Invacare Storm4 Series Service Manual
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Invacare Storm4 Series Service Manual

Invacare Storm4 Series Service Manual

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PROVIDER: Keep this manual.
The procedures in this manual MUST be performed by a qualified
technician.
Invacare® Storm⁴ Series
Storm⁴ Max
en Power Wheelchair
Service Manual

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Summary of Contents for Invacare Storm4 Series

  • Page 1 Invacare® Storm⁴ Series Storm⁴ Max en Power Wheelchair Service Manual PROVIDER: 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

    Contents 6.9.2 Making Power Module Accessible....41 6.9.3 Replacing Power Module ..... . 41 6.9.4 Replacing G-Trac Sensor .

  • Page 4: General

    Invacare reserves the right to alter product specifications without further notice. Before reading this document, make sure you have the latest version. You find the latest version as a PDF on the Invacare website. For pre-sale and user information, see the user manual.

  • Page 5: Images In This Manual

    General 1.5 Images in This Manual The detailed images in this manual are given marks to identify various components. Component marks in text and operational instructions always relate to the image directly above. 1555830-C...

  • Page 6: Safety

    Invacare® Storm⁴ Series 2 Safety 2.1 Safety and Fitting Instructions These safety instructions are intended to prevent accidents at work, and it is imperative that they are observed. Before any inspection or repair work • Read and observe this repair manual and the associated user manual.
  • Page 7 – Changes to the drive program may only be carried out by trained Invacare providers. – Invacare supplies all mobility devices with a standard drive program ex-works. Invacare can only give a warranty for safe mobility device driving behavior - especially tipping stability - for this standard drive program.

  • Page 8: Hygiene

    Use saturated Cleaning and reconditioning disinfectant wipes disinfection and clean* the device surface. *Invacare uses detergent "Nücosept special" 1.5% in water ml/ml Disinfection Tools • Disposable wipes (fleece) • Brushes to clean areas difficult to access Further Information For more information contact your Invacare service department.

  • Page 9: Setup

    6. Install parts in reverse order. 7. Check all mobility device functions. Fig. 4-1 4.2 Adjusting Lower Leg Length Invacare offers a range of legrests which can be adjusted individually. See user manual. 4.3 Adjusting Fixed Footboard • 5 mm Allen key 1.

  • Page 10: Adjusting Backrest

    Invacare® Storm⁴ Series 4.4 Adjusting Backrest CAUTION! Adjusting the seat tilt or the backrest angle changes the geometry of the mobility device and directly influences its dynamic stability! – For details regarding dynamic stability, negotiating gradients and obstacles and the correct adjustment of seat tilt or backrest angle, refer to Taking Obstacles and Driving up and down Gradients.

  • Page 11: Adjusting Height Of Backrest Tube

    Setup 4.4.3 Adjusting Height of Backrest Tube 1. Loosen handscrews on both sides. 2. Adjust backrest tube to desired height. 3. Re-tighten handscrews. Fig. 4-5 4.5 Adjusting seat tilt 4.5.1 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 12: Testing

    4. If there is a defect, replace the motor and send it to Invacare Service for inspection or repair. Fig. 5-2 A resistance of between 40 ohms 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 13: Field Load Test

    Testing 5.4 Field Load Test Old batteries loose their ability to store and release power due to increased internal resistance. In this procedure, batteries are tested under load using a digital voltmeter to check battery charge level at the charger connector. The charger connector is located on the remote.

  • Page 14: Checking Battery Charge Level

    Invacare® Storm⁴ Series 1. Turn OFF controls on remote. 2. If necessary, remove shroud. 3. Take note of the positions of all cables and sockets that they are connected to. Mark connectors and sockets or take a photograph with a digital camera.

  • Page 15: Service

    Service 6 Service 6.1 General warning information on installation work CAUTION! Risk of injury and damage to property, if the maximum speed reduction on a mobility device with a lifter does not function correctly The mobility device’s control unit must reduce the maximum possible speed as soon as the lifter is raised. –...

