURE 9)

REMOVING

1. Remove the drive wheels from the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in SECTION 12 of this manual.

2. Remove the drive wheel hub from the

existing gearbox drive shaft. Refer to

REMOVING/INSTALLING DRIVE

WHEEL HUBS in SECTION 12 of this

manual.

5/16-18 x 2-1/2-inch

Hex Screws

5/16-18 x

1-1/4-inch

Hex Screws

NOTE: Note mounting position of gearbox to

suspension arm before disassembly.

NOTE: To reposition the gearbox on the

suspension arm, refer to ADJUSTING WEIGHT

DISTRIBUTION in this section of the manual.

3. Remove the four (4) hex screws and

two (2) washers that secure the existing

motor/gearbox to the suspension arm.

4. Remove existing motor from gearbox.

Refer to REMOVING/INSTALLING THE

MOTOR in SECTION 12 of this manual.

Suspension

Arm

Gearbox

Motor

5. Install existing motor onto NEW gearbox.

Refer to REMOVING/INSTALLING THE

MOTOR in SECTION 12 of this manual.

INSTALLING

CAUTION

The REAR hex screws that secure

the gearbox to the suspension arm

MUST be 5/16-18 x 2-1/2-inches long

and the FRONT hex screws that

secure the gearbox to the suspension

arm MUST be 5/16-18 x 1-1/4-inches

long. Otherwise damage to the

gearbox casting can result.

Gearbox

Motor

FIGURE 9 - REMOVING/

INSTALLING GEARBOX

1. Position NEW gearbox with noted mounting holes.

2. When reassembling gearbox to suspension arm, use Loctite 242 and torque hex

screws to 160 in-lbs.

NOTE: Replace any parts that show signs of wear or damage.

3. Reinstall the drive wheel hub to the new gearbox driveshaft. Refer to REMOVING/

INSTALLING DRIVE WHEEL HUBS in SECTION 12 of this manual.

4. Reinstall the drive wheels onto the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in SECTION 12 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 15

RWD WHEELCHAIRS

ADJUSTING WEIGHT DISTRIBUTION (FIGURE 10)

NOTE: Seat mount plates and seat support brackets allow the seat frame to be repositioned

along the base frame. The range is determined by position of the seat stop screws. The front seat

stop screw is positioned at 4-inches and the rear seat stop screw is positioned at 10-inches. Both

seat stop screw positions are measured from the front of the base frame.

NOTE: The position of the seat support brackets is factory set at 7-inches, this measured from

the front of the base frame to the front of the seat support bracket. This will put about 70% of

the total weight of the chair and user over the large wheels. However, this setting may not be

the most desirable in terms of maneuverability, front rigging clearance and comfort for the user.

ADJUSTMENT OPTIONS

NOTE: This section will provide the user with some knowledge of what to expect if the

following adjustments are made.

1. Moving the seat forward.

Advantage: This adjustment allows more clearance for front riggings and a more

stable “feel” for the user.

Disadvantage: More weight is put on front casters and makes turning more difficult.

NOTE: This option can also be accomplished by moving the motor backward on the suspension

arm. Refer to REPOSITIONING THE MOTOR in this section of the manual.

2. Moving the seat rearward.

Advantage: Makes turning easier and provide better traction for the large wheels.

Disadvantage: This adjustment, however, allows less clearance for front riggings and

the user will experience more engagement of the anti-tippers.

NOTE: This option can also be accomplished by moving the motor forward on the suspension

arm. Refer to REPOSITIONING THE MOTOR in this section of the manual.

ADJUSTING WEIGHT DISTRIBUTION PROCEDURE

1. Loosen the four (4) mounting screws that secure the seat support brackets to the base frame.

WARNING

Mounting Screw

DO NOT adjust seat beyond limit

stops.

Washer

2. Adjust seat forward or back to the

position determined from the previous

procedure ADJUSTMENT OPTIONS.

3. Retighten the four (4) mounting screws

securing the seat support brackets to the

base frame.

Seat Support

Bracket

Base

Frame

4. Test wheelchair maneuverability,

comfort, and handling.

FIGURE 10 - ADJUSTING WEIGHT

DISTRIBUTION

5. Repeat STEPS 1-4 for further

adjustment, if necessary.

3G Storm Series Wheelchairs

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RWD WHEELCHAIRS

SECTION 15

REPOSITIONING THE MOTOR

REPOSITIONING THE MOTOR/GEARBOX (FIGURE 11)

NOTE: The motor/gearbox assembly can be repositioned to lengthen or shorten the wheelbase

by 2-inches in 1-inch increments.

STANDARD POSITION - LENGTHENS the wheelbase and gives you the most

stability and standard maneuverability.

1-INCH FORWARD - CENTERS the wheelbase and gives you standard stability and

maneuverability.

