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Invacare Storm4 Service Manual

Storm4 series
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Download this manual See also: Service Manual, Instruction Manual
Enlarged version
DEALER: Keep this manual.
The procedures in this manual MUST be performed by a qualified
technician.
Invacare® Storm4 Series
Storm4, Storm4 X-plore
en Power Wheelchair
Service Manual

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Summary of Contents for Invacare Storm4

  • Page 1 Invacare® Storm4 Series Storm4, Storm4 X-plore en Power Wheelchair Service Manual DEALER: Keep this manual. The procedures in this manual MUST be performed by a qualified technician.
  • Page 2 All rights reserved. Republication, 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 Corporation or its subsidiaries unless otherwise noted.

  • Page 3: Table Of Contents

    6.10.13 Replacing headlight holder (Modulite starting 6.6.3 Replacing drive unit (Storm4 X-plore) ... . . 23 03/2012) ....... . . 53 6.6.4 Replacing or rotating motor/ gearbox unit sealing...

  • Page 4: General

    Invacare® Storm4 Series • If you have any problems or questions contact Invacare 1 General Service. 1.1 About this manual 1.3 Notes on shipping • This manual refers to configurations with Modulite seat • If the mobility device has to be shipped back to the system.

  • Page 5: Safety

    Invacare specialist CAUTION! dealers. Injury hazard if the vehicle starts moving – Invacare supplies all mobility devices with a unintentionally during repair work standard drive program ex-works. Invacare can – Switch the power supply off (ON/OFF key).

  • Page 6: Hygiene

    *Invacare uses detergent "Nücosept special" 1.5% in water ml/ml Disinfection tools • One way wipes (fleece) • Brushes to clean difficult to access areas Further information For more information see Invacare RAN procedure and Invacare Repair and Hygiene guidelines, or contact your Invacare Service department. 1533060-M...

  • Page 7: Setup

    – Changes to drive program may only be carried column (3). out by trained Invacare specialist provider. – Invacare supplies all mobility devices with a 3. Lift off shroud plate (1). standard drive program ex-works. Invacare can The shroud plate has four flaps pointing only give a warranty for safe mobility device downward.
  • Page 8 Invacare® Storm4 Series Adjusting seat height on type A electrical lifter column 3. Fix adapter with two screws (1). with adapter 4. Replace seat support on lifter pillar (5). CAUTION! Risk of damage to lifter pillar Lifter pillar can be damaged if screws are too long.

  • Page 9: Adjusting Lower Leg Length

    8. Install cables. See “Installing on lifter column type B”. 9. Check all mobility device functions. 4.1.2 Adjusting lower leg length Invacare offers a range of legrests which can be adjusted individually. See user manual. 4.1.3 Adjusting the backrest CAUTION!

  • Page 10: Adjusting Seat Support

    Invacare® Storm4 Series 11. Adjust straps of sling backrest to new width or install 5. Re-insert two screws A into middle plate. adjusted Flex 3 backrest. 6. Retighten front lateral plates (2 and 4). 12. Install backrest cushion. 13. Perform a function check of mobility device.

  • Page 11: Adjusting Center Of Gravity Of The Seat

    Setup Adjusting seat depth Backrest posts for Flex3 only adjust up to a seat width setting of 480 mm. The remaining 5 cm are adjusted via backrest plates. A: Seat depth B: Center of gravity of the seat/ seat position Seat depth A can be adjusted by moving backrest in relation to seat surface.

  • Page 12: Adjusting Seat Tilt

    Invacare® Storm4 Series CAUTION! Risk of damage due to collisions of the legrests with other parts of the wheelchair – Set the legrests to the smallest angle before adjusting the seat center of gravity. – Pay attention with adjusting the seat center of gravity that the legrests do not touch any other parts of the wheelchair.
  • Page 13 Setup Adjusting seat tilt on a seat with a manual tilt module (from Dec. 2010) CAUTION! Risk of crushing Seat and frame are very heavy and can fall down without warning if seat tilt adjustment assembly is screwed apart too far. Risk of injury to hands and feet.