  • Page 16: Troubleshooting

    The power modules used are described in the corresponding controls manual. 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. 6.4.2 Drive Fault Diagnosis Documentation...
  • Page 17 Service Documentation Problem Other symptoms Possible cause Solution None Error message does Bad connections Check all connecting See 6.10.6 Cable not go out cables. Routing, page 48 Motor brake defective Measure internal See 6.7.1 Replacing resistance of brakes, Drive Unit, page 23 replace motor if defective.
  • Page 18 Invacare® Storm⁴ Series Documentation Problem Other symptoms Possible cause Solution Power module Replace power module See 6.9.3 Replacing defective Power Module, page Corroded contacts Water, salt or urine Check wiring, replace See 6.10.6 Cable has penetrated if necessary Routing, page 48...

  • Page 19: Charging Device Fault Diagnosis

    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. An internal fuse might be burnt out.
  • Page 20 Invacare® Storm⁴ Series Component Notes Check Remedy Posture belt Damage to posture belt Replace belt if damaged See 6.17 Posture Belt, page 64. Belt lock function Replace belt if damaged See 6.17 Posture Belt, page 64. Armrests Damage to armrests...

  • Page 21: Shrouds

    Service Component Notes Check Remedy Lighting (if installed) Check cable Replace lamp or cable See 6.11 Lighting Unit, page 49. if necessary Check function Battery mounting Check battery support Replace if necessary and mounting belts for damage Batteries Check batteries for Replace batteries if See 6.10.4 Removing Batteries, damage...

  • Page 22: Replacing Centre Shroud

    Invacare® Storm⁴ Series 6.6.2 Replacing Centre Shroud • 4 mm Allen key Removing Centre Shroud 1. Remove rear shroud. See 6.6.1 Replacing Rear Shroud, page 21. 2. If possible, use lifter to move seat to uppermost position. 3. Loosen two screws A.

  • Page 23: Replacing Fender

    Service Installing Rear Light Shroud 1. Install parts in reverse order. 2. Tighten screws finger-tight. 6.6.5 Replacing Fender • 5 mm Allen key Removing Fender 1. If possible, move seat to uppermost position. 2. Loosen and remove screws F and washers E. 3.

  • Page 24: Replacing Carbon Brushes

    Invacare® Storm⁴ Series Removing Drive Unit 1. Make power module accessible. See 6.9.2 Making Power Module Accessible, page 41. 2. Pull motor plug out of power module. Plugs differ according to controls system. 3. Remove centre shroud. See 6.6.2 Replacing Centre Shroud, page 22.
  • Page 25 Service • 5 mm Allen key • 6 mm Allen key • 10 mm wrench (SSD motors only) • 19 mm wrench • Flat screwdriver (large) • Oblong wooden blocks (at least 14 x 14 x 30 cm) Removing Carbon Brushes Fig.

  • Page 26: Replacing Bowden Cables And Clutch

    Invacare® Storm⁴ Series 1. Lift mobility device on one side and place a 14 cm high wooden block underneath it so that drive wheel is off ground and can rotate freely. Use proper lifting techniques. 2. Repeat this on other side of mobility device.

  • Page 27: Replacing Motor Swing Arm

    Service Removing Lever Unit 1. Loosen screw of clutch lever. 2. Remove clutch lever. 3. Loosen and remove four screws F and washers G of lever unit E. 4. Remove lever unit E from fixation bracket B. Fig. 6-12 Removing Fixation Bracket of Lever Unit 1.

  • Page 28: Replacing Suspension Strut

    1. Install parts in reverse order. 2. Test all functions. 6.7.5 Replacing Suspension Strut Invacare always recommends replacing both suspension struts to make sure that mobility device works perfectly. CAUTION! Risk of crushing Mobility device is very heavy. Risk of injury to hands and feet.

  • Page 29: Replacing Front Swing Arm

    Service Removing Suspension Strut 1. Remove rear and centre shroud. See 6.6.1 Replacing Rear Shroud, page 21 and 6.6.2 Replacing Centre Shroud, page 22. 2. Remove drive wheel. See 6.8.6 Replacing Drive Wheel (5–Screw Installation), page 34. 3. Loosen and remove nut (1). 4.