2-INCH FORWARD - SHORTENS the wheelbase and increases maneuverability

and distributes additional weight on rear wheels.

WARNING

When using a recliner/high back van seat, the motor/gearbox or motor

MUST use most REARWARD mounting holes on the suspension arm

assembly.

1. Determine the desired position for the

gearbox on the wheelchair.

MOTOR/GEARBOX ASSEMBLY

Standard -

1-Inch Forward -

Approximately 70%

of weight over rear

wheels

2. Remove the drive wheels from the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in

SECTION 12 of this manual.

Approximately 65%

of weight over rear

wheels

3. Remove gearbox from the suspension

arm. Refer to REMOVING/INSTALLING

GEARBOX in this section of the manual.

4. Move gearbox to the position

determine in STEP 1.

NOTE: If the wheelchair is equipped with

9-inch casters on a standard or heavy duty

base, the 2-inch forward position CAN NOT

be utilized.

2-Inch Forward -

Approximately 75%

of weight over rear

wheels

5. Reinstall the gearbox onto the existing

suspension arm. Refer to REMOVING/

INSTALLING GEARBOX in this

section of the manual.

6. Repeat STEPS 3-5 for opposite side of

the wheelchair.

FIGURE 11 - REPOSITIONING THE

MOTOR - REPOSITIONING THE

MOTOR/GEARBOX

7. Reinstall the drive wheel onto the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in

SECTION 12 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 15

RWD WHEELCHAIRS

REPOSITIONING THE STANDARD GEARLESS/BRUSHLESS

MOTOR - BEFORE 1/26/04 (FIGURES 12 AND 13)

NOTE: On models equipped with a fixed back only, the gearless/brushless motor can be

repositioned to lengthen or shorten the wheelbase by 2-inches in 1-inch increments.

ARROW AND RANGER X WITH

FIXED BACK

ARROW, RANGER X, AND

TORQUE SP WITH WITH

MANUAL RECLINER, 2G

STANDARD POSITION - CENTERS the

wheelbase and gives you standard stability

and maneuverability.

POWERED SEATING SYSTEM, OR

HIGH BACK VAN SEAT

STANDARD POSITION - LENGTHENS

the wheelbase and gives you the most

stability and standard maneuverability.

1-INCH REARWARD- LENGTHENS the

wheelbase and gives you the most stability

and standard maneuverability.

1-INCH FORWARD - CENTERS the

wheelbase and gives you standard stability

and maneuverability.

1-INCH FORWARD - SHORTENS the

wheelbase and increases maneuverability

and distributes additional weight on rear

wheels.

2-INCH FORWARD - SHORTENS the

wheelbase and increases maneuverability

and distributes additional weight on rear

wheels.

FORWARD

1-inch forward -

1-inch Rearward -

Approximately 65%

of weight over

Approximately 75%

of weight over

rear wheels

Standard -

Approximately 65%

2-inch Forward -

Approximately 75%

rear wheels

of weight over

Standard -

of weight over

rear wheels

Approximately 70%

of weight over

rear wheels

1-inch Forward -

Approximately 70%

of weight over

rear wheels

FIGURE 12 - ACCEPTABLE MOUNTING POSITIONS FOR THE

STANDARD GEARLESS/BRUSHLESS MOTOR - BEFORE 1/26/04

3G Storm Series Wheelchairs

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RWD WHEELCHAIRS

SECTION 15

Motor

1. Determine the desired mounting

position of the gearless/brushless

motor. Refer to ACCEPTABLE

MOUNTING POSITIONS FOR THE

GEARLESS/BRUSHLESS MOTOR in

this section of the manual.

Brake Release

Shaft

Adjustment

Screw

Motor

Release

Lever

2. Remove the 22NF battery box or

group 24 battery boxes. Refer to

REMOVING/INSTALLING BATTERY

BOXES in SECTION 9 of this manual.

Suspension Arm

3. If necessary, remove the battery box

tray. Refer to REMOVING THE

BATTERY BOX TRAY in this section

of the manual.

Washer

Mounting Screws

FIGURE 13 - REPOSITIONING THE

MOTOR - REPOSITIONING THE

STANDARD GEARLESS/

BRUSHLESS MOTOR -

4. Remove the drive wheel from the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in

SECTION 12 of this manual.

BEFORE 1/26/04

5. Loosen the adjustment screw that secures the motor release handle to the brake

release shaft.

6. Remove the four (4) mounting screws and washers that secure the motor to the

suspension arm.

7. Slide the motor forward or backward to the desired mounting position.

8. Secure the motor to the mounting position determined in STEP 1 and secure with

the four (4) existing mounting screws and washers. Torque to 13 ft-lbs.

