Invacare STORM4MAX, Service Manual

Page 1: ...Edition 24 11 12 Invacare STORM 4 MAX SERVICE MANUAL...

Page 2: ...Switzerland 41 0 61487 70 80 Fax 41 0 61487 70 81 switzerland invacare com WWW www invacare ch Invacare Aquatec GmbH Alemannenstra e 10 88316 Isny Deutschland 49 0 7562 70 00 Fax 49 0 7562 7 00 66 inf...

Page 3: ...town Rd Swords County Dublin Ireland 353 18 10 70 84 Fax 353 18 10 70 85 ireland invacare com WWW www invacare ie Invacare AS Grensesvingen 9 Postboks 6230 Etterstad N 0603 Oslo Norge Kundeservice 47...

Page 4: ...nvacare com finland invacare com WWW www invacare se M LNDAL 46 0 31 86 36 00 Fax 46 0 31 86 36 06 ginvacare invacare com LANDSKRONA 46 0 418 2 85 40 Fax 46 0 418 1 80 89 linvacare invacare com OSKARS...

Page 5: ...fitting removal 12 3 Tightening torques 15 4 Layout of components and componentry 16 4 1 Overview 16 4 2 Electronics modules 17 4 2 1 ACS 2 PMA90L electronics module 18 4 2 2 ACT actuator module 18 4...

Page 6: ...placing the main fuse 59 8 6 Checking the cable 61 8 6 1 Cable routing 62 8 7 Lighting unit 63 8 7 1 Replacing the front LED LED lighting unit 63 8 7 2 Replacing the complete front headlight LED light...

Page 7: ...t frame with a manual tilt module from Dec 2010 100 8 14 4 Adjusting the seat tilt on a seat with a manual tilt module from Dec 2010 102 8 14 5 Replacing the seat support with electric tilt module 103...

Page 8: ...ity aid may only be maintained and overhauled by qualified personnel The minimum requirement for service technicians is suitable training such as in the cycle or orthopaedic mechanics fields or suffic...

Page 9: ...are not avoided The following lines in italics refer to actions which serve to avoid such hazards ATTENTION The signal word ATTENTION refers to possibly occurring hazards which can lead to minor injur...

Page 10: ...nstructions to avoid injury to the user or damage to the product Wear safety shoes The symbol refers to the requirement for wearing safety shoes Wear standardised safety shoes during all work Wear eye...

Page 11: ...ERVICE MANUAL 11 1 5 Images in this manual The detailed images in this manual are given digits to identify various components Component numbers in text and operational instructions always relate to th...

Page 12: ...es or when handling batteries improperly Always wear eye protection when working on any defective or possibly defective batteries Safety gloves It is possible that battery acid can be discharged when...

Page 13: ...for tight fitting After completing your work before renewed start up of the mobility device check all parts for correct locking Only operate the vehicle with the approved tyre pressures see technical...

Page 14: ...ipping stability of the vehicle Changes to the drive program may only be carried out by trained Invacare specialist dealers Invacare supplies all mobility aids with a standard drive program ex works I...

Page 15: ...etermined All values assume dry and de greased threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque in Nm 10 3 Nm 6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 120 Nm 180 Nm CAUTION Damage can be caused to the...

Page 16: ...resent it controls the electrical tilt module as well as the electrical backrest adjustment Under the rear cowling Light terminal module 2 The lighting distributor module is located on top of the batt...

Page 17: ...uators or motors please begin by ascertaining which module is installed Please refer to the following table for an overview Electronic module Designation Notes Power module ACS 2 PMA90L The following...

Page 18: ...o the mobility aid These actuators are either connected directly to the power module or to a separate actuator module The actuator module is connected to the power module via a bus cable 4 2 2 1 ACT 2...

Page 19: ...power module 3 Bus cable to remote or power module 4 Actuator Channel 4 5 Actuator Channel 3 6 Actuator Channel 2 7 Actuator Channel 1 Rubber stoppers for free slots 1 Order number 1555701 2 3 Order n...