  • Page 14: Testing

    4. If there is a defect, replace the motor and send it to Invacare Service for inspection or repair. A resistance of between 40 and 80 ohms indicates an intact brake. A resistance of 0 ohms or a very high resistance (mega-ohms or infinity) indicates a short-circuit, a bad connection or a defective brake.

  • Page 15: Service

    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®. 6.3.2 Drive fault diagnosis Problem Other symptoms...
  • Page 16 Invacare® Storm4 Series Documentation Problem Other symptoms Possible cause Solution None See 6.9.15 Removing Mobility device Batteries defective Replace batteries batteries, page 46 judders in drive mode (unstable voltage) Drive motor(s) Replace motor(s) See6.6.1 Replacing defective drive unit, page 22 and 6.6.3 Replacing drive...
  • Page 17 Bearing defective Replacing motor See 6.6.1 Replacing drive unit, page 22 and 6.6.3 Replacing drive unit (Storm4 X-plore), page 23 Collector defective Measure internal See 6.6.1 Replacing resistance of motor, drive unit, page 22 and replace motor if 6.6.3 Replacing drive...

  • Page 18: Charging Device Fault Diagnosis

    Check the mains supply with a voltmeter. Defective mains supply cable. Check the mains supply cable. Replace damaged cables or send the battery charger to Invacare Service for repair. LEDs are burnt out Send the battery charger to Invacare Service for repair.

  • Page 19: Service Plan

    Battery charger could be defective. Use a battery charger which you know is working properly to charge the batteries. Send the defective battery charger to Invacare Service for repair. Battery voltage is too low to operate Replace the batteries. See “Removing mobility device.
  • Page 20 Invacare® Storm4 Series Component Notes Check Remedy Check suspension Repair or replace if See 6.6.9 Replacing damaged strut, page 30 Check straight running Replace wheels, wheel See 6.6.13 Replacing fork or wheel bearings front wheel fork , page Drive units, clutch...

  • Page 21: Overview Components

    Service Component Notes Check Remedy Drive lever function Replace drive lever if necessary Replace remote if necessary Power supply Tighten cables and connecting plugs, replace if necessary Drive program Check drive electronics Update software See “Updating program version if newer version software”...

  • Page 22: Chassis

    Invacare® Storm4 Series 6.5 Chassis 8. Remove screws together with washers. 9. Pull motor/transmission unit (3) out of mounting (2) in a forward direction. In doing so, please observe high 6.6 Drive components weight of unit. 6.6.1 Replacing drive unit Refitting motor/transmission unit 1.

  • Page 23: Replacing Drive Unit (Storm4 X-Plore)

    Removing motor/gearbox coupling 6.6.3 Replacing drive unit (Storm4 X-plore) 1. Remove motor/gearbox unit. See 6.6.1 Replacing drive WARNING! unit, page 22 or 6.6.3 Replacing drive unit (Storm4 Risk of crushing X-plore), page 23. Mobility device is very heavy. Risk of injury to hands and feet.

  • Page 24: Replacing Or Rotating Motor/ Gearbox Unit Sealing

    1. Replace defective parts. 1. Removing motor / gearbox unit. See 6.6.4 Replacing or rotating motor/ gearbox unit sealing ring (SSD motor), page 24 or 6.6.3 Replacing drive unit (Storm4 X-plore), page 23). 2. Loosen and remove self-securing nuts (4) including washers.

  • Page 25: Fitting Clutch Rotary Knob

    Service 5. Note fixing position and location of carbon brushes. To guarantee optimum contact to the collector used carbon brushes need to be refitted exactly in same position from which they were taken. 6. Make marking on motor and carbon brushes to guarantee correct refitting.
  • Page 26 Warranty on True Track Plus motors: If motors become defective within their guarantee period, they will either be replaced or repaired on Invacare® decision. This guarantee does not cover pay for working hours. We also accept no liability for physical injuries or unauthorised repairs.
  • Page 27 20 mm. 2. Loosen screws 2, 4 and 5 a single turn each, one – Only use original Invacare screws and washers. after other, going from screw to screw in a clockwise – Tighten screws with the prescribed tightening torque.
  • Page 28 Invacare® Storm4 Series WARNING! Risk of accidents Risks to workers, surroundings and mobility device. – Do not leave mobility device unattended during following procedure. – Make sure that both drive wheels are raised and can not touch ground. – Secure area.

