Invacare Storm 4 Series Service Manual Download

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Summary of Contents for Storm 4 Series

Page 1: ...Invacare Storm Series Storm Storm X plore en Power Wheelchair Service Manual PROVIDER Keep this manual The procedures in this manual MUST be performed by a qualified technician...

Page 2: ...ation duplication or modification in whole or in part is prohibited without prior written permission from Invacare Trademarks are identified by and All trademarks are owned by or licensed to Invacare...

Page 3: ...ypes 48 6 7 4 Specific Tightening Torques 49 6 7 5 Overview of Power Wheelchair Models and Wheel Types 49 6 7 6 Replacing Tyres 51 6 7 7 Replacing Drive Wheel 5 Screw Installation 53 6 7 8 Replacing D...

Page 4: ...Invacare Storm Series 7 Accessories 97 7 1 Accessories list 97 4 1533060 N...

Page 5: ...spare parts catalogue Spare parts must match original Invacare parts Only use spare parts which have been approved by Invacare We reserve the right to make any alterations on the grounds of technical...

Page 6: ...this product is stated in the CE declaration of conformity This symbol identifies a list of various tools components and items which you will need in order to carry out certain work 1 6 Images in This...

Page 7: ...a fire resulting in death serious injury or damage Mobility device occupants are at particular risk of death or serious injury from these fires and resulting fumes because they may not have the abilit...

Page 8: ...e to property if the maximum speed reduction on a wheelchair with a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is rai...

Page 9: ...tation Manual cleaning Surface of used device Before repair or reconditioning Use saturated towel to apply cleaning detergent and remove residues after impact Cleaning and disinfection Disinfection Su...

Page 10: ...y fixed mobility device component CAUTION Risk of tipping over Any change in seating position can negatively influence stability of mobility device Always make sure the wheelchair is stable and will n...

Page 11: ...s somewhat elevated depending on desired seat height 6 Install parts in reverse order 7 Check all mobility device functions Fig 4 1 4 2 2 Adjusting seat height on type A electrical lifter column with...

Page 12: ...ay protrude by a maximum of 8 5 mm from the adapters Only use screws supplied Check screw length precisely if you do use other screws 5 Apply medium strength screw blocker system to four screws 2 6 In...

Page 13: ...y screwed in When reinstalling screws make sure that they are screwed carefully into existing thread Tighten screws to a torque of 15 17 Nm 2 Position adapter 4 on top of lifter column 5 3 Secure adap...

Page 14: ...s to the smallest angle before adjusting the seat centre of gravity Pay attention with adjusting the seat centre of gravity that the legrests do not touch any other parts of the wheelchair This ensure...

Page 15: ...is an example 1 Remove seat plate 1 or sling seat See Modulite service manual Adjusting seat width backrest width chapter 2 Loosen Allen screws 2 in front and rear left and right DO NOT remove 3 Shift...

Page 16: ...nctions 4 5 2 Adjusting Seat Tilt on a Seat With Manual Tilt Module CAUTION Risk of crushing Seat and frame are very heavy and can fall down without warning if seat tilt adjustment assembly is screwed...

Page 17: ...to an intact power module Always replace shorted brakes immediately A defective motor can damage the power module but a defective power module cannot damage the motor Phillips screwdriver size 2 Digi...

Page 18: ...by polarity However analog meters meters with swinging needles can be and should be used carefully A good meter reading should be 25 5 VDC to 26 0 VDC with the chair in neutral 5 Switch electronics ON...

Page 19: ...anual Read and understand this manual and any service information that accompanies a battery and charger before operating the personal transporter Don t perform installation or maintenance of batterie...

Page 20: ...not listed here fingertight The tightening torques stated in the following list are based on the thread diameter for the nuts and bolts for which no specific values have been determined All values as...

Page 21: ...ual The tables for rectification of operational faults listed in the following chapters are only an excerpt from the original manufacturer s manuals You can obtain the original manuals from Invacare 6...

Page 22: ...all connecting cables See 6 9 15 Cables page 68 Motor brake defective Measure internal resistance of brakes replace motor if defective Motors stop and start again None Voltage decline Stop driving and...