Page 20: ...3 Lighting PCB Connections 1 Driving light l h indicator 1 2 Driving light l h indicator 2 3 Power module 4 Driving light r h indicator 1 5 Driving light r h indicator 2 The lighting PCB connections...

Page 21: ...ility aid components such as adjusting motors actuators or motors you should first ensure that you know exactly which joystick box has been fitted Please refer to the following table for an overview R...

Page 22: ...SERVICE MANUAL Invacare STORM 4 MAX 22 Remote Designation Notes REM B Can be connected to power module ACS 2 PMA90L REM 550 Can be connected to power module ACS 2 PMA90L...

Page 23: ...age to side panels Replace side panels if damaged Side panel fixings Tighten screws Seat angle adjustment Tight fit of the bolt retainer clips If necessary replace the bolt retainer clips Lifter Check...

Page 24: ...arings See chapter 8 8 Drive units clutch mechanism Motors Check motors See chapter 8 11 Check functions during drive operation and when pushing Check the clutch mechanism Check carbon brushes replace...

Page 25: ...ormation in chapter 8 4 2 and 8 4 3 for handling batteries Remote electronics modules Remote status display blinking Evaluate error blink code See chapter 6 Fixings Tighten fixings replace if necessar...

Page 26: ...hapter 4 2 Note 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 fro...

Page 27: ...apter 8 6 Remote defective Replace remote See chapter 8 2 1 Remote status display blinking Various causes Assess error code See chapter 6 2 Mobility aid judders in drive mode None Batteries defective...

Page 28: ...night with mobility aid switched on None Fuse burnt out Check cabling and replace fuse See chapters 8 6 and 8 5 None Motor defective Check carbon brushes and replace if necessary See chapter 8 11 2 Re...

Page 29: ...chapter 8 2 2 Corroded contacts Water salt or urine has penetrated Check cabling replace if necessary See chapter 8 6 Motor makes clicking noise None Bearing defective Replacing the motor See chapter...

Page 30: ...n if defective See chapter 8 11 1 Parts lost None Parts lost Reattach parts once found Batteries not being charged None Fuse burnt out cable defective Check cabling and replace fuse See chapters 8 6 a...

Page 31: ...does not go out even if the remote has been switched off or disconnected Lighting actuator module defective Replace lighting actuator module See chapter 8 2 4 None Cable disconnected or damaged Safegu...

Page 32: ...ection loose defective or motor defective Check connection plug check motor See chapters 8 6 and 8 11 1 5 x blink Fault brake fault on left hand motor M2 Connection loose defective or motor defective...

Page 33: ...nt out Send the battery charger to Invacare Service for repair Batteries do not charge Fuse on mobility aid has burnt out Check mobility aid fuses See chapter 8 5 Battery charger not connected to mobi...

Page 34: ...1 Pull the motor plug 1 out of the power module Connect the digital multimeter to the motor plug contacts 3 and measure the resistance between the contacts Note A resistance of between 0 5 and 5 ohms...

Page 35: ...with a short circuit Always replace short circuited brakes immediately Note A defective motor can damage the power module but a defective power module cannot camage the motor Requirements Phillips scr...

Page 36: ...e STORM 4 MAX 36 Note 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...

Page 37: ...osen and remove the two knurled thumb screws 1 on the left and right side of the rear casing Carefully raise the rear cover The front part of the cover is held at the top by means of a Velcro strip Yo...

Page 38: ...g the centre panel Requirements 4 mm Allen key Dismantling the centre panel Remove the rear cover as described in chapter 8 1 1 If possible use the lifter to move the seat to the uppermost position Lo...

Page 39: ...ers that are underneath the cover on the Allen screws Lift off the entire cover If the mobility aid does not have a lifter the cover must be bent apart carefully as shown in the picture on the right R...

Page 40: ...1 concealed by the motor in the picture using a 4 mm Allen key Pull the motor cable and the guide bushes 2 out of the lateral recesses Pull the connecting cable to the seat out of the recess 3 First...

Page 41: ...llen key socket spanner 13 mm Dismantling the rear light cover Remove the rear and centre cover as described in chapters 8 1 1 and 8 1 2 Loosen the nut 1 using a 13 mm socket spanner Refitting the rea...

