Invacare Storm4 X-plore User manual

Edition: 14.11.12
Invacare
®
STORM
4
SERVICE MANUAL

SERVICE MANUAL
Invacare®- STORM4
2
These instructions contain information about:
Testing work
Repair Instructions
This manual is part of the instructions for use.
Service addresses
Invacare Austria GmbH
Herzog Odilostrasse 101
A-5310 Mondsee
Austria
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.at
Invacare n.v.
Autobaan 22
B-8210 Loppem (Brugge)
Belgium
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.be
Invacare AG
Benkenstraße 260
CH-4108 Witterswil
Switzerland
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.ch
Invacare Aquatec GmbH
Alemannenstraße 10
88316 Isny
Deutschland
([phone]
Fax [phone]
@: [e-mail]
WWW: www.invacare-aquatec.de
Invacare A/S
Sdr. Ringvej 37
DK-2605 Brøndby
Danmark
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [e-mail]
WWW: www.invacare.dk
Invacare® SA
c/ Areny s/n
Polígon Industrial de Celrà
E-17460 Celrà (Girona)
ESPAÑA
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.es
Invacare® Poirier SAS
Route de St Roch
F-37230 Fondettes
France
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.fr

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Invacare® Ltd
Pencoed Technology Park
Pencoed
Bridgend CF35 5HZ
United Kingdom
((Customer services): [phone]
Fax (Customer services): [phone]
@: [e-mail]
WWW: www.invacare.co.uk
Invacare Mecc San s.r.l.
Via dei Pini, 62
I - 36016 Thiene (VI)
Italia
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.it
Invacare Ireland Ltd.
Unit 5 Seatown Business Campus
Seatown Rd, Swords
County Dublin
Ireland
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.ie
Invacare® AS
Grensesvingen 9
Postboks 6230
Etterstad
N-0603 Oslo
Norge
((Kundeservice): [phone]
Fax (Kundeservice): [phone]
@: [email protected]
@: [e-mail]
WWW: www.invacare.no
Invacare® B.V.
Celsiusstraat 46
NL-6716 BZ Ede
Nederland
(: [phone]
Fax: [phone]
@: [email protected]om
@: [e-mail]
WWW: www.invacare.nl
Invacare Lda
Rua Estrada Velha, 949
P-4465-784 Leça do Balio
Portugal
(: [phone]
(: [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.pt

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Återförsäljare:
Invacare® AB
Fagerstagatan 9
S-163 91 Spånga
Sverige
Tillverkare:
Invacare® Deutschland GmbH
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
((Kundtjänst): [phone]
Fax (Kundtjänst): [phone]
@: [email protected]
@: [e-mail]
WWW: www.invacare.se
MÖLNDAL
(: [phone]
Fax: [phone]
@: [e-mail]
LANDSKRONA
(: [phone]
Fax: [phone]
@: [e-mail]
OSKARSHAMN
(: [phone]
Fax: [phone]
@: [e-mail]
Eastern
european
countries
European Distributor
Organisation (EDO)
Kleiststraße 49
D-32457 Porta Westfalica
Deutschland
([phone]
Fax [phone]
@: [email protected]om
WWW: www.invacare.de

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Contents
Chapter Page
1Introduction 10
1.1 General information ................................................................................................................10
1.2 Notes on transport ..................................................................................................................10
1.3 Definition and representation of information and safety information in this manual ......11
1.4 Hazard symbols and symbols used.......................................................................................12
1.5 Images in this manual.............................................................................................................13
2Safety and fitting instructions 14
2.1 Before any inspection or repair work....................................................................................14
2.2 Personal safety equipment.....................................................................................................14
2.3 General safety information and information about fitting / removal..................................14
3Tightening torques 17
4Layout of components and componentry 18
4.1 Overview...................................................................................................................................18
4.2Electronics modules................................................................................................................19
4.2.1 ACS 2 PMA90L electronics module..............................................................................20
4.2.2 ACT actuator module....................................................................................................20
4.2.2.1 ACT 2 actuator module............................................................................................20
4.2.2.2 ACT 4 actuator module............................................................................................21
4.2.3 Lighting PCB.................................................................................................................21
4.3 Joystick boxes.........................................................................................................................22
5Service plan (1x annually) 24
6Operational faults 27
6.1 Drive fault diagnosis ...............................................................................................................28
6.2 REM remotes: Error codes and diagnostic codes ...............................................................33
6.3 Diagnosis of charging device faults......................................................................................34
7Test procedures 35
7.1 Testing the motor....................................................................................................................35
7.2 Testing the electro-mechanical parking brake.....................................................................36
8Repair work 38
8.1 Covers.......................................................................................................................................38
8.1.1 Opening the rear cover panel .......................................................................................38