  • Page 29: Replacing Rear Wheel Suspension

    Service The programming You should enter this device shows the following GB MOTOR "YES" (if drive wheels have CALIBRATION Chair been raised) will drive! Are wheels raised? EXIT GB MOTOR "BEGIN" (if drive wheels have CALIBRATION been raised) -BEGIN- to start. Wheels will drive! EXIT BEGIN GB MOTOR...

  • Page 30: Replacing Strut

    6.6.10 Replacing rear compression spring (True Track Plus to ensure that mobility device works perfectly. motor) Standard Storm4: The springs of wheel suspension Invacare always recommends replacing both spring can be chosen from three weight classes according elements to make sure the mobility device works to the users weight.

  • Page 31: Replacing Front Suspension Strut

    Service 6.6.11 Replacing front suspension strut (only Storm4 CAUTION! X-plore) Risk of crushing The mobility device is very heavy. Risk of Injury Invacare always recommends you replace both to hands and feet. suspension struts to make sure perfect mobility – Use proper lifting techniques.

  • Page 32: Replacing Front Wheel Fork

    Invacare® Storm4 Series 6.6.14 Adjusting front wheel fork CAUTION! Risk of crushing Mobility device is very heavy. Risk of injury to hands and feet. – Use proper lifting techniques. • 19 mm socket wrench • Blade screwdriver Removing 4–way bus socket 1.

  • Page 33: Replacing Front Wheel Carrier (Standard Storm4)

    Installing front wheel carrier 1. Install parts in reverse order. 2. Tighten Allen screw (4) to 200 -180 Nm. 3. Test all functions. 6.6.17 Replacing front wheel carrier (Storm4 X-plore) CAUTION! Risk of crushing Mobility device is very heavy. Risk of injury to hands and feet.

  • Page 34: Wheels

    – Observe recommended tire pressure. For recommended tire pressure see inscription on tire, rim, or contact Invacare. Compare table below for conversion. Loosen four or five screws (1). 3. Take wheel (2) off wheel hub. Installing drive wheel Make sure that wheel is re-fitted on same side and in same running direction as removed.

  • Page 35: Replacing A Tire Or Inner Tube

    Service 6.7.3 Replacing a tire or inner tube 3. Fill some air into inner tube. 4. Install five Allen screws on inner side of wheel and There are three different types of tires or inner tighten. tubes, and specific points must be observed for 5.

  • Page 36: Replacing Drive Wheel Hub

    Invacare® Storm4 Series 5. Check exact fit of tire on rim. 6.7.4 Replacing drive wheel hub 6. Inflate tire to prescribed air pressure. CAUTION! 7. Re-check exact fit of tire on rim. Risk of damage to mobility device 8. Screw valve cap back on.

  • Page 37: Repairing Punctures (Drive Wheel With True Track Plus Motor And Pneumatic Tires)

    Service 6.7.6 Repairing punctures (drive wheel with True Track Plus motor and pneumatic tires) CAUTION! Risk of injury If the wheel has been insufficiently tightened during assembly, it can become loosened during driving. – When reassembling the drive wheels, tighten the Allen screws at a torque of 25 Nm.

  • Page 38: Repairing Flat Front Tire (Pneumatic Tire 3.00-6)

    Invacare® Storm4 Series 6.7.7 Repairing flat front tire (pneumatic tire 3.00-6) • 5 mm Allen key • 24 mm socket wrench • wooden block (approx. 12 x 30 cm for propping up mobility device) • Repair kit for inner tubes or a new inner tube •...