  • Page 30: Replacing Castor Fork

    Invacare® Storm⁴ Series 6.7.7 Replacing Castor Fork CAUTION! Risk of injury due to uncontrolled movement of mobility device – Use proper lifting techniques. Risk of injury caused by uncontrolled movement of the mobility device. – Turn power off. – Engage motors.

  • Page 31: Wheels

    The following are instructions on maintenance and repairs that can be performed by the user. For the specifications of spare parts please see Technical Data, or consult the service manual, available from Invacare (in this connection please see the addresses and phone numbers at the end of this user manual). In case you require assistance, please contact your Invacare dealer.

  • Page 32: Tyre Types

    Invacare® Storm⁴ Series 6.8.3 Tyre Types There are three different types of tyres or 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.

  • Page 33: Overview Of Power Wheelchair Models And Wheel Types

    Service 6.8.5 Overview of Power 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 cap puncture-proof = no valve Models Drive wheels...

  • Page 34: Replacing Drive Wheel (5-Screw Installation)

    Invacare® Storm⁴ Series Models Castor Wheels 6” 8” 9” 10” Single- Double-Sided Fork Double- Double- Single- Sided/ Sided Fork Sided Fork Sided Fork Double- Sided Fork TDX SP2 S4 Series Kite Bora Stream Mirage Dragon * For wheelchair-specific mounting instruction, see respective manual.

  • Page 35: Replacing Castor Wheel On Double-Sided Fork

    Service • 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 removing, take care of small parts such as screws and washers. Put all small parts down so that they can be installed in correct sequence.
  • Page 36 Invacare® Storm⁴ Series Fig. 6-20 Remove nut from bolt A. 4. Remove bolt and wheel from fork. Installing Wheel 1. Install parts in reverse order. 2. When installing wheel, pay attention to correct direction of rotation. 3. Tighten nut to prescribed torque. See 6.8.4 Specific Tightening Torques, page 32.

  • Page 37: Replacing Flat Castor Tyre / Inner Tube

    Service 6.8.8 Replacing Flat Castor Tyre / Inner Tube • 5 mm Allen key • Torque wrench 5 Nm — 25 Nm (or similar) • Three joiner's clamps with plastic caps (puncture-proof tyres only) • Two long wooden blocks (min. 14 x 14 x 30 cm) •...
  • Page 38 Invacare® Storm⁴ Series 9. Install wheel. Replacing Puncture-Protected Tyres Puncture-protected tyres have red valve caps. Removing Tyres CAUTION! Risk of explosion There is considerable pressure in the tyre. Risk of injury. Parts can be thrown out and injure you if you do not deflate all air from tyre.

  • Page 39: Replacing Drive Wheel Hub

    Service 1. Remove wheel from fork. 2. Secure rim rings against unexpected discharge with three joiner's clamps. Make sure you do not to scratch rims. 3. Loosen and remove five screws F on inside of wheel. 4. Loosen joiner's clamps carefully and alternately until rim rings can be removed without danger.

  • Page 40: Replacing Big Anti-Tipping Wheel

    Invacare® Storm⁴ Series 6.8.10 Replacing Big Anti-Tipping Wheel Mark current settings of wheel, shim rings and spacer before dismantling. • 6 mm Allen key • 13 mm wrench 1. Remove end cap A. 2. Loosen and remove nut B including washer C.

  • Page 41: Making Power Module Accessible

    – Changes to the drive program may only be carried out by trained providers. – Invacare can only give a warranty for safe mobility device driving behaviour - especially the tipping stability - for unaltered standard drive programs.

  • Page 42: Replacing G-Trac Sensor

    Invacare® Storm⁴ Series Installing Power Module For details on cable routing and information about Updating drive program and Adapting drive program, see LiNX Service Manual. 1. Install parts in reverse order. Pay attention to place lock washers between bracket and power module, if available.