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8.1.2 Opening the centre panel..............................................................................................39
8.1.3 Opening the front panel ................................................................................................40
8.1.4 Opening the rear light cover..........................................................................................41
8.1.5 Replacing a front splash guard.....................................................................................42
8.1.6 Replacing the splash guard ..........................................................................................43
8.2 Electronics module..................................................................................................................45
8.2.1 Replace remote ............................................................................................................45
8.2.2 Replacing the power module ........................................................................................45
8.2.3 Replacing the actuator module on the battery compartment........................................47
8.2.4 Replacing the actuator module under the seat.............................................................48
8.2.5 Replacing the lighting PCB...........................................................................................49
8.2.6 Replacing the G-Trac sensor........................................................................................51
8.2.7 Drive program selection after component replacement................................................54
8.2.7.1 Profile selection with remote REM A or REM B.......................................................54
8.2.7.2 Profile selection with remote REM 550....................................................................55
8.3 Updating the driving program................................................................................................56
8.4 Batteries, cables & battery charger .......................................................................................57
8.4.1 Making the batteries accessible....................................................................................57
8.4.2 Replacing batteries.......................................................................................................59
8.4.3 Correct handling of damaged batteries.........................................................................61
8.5 Checking and replacing the main fuse..................................................................................62
8.6 Checking the cable..................................................................................................................64
8.6.1 Installing cables ............................................................................................................65
8.6.2 Installing cables on a lifter column type B.....................................................................67
8.6.2.1 Installing cables on a type B lifter column - part 1...................................................67
8.6.2.2 Installing cables on a type B lifter column - part 2...................................................70
8.7 Lighting unit.............................................................................................................................71
8.7.1 Replacing the front bulb (conventional lighting unit).....................................................71
8.7.2 Replacing the front LED (LED lighting unit)..................................................................71
8.7.3 Replacing the complete front headlight (conventional lighting unit until 03/2012)........72
8.7.4 Replacing headlamps completely (conventional lighting system starting 03/2012)......74
8.7.5 Replacing the complete front headlight (LED lighting unit)...........................................76
8.7.6 Replacing headlamps completely (LED lighting system starting 03/2012)...................78
8.7.7 Replacing the front bulb holder (conventional lighting unit until 03/2012).....................80
8.7.8 Replacing headlamp brackets (conventional lighting system starting 03/2012)...........81
8.7.9 Replacing the front bulb holder (LED lighting unit until 03/2012)..................................82
8.7.10 Replacing headlamp brackets (LED lighting system starting 03/2012) ........................83
8.7.11 Replacing the rear bulb (conventional lighting unit)......................................................84
8.7.12 Replacing the complete rear light (conventional lighting unit).......................................85
8.7.13 Replacing the rear bulb holder (conventional lighting unit)...........................................87