Page 42: ...umber SP1530557 Splash guard long LH Order Number SP1530558 Removing the splash guard Remove the seat Loosen and remove both hexagon socket head screws 1 together with the washers Remove the splash gu...

Page 43: ...ple of a mobility aid with an optional lighting PCB and an optional actuator module CAUTION Any changes to the drive program can affect the driving characteristics and the tipping stability of the mob...

Page 44: ...e 1 and of the optional G Trac sensor 4 Pull the plug 1 out of the power module Use a 4 mm Allen wrench to loosen both of the hexagon socket head screws 2 Remove the washers and the black intermediate...

Page 45: ...Invacare STORM 4 MAX SERVICE MANUAL 45 Adapt the drive program using the programming software if necessary To conclude check all the mobility aid functions...

Page 46: ...5 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 Pull the plug 1 out of the actu...

Page 47: ...e seat as described in chapters 8 14 1 and 8 14 5 Remove the rear and the centre cover as described in chapters 8 1 1 and 8 1 2 Carefully note the location of the cable and the connection locations of...

Page 48: ...ghting PCB together with the retaining bracket Loosen the two Allen screws 3 and the corresponding nuts on the rear using a 4 mm Allen key and an 8 mm socket spanner Replace the lighting PCB Refitting...

Page 49: ...escribed in chapter 8 1 1 Take note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera In the illustra...

Page 50: ...electronic module Loosen and remove the hexagon socket head screw 2 Remove the G Trac sensor 1 Installing the G Trac sensor Assembly of the G Trac sensor is carried out in the reverse order The G Tra...

Page 51: ...f the profile is selected afterwards 8 2 6 1 Profile selection with remote REM A or REM B Insert the plug into the remote or into the power module respectively Switch the remote on LEDs 1 and 4 blink...

Page 52: ...ofile Use the bottom rocker switch 3 to select where the required controller profile is saved I remote II power module The display shows which profile you have selected Press the Horn 4 and 1 buttons...

Page 53: ...teration to the drive program can influence vehicle handling and the tipping stability of the wheelchair Alterations to the drive program must only be carried out by trained Invacare dealers Invacare...

Page 54: ...The batteries are extremely heavy This results in injury hazards to your hands Bear in mind that the batteries are sometimes very heavy Please handle the batteries with care WARNING BURN HAZARD Injury...

Page 55: ...cribed in chapter 8 1 1 Press both catches 1 inwards and open the battery box cover Pull the quick release catch 1 to the left and place the power module on top of the battery box Pull on the strap 3...

Page 56: ...of crushing The batteries are extremely heavy This results in injury hazards to your hands Bear in mind that the batteries are sometimes very heavy Please handle the batteries with care WARNING BURN H...

Page 57: ...nd the fuse cable 2 Lift the battery from the battery carrier Pull on the strap of the second battery to move it forward Dismantle the cables on the second battery as well Lift the second battery from...

Page 58: ...ontact with eyes is made Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements protective goggles acid proof glov...

Page 59: ...the strip fuses in the sequence shown in the image on the right Tighten the nuts with 3 3 or 3 5 Nm 1 Strip fuse 2 Spade terminal 3 DIN 6923 nut Requirements 8 mm socket spanner Note If the fuseholde...

Page 60: ...you must first ascertain and rectify the cause of the fault The main fuse may only be replaced once the fault has been rectified Remove the strip fuse nuts 3 with an 8 mm socket spanner Replace the s...

Page 61: ...and battery cable 2 for visible damage and crushing points Replace any damaged cables Check all cables for visible damage and crushing locations Replace any damaged cables Pull each plug carefully The...

Page 62: ...s are fitted with protection covers 2 and are guided out of the front cover through recesses on the side Cables that lead to the seat upper actuator module remote headlight are guided out of the front...

Page 63: ...nit until 03 2012 Requirements 8 mm spanner 4 mm Allen key Diagonal pliers Cable ties Removing the front headlight Remove the rear and centre cover as described in chapters 8 1 1 and 8 1 2 Carefully n...