Page 23: ...lace fuse See 6 9 15 Cables page 68 and 6 9 14 Main Fuse page 67 Batteries defective Replace batteries See 6 10 4 Removing Batteries page 75 Cabling to power module or remote defective Check cabling S...

Page 24: ...age 27 Parts lost None Parts lost Re attach parts once found Batteries not being charged None Fuse burnt out cable defective Check cabling and replace fuse See 6 9 15 Cables page 68 and 6 9 14 Main Fu...

Page 25: ...h a lifter does not function correctly The wheelchair s control unit must reduce the maximum possible speed as soon as the lifter is raised Test the maximum speed reduction for correct function after...

Page 26: ...place if necessary Check clutch mechanism Replace motor if necessary Tighten screws nuts adjust or replace if necessary See 6 6 1 Replacing Motor Gearbox Unit page 27 6 6 4 Replacing Motor Gearbox Uni...

Page 27: ...onnecting plugs replace if necessary Drive program Check Chair configuration file Update software if newer version available See Updating software Screws Check screws for tight fit Tighten screws if n...

Page 28: ...g 6 5 Installing Unit 1 Replace defective parts 2 Check serial number of gearbox housing Up to serial number 20110400xx gearbox housing is 44 5 mm wide The compensation sheet see above must be install...

Page 29: ...Coupling 1 Place new clutch 7 on the motor axle Pay attention to the position of the groove 2 Position locking ring 5 on motor 4 or gearbox 1 3 Carefully insert motor into gearbox Pay attention to th...

Page 30: ...eplacing Motor Gearbox Unit Storm4 X plore CAUTION Risk of crushing Mobility device is very heavy Risk of injury to hands and feet Use proper lifting techniques CAUTION Risk of injury caused by uncont...

Page 31: ...is not exposed to chafing in any place 5 Install parts in reverse order 6 If LiNX system is used perform calibration process See Suggested programing procedure in LiNX service manual 7 Test all functi...

Page 32: ...does not cover pay for working hours We also accept no liability for physical injuries or unauthorised repairs Invacare sole obligation and its exclusive remedy during this is limited to such repair...

Page 33: ...d numbering for screws There is for example no screw with pre defined number 1 For this reason you can start with any screw as Number 1 Number 2 is then screw next to it in clockwise direction 3 is ne...

Page 34: ...4 Fill inner tube with a little air 5 Tighten screws that hold rim 6 Check to make sure tyre is fitted snugly to rim 7 Pump up tyre to prescribed air pressure 8 Check again to make sure tyre fits rim...

Page 35: ...raised and can not touch ground Secure area Dynamic DX HHP handheld programming device 1 Prop up mobility device with wooden blocks Drive wheels must not be touching floor or work surface 2 Connect p...

Page 36: ...e wait No entry required Wait till end of calibration GB MOTOR CALIBRATION Successful EXIT EXIT 3 Separate programming device from mobility device Calibration is complete Replacing Relay Phillips scre...

Page 37: ...ght sequence Fig 6 22 Refitting Relay 1 Install parts in reverse order 2 Test all functions 6 6 6 Replacing Carbon Brushes This chapter refers to Storm4 Storm4 X plore and Storm4 Max Always replace al...

Page 38: ...fit new brushes 2 Refit plastic caps and tighten firmly 3 If necessary turn motor into original position and tighten nut 5 fingertight 4 Install drive wheels See 6 7 7 Replacing Drive Wheel 5 Screw I...

Page 39: ...itioned precisely in engaging turn knob 4 Place nonwoven fabric 3 in engaging turn knob rear side 1 5 Fig 6 27 When installing engaging turn knob 5 make sure that position 6 is correct 6 Fig 6 28 Tigh...

Page 40: ...el 5 Screw Installation page 53 2 Remove motor gearbox unit See 6 6 1 Replacing Motor Gearbox Unit page 27 6 6 4 Replacing Motor Gearbox Unit Storm4 X plore page 30 or Replacing Drive Unit Storm4 Max...

Page 41: ...2 Pay attention to washers and spacers 8 Remove suspension strut Fig 6 31 Installing Suspension Strut 1 Install parts in reverse order 2 Test all functions 6 6 10 Replacing Upper Suspension Strut onl...