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8.7.14 Replacing the complete rear light (LED lighting unit)....................................................88
8.7.15 Replacing the rear bulb holder (LED lighting unit) ........................................................89
8.8 Front wheel forks.....................................................................................................................90
8.8.1 Replacing the wheel fork...............................................................................................90
8.8.2 Adjusting the wheel fork................................................................................................92
8.8.3 Changing a front wheel.................................................................................................93
8.9 Replacing the front wheel carrier...........................................................................................95
8.9.1 Replacing the front wheel carrier (only Standard Storm4).............................................95
8.9.2 Replacing the front wheel carrier (only Storm4X-plore)................................................96
8.10 Drive wheels.............................................................................................................................98
8.10.1 Replacing the drive wheel.............................................................................................98
8.10.2 Replacing a tyre or inner tube.....................................................................................100
8.10.2.1 Replacing pneumatic tyres ....................................................................................100
8.10.2.2 Replacing puncture-protected tyres.......................................................................102
8.10.2.3 Replacing puncture-proof tyres..............................................................................104
8.10.3 Replacing the drive wheel hub....................................................................................105
8.11 Drive unit................................................................................................................................106
8.11.1 Replacing the motor/transmission unit (Standard Storm4)..........................................106
8.11.2 Replacing the motor/transmission unit (SSD motor) ..................................................108
8.11.3 Replacing the motor/transmission unit (Storm4X-plore) ............................................110
8.11.4 Replacing or rotating the motor / gearbox unit sealing ring (SSD motor)...................113
8.11.5 Replacing the motor / gearbox coupling (SSD motor)................................................114
8.11.6 Replacing the carbon brushes (Standard motor)........................................................116
8.11.7 Replacing the carbon brushes (SSD motor)...............................................................118
8.12 Rear wheel suspension.........................................................................................................120
8.12.1 Replacing the rear wheel suspension.........................................................................120
8.13 Replacing the strut................................................................................................................122
8.13.1 Removing the suspension strut ..................................................................................122
8.13.2 Replacing the front suspension strut (only Storm4X-plore)........................................124
8.14 Seat support and tilt module................................................................................................126
8.14.1 Replacing the seat support with manual tilt module (till Dec. 2010) ...........................126
8.14.2 Replacing the seat frame with a manual tilt module (from Dec. 2010).......................127
8.14.3 Replacing the seat support with electric tilt module....................................................129
8.14.4 Replacing the tilt actuator ...........................................................................................131
8.15 Seat column / lifter column...................................................................................................132
8.15.1 Replacing the seat column .........................................................................................132
8.15.2 Replacing a type A electrical lifter column..................................................................134
8.15.3 Replacing a type B electrical lifter column..................................................................136
8.16 Back unit.................................................................................................................................139
8.16.1 Replacing the standard back ......................................................................................139

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8.16.1.1 Adjusting the belt back...........................................................................................140
8.16.2 Replacing the EasyAdapt back...................................................................................141
8.16.3 Replacing / adjusting the universal backrest frame for the EasyAdapt backrest........142
8.17 Back unit with ergonomic length adjustment.....................................................................145
8.17.1 Adjusting the width......................................................................................................145
8.17.2 Replacing the planetary gear......................................................................................146
8.17.3 Replacing the servo motor..........................................................................................148
8.17.4 Replacing the microswitch..........................................................................................149
8.17.5 Fitting back plates to the base support of the back with ergonomic length adjustment150
8.17.6 Fitting the handlebar...................................................................................................151
8.17.7 Replacing the travelling armrest .................................................................................152
8.17.8 Replacing the arm support on the travelling armrest..................................................153
8.17.9 Retrofitting a travelling armrest...................................................................................154
8.18 Storm4X-plore specific parts ...............................................................................................155
8.18.1 Replacing X-plore trim on the swing arm....................................................................155
8.18.2 Replacing the front X-plore swing arm........................................................................156
8.18.3 Removing the rear X-plore swing arm........................................................................158
9Installing accessories 160
9.1 Replacing the safety belt ......................................................................................................160
9.2 Fitting the stick holder..........................................................................................................161
9.3 Fitting the headrest ...............................................................................................................162
9.3.1 Fitting the headrest to the standard back ...................................................................162
9.3.2 Fitting the headrest to the EasyAdapt back................................................................163
9.4 DAHL Docking Station ..........................................................................................................165
9.5 Curb climber...........................................................................................................................167
9.5.1 Fitting the curb climber ...............................................................................................167
9.5.2 Replacing the positioning shoe...................................................................................167
9.5.3 Replacing the curb climber .........................................................................................168
9.6 Luggage carrier......................................................................................................................169
9.7 Anti-tippers.............................................................................................................................171
9.7.1 Installing anti-tippers...................................................................................................171
9.7.2 Installing the locking pin..............................................................................................172
9.8 Further accessories...............................................................................................................172
10 Adjusting the seating position 173
10.1 Adjusting the seat height......................................................................................................174
10.1.1 Adjusting the seat height with a seat column installed................................................174
10.1.2 Adjusting the seat height on a type A electrical lifter column with an adapter............176
10.1.3 Adjusting the seat height on a type B electrical lifter column with an adapter............178