Page 64: ...front headlight Refit the parts in reverse order Lay the cables carefully and fasten them using the cable clamps and cable ties In doing so please pay attention to chapter 8 6 1 Now tighten all the sc...

Page 65: ...d 8 1 2 Take exact note of the positions of all cables and the sockets that they are connected to Mark the connectors and sockets or take a photograph with a digital camera Disconnect the cable of the...

Page 66: ...ure them with the cable clamps and cable ties When doing so pay attention to chapter 8 6 1 Tighten the screws hand tight Check all vehicle functions Perform an approximate adjustment of the headlight...

Page 67: ...d remove the headlight from the mounting Loosen the two cap nuts 2 using an 8 mm spanner and remove the headlight with the mounting from the rubber bumpers Replace the mounting Refitting the bulbholde...

Page 68: ...w 1 with a 4 mm Allen wrench and remove the headlight from the bracket Loosen both of the nuts 2 with an 8 mm open end wrench and remove the bracket from the rubber mounting Replace the bracket Instal...

Page 69: ...ar and the centre cover as described in chapters 8 1 1 and 8 1 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 p...

Page 70: ...tting the rear light Refit all parts in reverse order Now tighten all the screws finger tight again Check all vehicle functions 8 7 7 Replacing the rear bulb holder LED lighting unit Requirements 4 mm...

Page 71: ...the drive Before raising the vehicle secure the wheels by blocking them with wedges Requirements 19 mm socket spanner blade screwdriver long wooden blocks min 14 x 14 x 30 cm Dismantling the wheel fo...

Page 72: ...g the wheel fork Refit the parts in reverse order When fitting the ball bearings please ensure that the wide inner ring faces outward in each case Adjust the wheel fork as described in chapter 8 8 2 T...

Page 73: ...mobility aid to the rear Rotate the wheel forks 6 upwards Let go of the wheel forks so that they can swing downwards again Adjust the nut 2 with a 19mm socket spanner so that the wheel forks are not t...

Page 74: ...ng the vehicle secure the wheels by blocking them with wedges Requirements 5 mm Allen wrench Oblong wooden blocks at least 14 x 14 x 30 cm Removing the wheel Prop up the wheelchair on multiple wooden...

Page 75: ...blong wooden blocks at least 14 x 14 x 30 cm Repair kit for inner tube tires or a new inner tube Air pump or compressor Talcum powder Removing a tire inner tube Uninstall the wheel as described in cha...

Page 76: ...during repair work powdering the hose with some talcum powder can simplify the fitting procedure Re position the rim halves 3 in the tire again Make sure that the holes and threads for the screws are...

Page 77: ...le secure the wheels by blocking them with wedges Requirements 5 mm Allen key 17 mm Allen key blade screwdriver 25 Nm torque wrench 200 Nm torque wrench long wooden blocks min 14 x 14 x 30 cm Dismantl...

Page 78: ...tting the front wheel carrier Refit the parts in reverse order Use Loctite locking varnish to secure the Allen screw 2 Tighten the Allen screw 2 to 25 Nm Tighten the Allen screw 5 to 200 180 Nm To con...

Page 79: ...ases the drive wheel is fixed to the wheel hub by means of five Allen screws Only Trelleborg tyres are fixed by means of four Allen screws Requirements 6 mm Allen key Long wooden blocks min 14 x 14 x...

Page 80: ...red valve caps puncture proof tyres have no valves Please proceed in accordance with the appropriate chapter Replacing pneumatic tyres see chapter 8 10 2 1 Replacing puncture protected tyres see chapt...

Page 81: ...d outer rim ring 6 from the tyre 1 Remove the inner tube 5 from the tyre Replace defective or worn parts or repair the parts Refitting the tyres Refit the inner tube in the tyre NOTE If the old inner...

Page 82: ...bed in chapter 8 10 1 ATTENTION Explosion hazard If the wheelchair is fitted with pneumatic tyres the wheel can explode if the air is not released from the tyre before removing the wheel Always releas...