  • Page 43: Replacing Light Board

    Service Removing ACT2 1. Remove rear and centre shroud. See 6.6.1 Replacing Rear Shroud, page 21 and 6.6.2 Replacing Centre Shroud, page 22. 2. Carefully note the location of the cable and the connection locations of the various plugs. Either mark each plug and socket, or take a photograph with a digital camera.

  • Page 44: Updating Software

    – Changes to the drive program may only be carried out by trained Invacare specialist dealers. – Invacare can only give a warranty for safe mobility device driving behaviour - especially the tipping stability - for unaltered standard drive programs.

  • Page 45: General Instructions On Handling The Batteries

    Wash all objects that have come into contact 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 Various power modules can be installed to the mobility device.

  • Page 46: Removing Batteries

    Invacare® Storm⁴ Series 1. Remove rear shroud. See 6.6.1 Replacing Rear Shroud, page 21. 2. Press both catches (3) inwards and open battery box shroud. Fig. 6-35 3. Pull locking pin A. 4. Place power module, together with bracket, on top of battery box or actuator module, if installed.
  • Page 47 Service CAUTION! Risk of fire and burns Fitting incorrect strip fuse causes fire hazard. – Only fix strip fuses in sequence shown in image below. – Tighten nuts with 3.3 or 3.5 Nm. Fig. 6-39 Correct sequence of fitting original strip fuse Strip fuse Ring terminal DIN 6923 nut...

  • Page 48: Cable Routing

    Invacare® Storm⁴ Series 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 once fault has been rectified.

  • Page 49: Lighting Unit

    Service Installing 1. Remove rear and centre shroud. See 6.6.1 Replacing Rear Shroud, page 21 and 6.6.2 Replacing Centre Shroud, page 22. 2. Lead cables on power module and actuator module fitted at rear through recess in battery flap under actuator module to cable bridge (1).

  • Page 50: Replacing Headlight Holder (Led)

    Invacare® Storm⁴ Series Removing Headlight 1. Remove rear and centre shrouds. See 6.6.1 Replacing Rear Shroud, page 21 and 6.6.2 Replacing Centre Shroud, page 22. 2. Take exact note of positions of all cables and sockets that cables are connected to. Mark connectors and sockets or take a photograph.

  • Page 51: Replacing Complete Rear Light (Led)

    Service Removing Headlight Holder 1. Remove rear and centre shroud. See 6.6.1 Replacing Rear Shroud, page 21 and 6.6.2 Replacing Centre Shroud, page 22. 2. Take exact note of positions of all cables and sockets that cables are connected to. Mark connectors and sockets or take a photograph.

  • Page 52: Seating

    Invacare® Storm⁴ Series 5. Loosen nut (1). 6. Lift off rear light shroud (2) carefully. Fig. 6-51 7. Open rear light plug (3) that is to be replaced. 8. The rear lights are only clamped in plastic casing. Replace red rear light (1) or indicator (2) as required.

  • Page 53: Replacing Tilt Spindle

    Service 9. Loosen and remove bolts F, washers E and bushings C at front of seat frame. Pull out tilt sheet D and lay down seat frame carefully. Fig. 6-54 10. Loosen and remove screws G and washers H at rear of seat frame.

  • Page 54: Replacing Tilt Bracket

    Invacare® Storm⁴ Series Removing Tilt Actuator 1. Remove legrests. 2. Unplug actuator plug out of module. 3. Remove cable ties. 4. Remove cable. 5. Remove upper pin retainer clip A. 6. Remove upper pin B and tip tilt actuator E forward.

  • Page 55: Replacing Seat Column

    Service • TX40 Torx key • Oblique pliers • Cable ties We use different types of seat supports in our mobility devices. Due to this fact the seat support and the screws on your mobility device may look different to the illustrations below. The mounting instructions are not affected by this. Removing Seat Support 1.