  • Page 39: Replacing Front Shroud

    Service Removing center shroud Module shroud protects cables. 1. Remove rear shroud. See 6.8.1 Replacing rear shroud, page 38. 2. If possible, use lifter to move seat to uppermost position. 1. Remove both rivets B. 2. Remove module shroud A. Loosen two screws (1).

  • Page 40: Replacing Mud Guard

    Invacare® Storm4 Series 1. Lift mobility device on one side and place wooden block Removing mud guard underneath it, so that front wheel is off ground and can rotate freely. Use proper lifting techniques. 2. Remove front wheel, as described in 6.6.15 Replacing front wheel , page 32.

  • Page 41: Controls

    1. If possible, move seat to uppermost position. Loosen and remove two Allen screws (2) and washers. 3. Remove mud guard (1) from transmission mounting (3). 4. Storm4 X-plore: Take care of spacers (4). 5. Replace mud guard according to table above. Installing mud guard 1.

  • Page 42: Replacing Linx Power Module Bracket

    5. Select drive program (see “Drive program selection after out by trained Invacare specialist providers. component replacement”). – Invacare can only give a warranty for safe mobility device driving behaviour - especially 6. If new software version is available, update drive tipping stability - for unaltered standard drive program.

  • Page 43: Replacing Actuator Module Under Seat

    Service Removing G-Trac sensor Dismantling tilt module 1. If possible, completely raise the seat with the lifter. 1. If possible, use lifter to move seat to uppermost position. 2. Switch OFF electronics of mobility device. 3. Remove rear shroud. See 6.8.1 Replacing rear shroud, page 38.

  • Page 44: Replacing Lighting/Actuator Module Clam

    Invacare® Storm4 Series 6.9.7 Replacing lighting/actuator module CLAM Tools: • Phillips screwdriver size 2 • 3 mm Allen key • 4 mm Allen key • 8 mm socket spanner Dismantling CLAM 1. If possible, use the lifter to move the seat to the uppermost position.

  • Page 45: Drive Program Selection After Component

    Profile selection with remote REM A or REM B 6.9.12 Updating software Invacare is continuously carrying out further development and improvements to drive programs for electric vehicles. For this reason, you should always check whether the drive program version number is up-to-date when carrying out any repairs or regular maintenance.

  • Page 46: Batteries

    – Always wear protective goggles when handling dealers. batteries. – Invacare can only give a warranty for safe What to do if acid is discharged mobility device driving behaviour - especially – Always take clothing which has been soiled by...

  • Page 47: General Instructions On Handling The Batteries

    Service Removing batteries Dead or damaged batteries can be given back to your provider or directly to Invacare. 1. Make batteries accessible. See 6.9.14 Making batteries accessible, page 46. 6.9.18 Main fuse CAUTION! Risk of fire – Always use an original strip fuse with the approved amperage.

  • Page 48: Cables

    Invacare® Storm4 Series Installing Pay attention to “Installing on lifter column type B” if a type B lifter column is installed. • 4 mm Allen key • Oblique pliers You see strip fuse (2) once fuse holder (1) is open.
  • Page 49 Service View of seat from below View from rear. Lifter column type A Lifter column type B with ACT (1). electrically adjustable electrically adjustable Attach cable guide for lifter (1) using two screws, on left underneath seat. Installing on type B lifter column - part 1 •...

  • Page 50: Lighting Unit

    Invacare® Storm4 Series 6.10 Lighting unit Removing headlight 6.10.1 Replacing front bulb • Size 2 Phillips screwdriver Remove rear and center shroud. See 6.8.1 Replacing rear shroud, page 38 and 6.8.2 Replacing center shroud, page 38) 2. Carefully note location of cable and connection locations of various plugs.

  • Page 51: Replacing Headlight (On Modulite Conventional)

    Service Removing headlight Removing headlight Remove rear and center shroud. See 6.8.1 Replacing Remove rear and center shroud. See 6.8.2 Replacing rear shroud, page 38 and 6.8.2 Replacing center shroud, center shroud, page 38 and6.8.1 Replacing rear shroud, page 38. page 38.