Page 83: ...nner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder Refit rim rings 3 and 6 to the tyre Pl...

Page 84: ...unexpected discharge with three joiner s clamps When doing so ensure that you do not scratch the rims Undo the five 6 mm Allen screws 2 on the inside of the wheel Now loosen the joiner s clamps carefu...

Page 85: ...adjusting washers are removed and not replaced again collisions can be caused Always replace the adjusting washers exactly as they were before you started dismantling Requirements 19 mm socket spanne...

Page 86: ...them with wedges ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands Please note the high weight Requirements 5 mm Allen key 6 mm Allen key 19 mm socket spa...

Page 87: ...4 with a 5 mm Allen key Remove the screws together with the washers Pull the motor transmission unit 2 out of the mounting 3 in a forward direction In doing so please observe the high weight of the u...

Page 88: ...panner 19 mm socket spanner blade screwdriver long wooden blocks min 14 x 14 x 30 cm Removing the carbon brushes Switch off the mobility aid Remove the drive wheels as described in chapter 8 10 1 Dise...

Page 89: ...cribed in chapter 8 10 1 Note The following procedure is necessary to run the carbon brushes in after replacement and thus guarantee maximum performance WARNING Risk of accidents Hazards to workers su...

Page 90: ...ve motors Secure the vehicle against rolling away by placing wedges under the wheels CAUTION Danger of crushing The motor gearbox unit is very heavy Danger of injury to the hands Pay attention to the...

Page 91: ...Bowden cable on the motor Loosen the adjustment nut 3 of the Bowden cable on the motor Pull the Bowden cable out of its holder on the motor Repeat the procedure on the other motor Uninstalling the lev...

Page 92: ...on socket head screw is screwed into one of the frame supports Pull the fixation bracket out of the seat frame Installing Bowden cables lever unit and fixation bracket Replace the defective components...

Page 93: ...ents 5 mm Allen key 6 mm Allen key T40 torx wrench 13 mm socket spanner 19 mm socket spanner blade screwdriver long wooden blocks min 14 x 14 x 30 cm Dismantling the wheel suspension Remove the rear a...

Page 94: ...et head bolt 6 In doing so please pay attention to the washer 8 and the spacer 7 Remove the plastic cover 4 Loosen and remove the torx screw 3 Remove the spacer 2 Remove the entire wheel suspension 5...

Page 95: ...er of crushing The mobility device is very heavy Injury hazard to hands and feet You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device Switch t...

Page 96: ...5 on the spring Remove the spacer 8 Remove the hexagon socket head bolt 5 In doing so please pay attention to the washer 7 and the spacer 6 Loosen the Allen screw 4 with a 4 mm Allen key Remove the A...

Page 97: ...the legrests Remove the armrests Remove the seat cushion Remove any existing cable ties holding the cables on the remote or lighting Remove the cables from the stuck on clamps Loosen the cap nuts of...

Page 98: ...p 5 Remove the bolt 4 Remove the brace Fold back the entire seat Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 Lift the seat and the seat suppo...

Page 99: ...a second person Requirements 6 mm Allen key Let a 2 nd person hold on to the seat Please take into account that the seat is very heavy Be sure not to crush your fingers or other parts of the body Loo...

Page 100: ...ts Remove the seat cushion Remove any existing cable ties holding the cables on the remote or lighting Remove the cables from the stuck on clamps Loosen the cap nuts of the headlight mountings using a...

Page 101: ...he bolt 4 Fold back the entire seat Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 Lift the seat and the seat support from the vertical column R...

Page 102: ...can fall down without warning if the seat tilt adjustment assembly is screwed apart too far Danger of injury to hands and feet Make sure that you only adjust the seat tilt to a maximum of 25 Requireme...

Page 103: ...ion Remove any existing cable ties holding the cables on the remote or lighting Remove the cables from the stuck on clamps Loosen the cap nuts of the headlight mountings using an 8 mm jaw spanner see...

Page 104: ...ctuator 6 Fold back the entire seat Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 Lift the seat and the seat support from the vertical column R...