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10.2 Seat support...........................................................................................................................180
10.2.1 Adjusting the seat width..............................................................................................180
10.2.2 Adjusting the seat depth .............................................................................................181
10.2.2.1 Adjusting the seat depth without replacing the seat support plates.......................183
10.2.2.2 Adjusting the seat depth and replacing the seat support plates............................183
10.3 Adjusting the seat tilt............................................................................................................185
10.3.1 Adjusting the seat tilt on a seat with a manual tilt module (till Dec. 2010)..................185
10.3.2 Adjusting the seat tilt on a seat with a manual tilt module (from Dec. 2010)..............186

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1 Introduction
1.1 General information
•Service and maintenance work must be carried out taking this service manual into account.
•It is imperative that you observe safety information.
•Information about operation or about general maintenance and care work on the mobility aid
should be taken from the operating manual.
•You can find information about ordering spare parts in the spare parts catalogue.
•Only use original Invacare® spare parts. The guarantee will become invalid if other spare parts
are used!
•We reserve the right to make any alterations on the grounds of technical improvements.
•The mobility 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 sufficiently long-term job experience.
- Experience in the use of electrical measuring equipment (multimeters) is also a requirement.
- Special Invacare® training is recommended.
•Alterations to the mobility aid which occur as a result of incorrectly or improperly executed
maintenance or overhaul work lead to the exclusion of all liability on the side of INVACARE.
•If you have any problems or questions please contact Invacare® Service.
1.2 Notes on transport
•If the mobility aid has to be shipped back to the manufacturer for major repairs, you should
always use the original packaging for transport.
•Please attach a precise description of the fault.

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1.3 Definition and representation of information and safety
information in this manual
Different types of information and signal words are used throughout this manual.
HAZARD!
The signal word "HAZARD!" refers to immediate hazards.
•The following lines in italics refer to actions which serve to avoid such hazards.
WARNING!
The signal word "WARNING!" refers to possibly-occurring hazards which can lead to
death or serious injuries if they 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 injuries and/or material damage if they are not avoided.
•The following lines in italics refer to actions which serve to avoid such hazards.
CAUTION!
The signal word "CAUTION!" refers to hazards which could lead to material damage if they
are not avoided.
•The following lines in italics refer to actions which serve to avoid such hazards.
Note
The signal word "Note" is used to denote general information which simplifies the handling of
your product and refers to special functions.

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1.4 Hazard symbols and symbols used
Different types of hazard symbols and symbols are used throughout this manual.
General hazards
This symbol warns you of general hazards!
•Always follow the instructions to avoid injury to the user or damage to the product!
BURN HAZARD!
This symbol warns you of the danger of chemical burns, for example due to the discharge
of battery acids!
•Always follow the instructions to avoid injury to the user or damage to the product!
DANGER OF CRUSHING!
This symbol warns you of crushing hazards due to inattentive working with heavy
components.
•Always follow the instructions to avoid injury to the user or damage to the product!
EXPLOSION HAZARD!
This symbol warns you of an explosion hazard, which can be caused by excessive tyre
pressure in a pneumatic tyre.
•Always follow the instructions 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 protection
This symbol refers to the requirement for wearing eye protection, for example when
working with batteries.
•Wear eye protection when this symbol is shown.
Wear safety gloves
This symbol refers to the requirement for wearing safety gloves, for example when
working with batteries.
•Wear safety gloves when this symbol is shown.
Note
This symbol identifies general information which is intended to simplify working with your product
and which refers to special functions.
Requirements:
•This symbol identifies a list of various tools, components and items which you will need in
order to carry out certain work. Please do not attempt to carry out the work if you do not have
the listed tools available.
Always dispose used or damaged batteries correctly
The symbol refers to information for the correct disposal of used or damaged batteries.

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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 the image directly above.

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2 Safety and fitting instructions
These safety instructions are intended to prevent accidents at work, and it is imperative that they
are observed.
2.1 Before any inspection or repair work
•Read and observe this repair manual and the associated operating manual!
•Observe the minimum requirements for carrying out the work (see chapter entitled " General
information)!
2.2 Personal safety equipment
Safety shoes
The mobility device, and some of its components, are very heavy. These parts can result
in injuries to the feet if they are allowed to drop.
•Wear standardised safety shoes during all work.
Eye protection
It is possible that battery acid can be discharged when working on defective batteries 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 working on defective batteries or
when handling batteries improperly.
•Always wear acid-proof safety gloves when working on any defective or possibly defective
batteries.
2.3 General safety information and information about fitting / removal
WARNING: Danger of crushing!
Various components such as the drive unit, batteries, seat etc are very heavy. This results
in injury hazards to your hands!
•Please note the high weight of some components! This applies especially to the removal of
drive units, batteries and the seat.
WARNING!
Injury hazard if the vehicle starts moving unintentionally during repair work!
•Switch the power supply off (ON/OFF key)!
•Engage the drive!
•Before jacking up, secure the vehicle by using chocks to block the wheels.