  • Page 52: Replacing Headlight (Led)

    Invacare® Storm4 Series 6.10.9 Replacing front bulb holder (until 03/2012) • Phillips screwdriver size 2 • 8 mm wrench Removing headlight holder Loosen Allen screw (1) and remove headlight from mounting. 6. Replace headlight. Installing headlight 1. Install parts in reverse order.

  • Page 53: Replacing Headlight Holder

    Service 6.10.11 Replacing headlight holder (Modulite starting 03/2012) • Phillips screwdriver size 2 • 8 mm wrench Removing rear light holder 1. Loosen screw (1) and remove headlight from holder. 2. Loosen both nuts (2) and remove holder from rubber Removing rear light bracket mounting.

  • Page 54: Replacing Rear Light (Conventional)

    Invacare® Storm4 Series 3. Replace defective bulb. Removing rear light 4. Replace glass and tighten Phillips screw finger-tight. 6.10.16 Replacing rear light (conventional) • 4 mm Allen key • 8 mm socket wrench • 13 mm socket wrench Removing rear light Remove rear and center shroud.

  • Page 55: Replacing Rear Bulb Holder

    Service Removing rear light holder 4. Loosen nut (1). 5. Lift off shroud (2) carefully. 1. Remove rear light as described in 6.10.16 Replacing rear light (conventional), page 54. 2. Loosen and remove both Allen screws (1). 3. Replace rear light holder (2). Refitting bulbholder 1.
  • Page 56 Invacare® Storm4 Series 8. Remove cable or cables so that there is no longer any 12. Keep firm hold on seat and seat support whilst loosening cable connection between seat and chassis. and removing four torx screws (1). 13. Lift seat and seat support from vertical column.

  • Page 57: Seat Column/Lifter Column

    Service 3. Unclip cable. Remove any cable ties which are fitted. Replacing seat column CAUTION! Risk of crushing The seat is very heavy. Risk of injury to hands and feet. – Use proper lifting techniques. CAUTION! Risk of crushing Remove upper pin retainer (1). The mobility device is very heavy.
  • Page 58 Invacare® Storm4 Series Replacing type A electrical lifter column 8. Loosen and remove four screws (3) on underside of chassis (2). WARNING! 9. Remove lifting column (1). Risk of crushing Installing lifting column The seat is very heavy. Risk of injury to hands and feet.

  • Page 59: Storm X-Plore

    Service Replacing front X-plore swing arm WARNING! Risk of crushing The mobility device is very heavy. Risk of injury to hands and feet. – Use proper lifting techniques. • 4 mm Allen key • 6 mm Allen key • Long wooden blocks, min. 14 x 14 x 30 cm Loosen and remove four screws (3) on underside of chassis (2).
  • Page 60 Invacare® Storm4 Series 3. Remove securing clip (4). 4. Remove spacer (3). 5. Carefully remove bolts (1) which connect shock absorber (2) to swing arm (5). 6. Loosen three screws (6). 7. Remove bolts (3) together with washers. 8. Pull swing arm (5) out of rear wheel link fork (7) and replace it.

  • Page 61: Accessories

    Caneholder, to be mounted on the right side The installation instructions for additional accessories • Caneholder, to be mounted on the left side are available at your Invacare specialist provider or • Fender for rear/drive wheels directly from Invacare. •...
  • Page 62 Notes...
  • Page 63 Notes...
  • Page 64 Invacare Sales Companies Australia: Canada: Ireland: New Zealand: Invacare Australia PTY. Ltd. Invacare Canada LP Invacare Ireland Ltd, Invacare New Zealand Ltd 1 Lenton Place, North Rocks NSW 570 Matheson Blvd E. Unit 8 Unit 5 Seatown Business Campus 4 Westfield Place, Mt Wellington 1060...

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Storm4 x-plore

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