Page 105: ...tuator module under the seat Unclip the cable Remove any cable ties which are fitted Remove the upper pin retainer 1 Remove the upper bolt 2 Swing the tilt actuator 6 forwards Remove the lower pin ret...

Page 106: ...h the power supply off ON OFF key Engage the drive Save the vehicle laid on its side against overturning Requirements 4 mm Allen key T40 torx wrench Oblique pliers Cable ties Dismantling the lifting c...

Page 107: ...E MANUAL 107 Loosen and remove the four torx screws 3 on the underside of the chassis 2 Remove the lifting column 1 Refitting the lifting column Refit the parts in reverse order To conclude check all...

Page 108: ...n be individually adapted to the back shape of the user Pull apart the front and back of the back cushion 1 and remove it Front and back of the back cushion is held together by Velcro Open Velcro stra...

Page 109: ...8 16 2 Adjusting a sling backrest Requirements 5 mm Allen key Loosen the hexagon socket head screws 1 Shift the position of the cross braces 2 together with the sliding nuts in the channels Re tighte...

Page 110: ...0 8 16 3 Replacing the cross braces Requirements 5 mm Allen wrench Loosen and remove the hexagon socket head screws 1 of the cross brace to be replaced 2 Remove the cross brace 2 and replace it Instal...

Page 111: ...krest unit Remove the backrest cushion 1 Loosen the hand wheels 2 and the hexagon socket head screws 4 on the left and right side of the chair Remove the backrest tube 3 from the channels 5 Remove the...

Page 112: ...t out of both belt guides 1 Pull the restraining belt 2 out of the loop on the wheelchair Pull the complete restraining belt 2 out of both of the belt guides 1 Remove the nut including the washer Repl...

Page 113: ...t at the base hold the lower section of the headrest mounting 4 with the clamp block against the handlebar 3 Attach the clamp cover 2 Insert the four Allen screws 1 from above through the boreholes Fi...

Page 114: ...pad as shown in the illustration above Install the armrest as shown in the illustration above Attach the armrest along with the holder 1 to the mounting bracket 2 Utilize the screws 3 for this purpose...

Page 115: ...AX SERVICE MANUAL 115 Insert the four fixation screws of the armrests 2 and tighten them The insertion depth depends on the desired seat width Insert the four Phillips screws 3 that secure the armrest...

Page 116: ...Requirements 5 mm Allen wrench T30 Torx wrench 10 mm socket wrench Insert the braces 3 of the footrest 2 into the fixation tubes Pay attention to the correct height while doing so Insert the four hexa...

Page 117: ...tach the fixation bracket 1 of the calf support to the wheelchair using the hexagon socket head screws 2 The angle of the calf supports can be adjusted by loosening the screws 3 The cover 4 has openin...

Page 118: ...arious threaded holes Depending on the seat that is installed you can attach the seat at different points on the seat frame and thus set the seat depth Additionally you can move the seat surface and a...

Page 119: ...You should seek help from a second person WARNING Danger of crushing Injury hazard caused by uncontrolled movement of the mobility device Switch the power supply off ON OFF key Engage the drive Requir...

Page 120: ...d There are two tapped holes on each flap for the screws 2 By selecting the upper or lower holes the seat can be adjusted to two different heights Attach the cover plate 1 Install the screws 2 in such...

Page 121: ...ree different seat frames Requirements Phillips screwdriver size 2 6 mm Allen wrench 8 mm Allen wrench Uninstalling the seat frame Remove the seat cushion 1 Loosen both Phillips screws 3 and remove th...

Page 122: ...the armrests Loosen the four fastening screws of the armrests 6 Remove the armrests Loosen and remove both of the fastening screws 7 and 8 of the front frame fixation Loosen and remove both of the sc...

Page 123: ...seat support must be used for the screws depending on the desired seat depth It may possibly be necessary to replace the seat support plates Use the following illustration and table to determine whic...

Page 124: ...unit Swing the backrest unit 2 towards the rear Loosen and remove the hexagon socket head screws 3 including the washers the cover plate 4 and the bearing plate 5 The sticker 6 indicates the holes fo...