  • Page 56: Headrest / Neckrest

    Invacare® Storm⁴ Series Removing Seat Column 1. Remove seat. See 6.12.5 Replacing Seat Support, page 2. Remove shrouds. See 6.6.1 Replacing Rear Shroud, page 21, 6.6.2 Replacing Centre Shroud, page 22 and 6.6.3 Replacing Front Shroud, page 22. 3. Place mobility device on side and safeguard it against overturning.

  • Page 57: Replacing Rea Headrest Mounting Bracket (Sling Backrest)

    Service 6.13.2 Replacing Rea Headrest Mounting Bracket (Sling Backrest) • 4 mm Allen key Removing Bracket Not all bolts and washers are shown in illustration. 1. Loosen and remove bolts E including washers F, mounting plate D and bottom side of bracket C. 2.

  • Page 58: Replacing Calf Pads

    Invacare® Storm⁴ Series 1. Loosen four screws on both sides of footboard holder. 2. Pull out lower footboard assembly out of footboard holder. 3. Heat thread of screw from upside direction (see arrow) to soften thread locking adhesive. Loosen and remove screw F.

  • Page 59: Armrests

    Service 6.15 Armrests 6.15.1 Replacing Armrest Replacing Armpad • 3 mm Allen key 1. Remove remote. 2. Loosen screw B. Do not remove it. 3. Pull armpad bracket C out of clothes-guard assembly. 4. Loosen and remove screws D. 5. Replace armpad A. 6.
  • Page 60 Invacare® Storm⁴ Series Replacing Clothes-Guard • 4 mm Allen key • Phillips screwdriver, size 2 1. Loosen and remove screws A, saddle washers C and clothes-guard B. 2. Replace clothes-guard B. Fig. 6-69 When installing, ensure that saddle washer C is in the correct position.

  • Page 61: Backrest

    Service 6.16 Backrest 6.16.1 Replacing Backrest Tube 1. Loosen handscrew C on both sides. 2. Pull backrest tube A out of backrest rail B. 3. Install parts in reverse order. 4. Test all functions. Fig. 6-71 6.16.2 Replacing Backrest Frame •...

  • Page 62: Replacing Seat Depth Adapter

    Invacare® Storm⁴ Series 1. Remove Backrest tube and backrest frame. See 6.16.1 Replacing Backrest Tube, page 61 and 6.16.2 Replacing Backrest Frame, page 61. 2. Loosen handscrew of locking slide C. 3. Remove backrest rail A by lifting upwards from backrest bracket B.

  • Page 63: Replacing Backrest Bracket

    Service 1. Remove backrest frame and backrest tube. See 6.16.3 Replacing Backrest Rail, page 61. 2. Loosen four screws D on each side. Do not unscrew them. 3. Remove backrest rail A by pulling it upwards. Fig. 6-76 4. Loosen set screw A. 5.

  • Page 64: Posture Belt

    Invacare® Storm⁴ Series 5. Loosen and remove screws J including washers L and bushings K on both sides. 6. Remove backrest bracket B. 7. Loosen and remove screws I, washers H, cover plates G and bearing sheet F on both sides.
  • Page 65 Service 1. Loosen and remove nut J including washer I. Fig. 6-83 Example of a lap belt on a Storm 2. Remove bolt B and belt D. Pay attention to washers (C and F) and nut E. Fig. 6-84 Installing Lap Belt •...

  • Page 66: Accessories

    Caneholder, left-hand mounted • Fender for drive wheels • Bumber for remote • Trip recorder • Hour counter • Toolkit (incl. bit holder, bits and fork wrenches) Installation instructions for additional accessories are available at your provider or directly from Invacare. 1555830-C...
  • Page 67 Notes...
  • Page 68 Invacare Sales Companies Australia: Canada: Ireland: New Zealand: Invacare Australia Pty. Ltd. Invacare Canada L.P. Invacare Ireland Ltd, Invacare New Zealand Ltd 1 Lenton Place, North Rocks NSW 570 Matheson Blvd East, Unit 8 Unit 5 Seatown Business Campus 4 Westfield Place, Mt Wellington 1060 2151 CDN Mississauga, On.

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