9. Securely tighten adjustment screw.

10. Reinstall the drive wheel to the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in SECTION 12 of this manual.

11. Repeat STEPS 1-9 for opposite side of wheelchair.

12. If necessary, reinstall the battery box tray. Refer to REMOVING THE BATTERY

BOX TRAY in this section of the manual.

13. Install the 22NF battery box or group 24 battery boxes. Refer to REMOVING/

INSTALLING BATTERY BOXES in SECTION 9 of this manual.

3G Storm Series Wheelchairs

Part No. 1104849

133

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SECTION 15

RWD WHEELCHAIRS

REPOSITIONING THE HEAVY DUTY GEARLESS/BRUSHLESS

MOTOR (FIGURE 14)

STANDARD POSITION - LENGTHENS the wheelbase and gives you the most stability

and standard maneuverability.

1-INCH FORWARD - CENTERS the wheelbase and gives you standard stability and

maneuverability.

2-INCH FORWARD - N/A

1. Determine the desired mounting position of the gearless/brushless motor.

2. Remove the Heavy Duty Gearless/Brushless Motors. Refer to REMOVING/

INSTALLING THE MOTOR (GEARLESS/BRUSHLESS MOTOR) in SECTION 12 of

this manual.

3. Remove the mounting screw and attaching hardware that secures the motor lock

lever to the suspension arm.

4. Reposition motor lock lever to mounting hole corresponding with motor mount

location. Mounting position shown in FIGURE 14 is for the standard mounting

position for the motor. Moving the motor lock lever one position forward would

correrspond with the one inch forward motor mounting position.

5. Reposition the motor to the desired mounting position. Refer to the chart above to

for motor mounting options.

6. Reinstall the motor to the mounting position determined in STEP 1. Refer to

REMOVING/INSTALLING THE MOTOR (GEARLESS/BRUSHLESS MOTOR) in

SECTION 12 of this manual.

Motor Lock Lever

mounting position

for standard

motor mount

Standard -

Approximately 70%

of weight over

Motor Lock Lever

mounting position

for 1-inch forward

motor mount

Attaching

Hardware

Not

Available

rear wheels

(For 3G chairs equipped

with High Back Van

or 2G Tilt and Recline

Seating Systems)

Motor

Lock

Lever

1-inch Forward - Approximately 65%

of weight over rear wheels

(Optional on 3G chairs equipped with

ASBA seats or Low Back Van Seat)

FIGURE 14 - REPOSITIONING THE MOTOR - REPOSITIONING THE

HEAVY DUTY GEARLESS/BRUSHLESS MOTOR

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RWD WHEELCHAIRS

SECTION 15

REPLACING SUSPENSION ARM FOR WHEELCHAIRS

WITH MOTOR/GEARBOX ASSEMBLY (FIGURE 15)

1. Remove the drive wheels from the

wheelchair. Refer to REMOVING/

INSTALLING DRIVE WHEELS in

Suspension Arm

SECTION 12 of this manual.

Beveled

Washers

2. Loosen the hex screws that secure

wiring harness to sub-frame assembly.

3. Remove gearbox from the existing

suspension arm. Refer to REMOVING/

INSTALLING GEARBOX in this

section of the manual.

Plug

Button

Suspension Arm Hex Screw

(1/2 x 7-inches)

4. Remove plug buttons from the middle

of the base frame.

FIGURE 15 - REPLACING

SUSPENSION ARM FOR

5. Remove the hex screws and the bev-

eled washers that secure the suspension

arm assembly to the base frame.

WHEELCHAIRS WITH MOTOR/

GEARBOX ASSEMBLY

6. Remove existing suspension arm from the wheelchair.

NOTE: When installing the NEW suspension arm, the beveled washers MUST be placed on

the inside and outside of the base frame, with the bevels facing each other.

7. Install the NEW suspension arm assembly onto the base frame.

8. Torque suspension arm hex screws (1/2 x 7-inches) to 85 ft-lbs (approximately

1,020 in-lbs) and replace plug buttons.

9. Reinstall the gearbox onto the existing suspension arm. Refer to REMOVING/

INSTALLING GEARBOX in this section of the manual.

10. Tighten the hex screws that secure wiring harness to sub-frame assembly securely.

11. Reinstall the drive wheel onto the wheelchair. Refer to REMOVING/INSTALLING

DRIVE WHEELS in SECTION 12 of this manual.

12. Repeat STEPS 1-11 for the opposite side of the wheelchair, if necessary.

3G Storm Series Wheelchairs

Part No. 1104849

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SECTION 15

RWD WHEELCHAIRS

REPLACING SUSPENSION ARM FOR WHEELCHAIRS

WITH GEARLESS/BRUSHLESS MOTORS (FIGURE 16)

1. Perform one (1) of the following:

Suspension Arm

A. Remove the seating system.

Refer to the Seating Systems

Owner’s Manual for removal/

installation instructions.