Page 42: ...el suspension can be chosen from three weight classes according to user s weight In the case of True Track Plus motors the compression springs are combined with elastomer springs which are placed insi...

Page 43: ...top 4 Retighten motor swing arm 5 Reconnect motor cable with motor Note torques 6 When refitting cable shroud and tension relief make sure that they are seated correctly The union is eccentric narrow...

Page 44: ...s 19 mm socket wrench Blade screwdriver 1 Remove cover cap 2 2 Tilt mobility device to rear Use proper lifting techniques 3 Rotate castor forks 5 upwards 4 Let go of castor forks so that they can swin...

Page 45: ...l functions 6 6 15 Replacing Trim on Suspension Brackets Storm4 X plore 4 mm Allen key The procedure is identical for the front bracket 4 and the rear bracket of the upper suspension 5 Removing Trim 1...

Page 46: ...ve Before raising mobility device secure wheels by blocking them with wedges Prevent the mobility device tipping by propping it up on a wooden block which is long and wide enough under the battery cas...

Page 47: ...and replace it Fig 6 41 Installing Rear Suspension Bracket 1 Install parts in reverse order 2 Test all functions 6 7 Wheels 6 7 1 Repair Instructions Important information about maintenance work tools...

Page 48: ...r inner tubes and specific points must be observed for the replacement of each type The individual types of tyres can be easily distinguished Pneumatic tyres have black valve caps Puncture protected t...

Page 49: ...Wheelchair Models and Wheel Types Not all wheel types are available for all power wheelchairs see footnotes The symbols indicate three tyre types pneumatic black valve cap puncture protected red valve...

Page 50: ...stallation 5 Spoke Rim 1 Bolt In stallation 5 Spoke Rim 5 Screw Installation 5 Spoke Rim for True Track Bora Fox Stream Mirage Dragon For wheelchair specific mounting instruction see respective manual...

Page 51: ...here is considerable pressure in the tyre Risk of injury Parts can be thrown out and injure you if you do not secure rim halves Secure rim halves with joiner s clamps Risk of Damage to Rim Threads Inc...

Page 52: ...instruction See respective chapter Repairing Solid Tyre 6 mm Allen key 3 joiner s clamps with plastic caps Risk of Damage to Rim Threads Incorrectly tightened screws can cause damage to rim threads T...

Page 53: ...opping up mobility device 6 mm Allen key Torque wrench Oblong wooden block at least 12 x 12 x 30 cm for propping up mobility device Medium strength thread locking adhesive Loctite 243 or similar When...

Page 54: ...sing in pin in valve 1 4 Loosen and remove screws 2 which secure wheel 5 Remove wheel rim halves 6 Remove inner tube from tyre 7 CAUTION Risk of Injury if Wheels Come Off If drive wheels are insuffici...

Page 55: ...B 3 Remove shim ring C 4 Remove wheel hub D from axle F 5 Remove shim ring E 6 Remove feather key G from axle Fig 6 44 Installing Drive Wheel Hub 1 Install drive wheel hub parts in reverse order 2 Us...

Page 56: ...nstalled remove seat as described in or 6 12 Seating page 87 2 Remove rear and centre shroud See 6 8 1 Replacing Rear Shroud page 55 and 6 8 2 Replacing Centre Shroud page 55 3 Loosen two screws 1 con...

Page 57: ...king them with wedges Prevent the mobility device tipping by propping it up on a wooden block which is long and wide enough under the battery case If the wooden block is too short or too high the mobi...

Page 58: ...yes yes x x D 41 W 53 yes yes x x D 38 W 38 yes yes x x D 38 W 43 yes yes x x D 38 W 48 yes yes x x D 38 W 53 yes yes x x Medium D 48 W 38 yes yes x x D 48 W 43 yes yes x x D 48 W 48 yes yes x x D 48...

Page 59: ...ll power modules are delivered with standard drive program If you have made any customer specific modifications to drive program they must be adapted after installation of new power module 8 mm socket...

Page 60: ...lighting PCB and an optional actuator module CAUTION Any changes to drive program can affect driving characteristics and tipping stability of mobility device Changes to drive program may only be carr...