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ATTENTION!
Fire and burn hazard due to electrical short-circuit!
•The mobility device must be completely switched off before removal of voltage-carrying
components! To do this, remove the batteries.
•Avoid short-circuiting the contacts when carrying out measurements on voltage-carrying
components!
CAUTION!
Danger of burns from hot surfaces on the motor!
•Allow the motors to cool down before commencing work on them.
ATTENTION!
Injury hazard and danger of damage to vehicle due to improper or incomplete
maintenance work!
•Use only undamaged tools in good condition.
•Some moving parts are mounted in sockets with PTFE coating (Teflon™). Never grease these
sockets!
•Never use "normal" nuts instead of self-locking nuts.
•Always use correctly-dimensioned washers and spacers
•When reassembling, always replace any cable ties which were cut during dismantling.
•After completing your work / before renewed start-up of the mobility device, check all
connections 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 data).
•Check all electrical components for correct function. Please note that incorrect polarity can
result in damage to the electronics.
•Always carry out a trial run at the end of your work.
CAUTION!
Danger of injury and damage 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 raised.
•Test the maximum speed reduction for correct function after any maintenance work or
modifications to the wheelchair.
Note
Mark all current settings for the mobility aid (seat, armrests, backrest etc.), and the associated
cable connecting plugs, before dismantling. This makes reassembly easier.
All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When
reassembling ensure that these safety devices are correctly engaged.

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CAUTION!
Any changes to the drive program can affect the driving characteristics and the tipping
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. Invacare® can
only give a warranty for safe vehicle driving behaviour - especially tipping stability - for this
standard drive program!

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3 Tightening torques
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 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 mobility device due to improperly tightened screws, nuts or
plastic connections.
•Always tighten screws, nuts etc to the stated tightening torque.
•Only tighten screws or nuts which are not listed here fingertight.

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4 Layout of components and componentry
4.1 Overview
The electronic control modules and regulators are situated at the rear underneath the rear plastic
cover and directly under the seat.
Directly under the seat:
•Actuator module (1)
The actuator module is optional. If available, it controls the electric leg supports, the electric tilt
module and the electric back adjustment.
Underneath the rear cover:
•Light terminal block (2)
The light terminal block is in front of the actuator module (3). The light terminal block is
optional. It is only available if the mobility aid is fitted with lighting.
•Actuator module (3)
The actuator module is on the top of the battery compartment. The actuator module is optional.
It is only available if the mobility aid is fitted with a lifter.

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•Power module (4)
The power module is at the rear of the battery compartment.
•G-Trac (5)
The G-Trac sensor is located in the rear on the right, next to the battery box.
4.2 Electronics modules
A variety of electronics modules can be fitted to the mobility aid.
Before you connect mobility aid components such as adjusting motors/actuators 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 remotes can be connected:
- REM 24 SD
- REM A
- REM B
- REM 550
Actuator module
ACT 2 / ACT 4 The actuator module is optional.
Lighting PCB The lighting PCB is optional.
G-Trac sensor The G-Trac sensor is optional

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4.2.1 ACS 2 PMA90L electronics module
Connections
1) Battery 24V
2) Cable to G-Trac sensor (GYRO
3) Bus cable (to remote or ACT)
4) Motor M1
5) Light
6) Motor M2
Rubber stoppers for free slots
2) & 3) Order number: 1552876
4.2.2 ACT actuator module
A range of adjusting motors, also known as actuators, can be fitted to 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 actuator module
Connections
1) ACI*
2) Bus cable (to remote or ACT)
3) Bus cable (to remote or ACT)
4) Adjusting motor/actuator - Channel 2
5) Adjusting motor/actuator - Channel 1
Rubber stoppers for free slots
1) Order number: 1555701
2) & 3) Order number: 1552876
4) to 7) Order number: 1555700
* The ACI connection is used for actuator limitation or speed reduction.