Beveled

Washers

B. Remove the seat pan. Refer to

REMOVING/INSTALLING THE

SEAT PAN in SECTION 6 of this

manual.

Plug

Button

Suspension Arm Hex Screw

(1/2 x 7-inches)

2. Remove the motor. Refer to

REMOVING/INSTALLING THE

MOTOR in SECTION 12 of this

manual.

FIGURE 16 - REPLACING

SUSPENSION ARM FOR

WHEELCHAIRS WITH GEARLESS/

BRUSHLESS MOTOR

3. Cut the tie-wrap(s) that secure the

wiring harness/charger cable to the suspension arm.

4. Remove the anti-tip assembly from the rear of the suspension arm. Refer to REMOVING/

INSTALLING THE 3-INCH ANTI-TIP ASSEMBLY in this section of the manual.

5. Remove the shock from the suspension arm. Refer to SHOCK OR RUBBER

ELEMENT REPLACEMENT in this section of the manual.

6. Remove the plug buttons from the side of the base frame.

7. Remove the mounting screw and beveled washers that secure the front of the

suspension arm to the base frame.

8. Remove the existing suspension arm from the base frame.

9. Install the new suspension arm onto the base frame.

10. Install mounting screw and beveled washers that secure the front of the suspension

arm to the base frame.

11. Install the plug buttons into the side of the base frame

12. Install the shock onto the new suspension arm. Refer to SHOCK OR RUBBER

ELEMENT REPLACEMENT in this section of the manual.

13. Install the motor onto the new suspension arm. Refer to REMOVING/INSTALLING

THE MOTOR in SECTION 12 of this manual.

14. Install anti-tip assembly onto the rear of the new suspension arm. Refer to REMOVING/

INSTALLING THE 3-INCH ANTI-TIP ASSEMBLY in this section of the manual.

15. Perform one (1) of the following:

A. Remove the seating system. Refer to the Seating Systems Owner’s Manual for

removal/installation instructions.

B. Remove the seat pan. Refer to REMOVING/INSTALLING THE SEAT PAN in

SECTION 6 of this manual.

3G Storm Series Wheelchairs

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RWD WHEELCHAIRS

SECTION 15

ANTI-TIPPER WHEEL REPLACEMENT (FIGURE 17)

1. Remove the locknuts, hex screws and

spacers that secure the anti-tipper

wheels to the anti-tip bracket

Spacer

Locknut

Spacer

2. Replace anti-tipper wheel(s) and

torque existing hardware to 156 in-lbs.

DO NOT overtighten.

Anti-Tipper

Wheel

FIGURE 17 - ANTI-TIPPER WHEEL

REPLACEMENT

REMOVING/INSTALLING THE 3-INCH ANTI-TIP ASSEMBLY

(FIGURE 18)

1. Remove the 5/16-18 x 3-1/2-inch hex head cap screw, two (2) short spacers, two (2)

large washers, and locknut that secure the rear of the anti-tip bracket and shock (or

rubber element) to the suspension arm. Save hex head mounting screw, two (2)

small spacers, and locknut for installation of the 4-inch active anti-tip assemblies.

2. Remove the 5/16-18 x 3-1/4-inch hex head cap screw, two (2) small washers, long

spacer and locknut that secure the front of the anti-tip bracket to the the suspension

arm. Save hex head mounting screw and locknut for installation of 4-inch active

anti-tip assemblies.

Shock or

Rubber Element

Short

Locknuts

Spacer

Suspension Arm

for Gearless/Brushless

Motors (Reference)

Long

Spacer

Anti-tip

Bracket

Suspension Arm

for 4 Pole Motors

(Reference)

Large

Washer

Small

Washer

5/16-18 x 3-1/2-inch

Hex Head Cap Screw

5/16-18 x 3-1/4-inch

Hex Head Cap Screw

FIGURE 18 - REMOVING/INSTALLING THE 3-INCH ANTI-TIP ASSEMBLY

3G Storm Series Wheelchairs

Part No. 1104849

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NOTES

3G Storm Series Wheelchairs

138

Part No. 1104849

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WARRANTY

LIMITED WARRANTY

For warranty information, please refer to the original owner’s manual which came with

this product, or contact Invacare for more information.

3G Storm Series Wheelchairs

Part No. 1104849

139

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Invacare Corporation www.invacare.com

USA

Canada

One Invacare Way

Elyria, Ohio USA

44036-2125

570 Matheson Blvd E Unit 8

Mississauga Ontario

L4Z 4G4 Canada

800-668-5324

Invacare, Yes, you can., the Medallion

Design, Storm Series and Arrow are

registered trademarks of Invacare

Corporation.

800-333-6900

Ranger X, Torque SP and MKIV

are trademarks of

Invacare Corporation.

Loctite is a registered trademark of

Loctite Corporation.

Part No. 1104849 Rev D - 12/13/06

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