Page 61: ...motor cable terminal ends in from side and fit Tighten bolts with 2 5 Nm 5 Select drive program see Drive program selection after component replacement 6 If new software version is available update dr...

Page 62: ...their former positions 3 The G Trac sensor must be installed with the cable pointing upwards The module has a guide that must fit exactly into the G Trac sensor holder 4 Test all functions 6 9 5 Repla...

Page 63: ...Allen key 8 mm socket wrench Removing Light Board 1 If possible use lifter to move seat to uppermost position 2 Remove rear and centre shroud See 6 8 1 Replacing Rear Shroud page 55 and 6 8 2 Replaci...

Page 64: ...s including CLAM mounting 2 8 Replace lighting actuator module CLAM 3 When disassembling take care of small parts such as screws and washers Put all small parts down so that they can be reassembled in...

Page 65: ...harger in first third of the rail of telescopic seat frame Removing USB charger 1 Loosen and remove screw D including washer C 2 Take off USB charger B from rail of telescopic seat frame A 3 Replace U...

Page 66: ...the process the selected profile is saved in the remote and in the power module Profile selection with remote REM 550 1 Insert the plug into the remote or into the power module respectively 2 Switch t...

Page 67: ...taken from the Wizard software operating manual When an electrical adjustment option is retrofitted such as electrical legrests then this option needs to be activated in the drive program as well if...

Page 68: ...to access fuse strip Fig 6 57 5 You see strip fuse 2 once fuse holder 1 is open 6 If strip fuse has blown you must first ascertain and rectify the cause of the fault 7 Main fuse may only be replaced o...

Page 69: ...ts Replace any damaged cables 6 Pull each plug coming out of power module carefully The plug should not come out of socket 7 If one of plugs is loose press it back into socket with light pressure Plug...

Page 70: ...nt shroud through recesses on side 7 Cables that lead to seat upper actuator module remote headlight are guided out of front shroud through an upper left recess 3 8 Make sure cable has enough play so...

Page 71: ...from actuator 2 of seat tilt to cable holder 1 2 Secure cables with tie wrap 3 Run cables further to lateral bar Fig 6 66 Fig 6 67 4 Secure cables with tie wraps 1 under outer side of bar 2 Fig 6 68 F...

Page 72: ...Invacare Storm Series Fig 6 70 View of seat from below with ACT 1 Fig 6 71 View from rear 5 Attach cable guide for lifter 1 using two screws on left underneath seat Fig 6 72 72 1533060 N...

Page 73: ...ube for cables through opening in front shroud 2 2 Secure cable bundle with tie wrap under shroud Fig 6 75 3 Raise and lower seat several times while closely watching cable bundle The cable bundle mus...

Page 74: ...arged acid Always wear acid proof protective gloves when handling batteries Always wear protective goggles when handling batteries What to do if acid is discharged Always take clothing which has been...

Page 75: ...with acid with lots of water Disposing of Dead or Damaged Batteries Correctly Dead or damaged batteries can be given back to your provider or directly to Invacare 6 10 3 Making Batteries Accessible Va...

Page 76: ...s in reverse order 2 Make sure battery cage sockets plugs have been correctly refitted A polarity diagram is located in rear shroud 6 11 Lighting Unit 6 11 1 Replacing Front Bulb Size 2 Phillips screw...

Page 77: ...rts in reverse order 2 Install cables carefully and secure them with cable clamps and tie wraps 3 Tighten screws finger tight 4 Adjust headlight roughly using ratchet plate as a guide The user can car...

Page 78: ...light Fig 6 87 Installing Headlight 1 Install parts in reverse order 2 Install cables carefully and secure them with cable clamps and tie wraps 3 Tighten screws finger tight 4 Adjust headlight roughly...

Page 79: ...device 4 Disconnect cable of affected headlight from light board 2 Fig 6 88 5 Loosen screw 1 and remove headlight from holder 6 Replace headlight Fig 6 89 Installing Headlight 1 Install parts in rever...

Page 80: ...nnect cable of affected headlight from light board 2 Fig 6 90 5 Loosen screw A to remove washer B and headlight from holder 6 Replace headlight Fig 6 91 Installing Headlights 1 Install parts in revers...

Page 81: ...reverse order 2 Install cables carefully and secure them with cable clamps and tie wraps 3 Tighten screws finger tight 4 Adjust headlight roughly using ratchet plate as a guide The user can carry out...

Page 82: ...t F from holder E 9 Replace holder Fig 6 97 Installing Headlight Holder 1 Install parts in reverse order 2 Install cables carefully and secure them with cable clamps and tie wraps 3 Tighten screws fin...

Page 83: ...everse order 2 Install cables carefully and secure them with cable clamps and tie wraps 3 Tighten screws finger tight 4 Adjust headlight roughly using ratchet plate as a guide The user can carry out f...

Page 84: ...ully and secure them with cable clamps and tie wraps 3 Tighten screws finger tight 4 Adjust headlight roughly using ratchet plate as a guide The user can carry out final adjustment following user manu...

Page 85: ...s 1 remove all tie wraps and pull cable out of mobility device 4 Disconnect cable of affected headlight from light board 2 Fig 6 105 5 Loosen nut 1 6 Lift off rear light shroud 2 carefully Fig 6 106 7...

Page 86: ...rench Oblique pliers Tie wraps Removing Rear Light 1 Remove rear and centre shroud See 6 8 1 Replacing Rear Shroud page 55 and 6 8 2 Replacing Centre Shroud page 55 2 Take exact note of positions of a...

Page 87: ...Support Plates Tools 4 mm Allen key Easy Adapt Seat Removing Seat Support Plates 1 Remove cover plates 1 2 Loosen and remove two Allen screws 7 which are located on side at front of seat support plat...

Page 88: ...Test all functions 6 12 2 Replacing Tilt Actuator Oblique pliers Cable ties Removing Tilt Actuator 1 Remove legrests 2 Unplug actuator plug out of module 3 Remove cable ties 4 Remove cable 5 Remove up...

Page 89: ...this fact the carrier on your mobility device may look different to the illustrations below The following mounting instructions are not affected by this 6 mm Allen key Removing Tilt Bracket 1 Remove s...

Page 90: ...1 Install parts in reverse order 2 Test all functions 6 12 6 Replacing Seat Support CAUTION Risk of strains from lifting heavy parts Use proper lifting techniques TX40 Torx key Oblique pliers Cable t...

Page 91: ...Allen screws on the plastic shroud 1 2 Remove the plastic shroud 3 Loosen and remove the Phillips screw 3 4 Remove reflector 4 5 Remove snap ring under reflector not in the picture 6 Undo two Allen sc...

Page 92: ...device on it s side and secure position so it does not turn over TX40 Torx key Oblique pliers Cable ties Removing Seat Column 1 Remove seat See 6 12 6 Replacing Seat Support page 90 2 Remove shrouds...

Page 93: ...8 1 Replacing Rear Shroud page 55 2 Remove center battery box shroud See 6 8 2 Replacing Centre Shroud page 55 3 Remove front battery box shroud See 6 8 3 Replacing Front Shroud page 56 4 Remove seat...

Page 94: ...able clamps on battery box and expose cables 4 Disconnect cables on actuator module on battery box and if necessary on lighting circuit board 5 Disconnect plug at top of lifter column 6 Remove seat Se...

Page 95: ...ully remove back section 1 together with lower part 2 from seat support 3 Two parts are interconnected via the arm 4 Fig 6 128 Installing Back Unit 1 Refit parts in reverse order 2 Test all functions...

Page 96: ...rews just tight enough that lateral tubes can slide and be adjusted without difficulty 5 Adjust distance between lateral tubes to desired value using measuring tape Make sure both lateral tubes are at...

Page 97: ...ender for rear drive wheels Fender for castors Swing away tray Bumper for remote Km counter Hour counter Toolkit incl bit holder bits and fork spanners DAHL Docking Station Curb climber Anti Tippers T...

Page 98: ...Notes...

Page 99: ...Notes...

Page 100: ...Notes...

Page 101: ...Notes...

Page 102: ...vacare ie New Zealand Invacare New Zealand Ltd 4 Westfield Place Mt Wellington 1060 New Zealand Phone 0800 468 222 Fax 0800 807 788 sales invacare co nz www invacare co nz United Kingdom Invacare Limi...

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