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Invacare ® STORM 4MAX SERVICE MANUAL
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1. Invacare STORM MAX SERVICE MANUAL 7 3 4 A A Wd Checking and replacing the main fuse CAUTION Fire hazard e Always use an original strip fuse with the approved amperage e Ifthe main fuse has blown first rectify the cause before fitting a new one CAUTION Fire hazard Fitting the incorrect strip fuse causes a fire hazard e Only fix the strip fuses in the sequence shown in the image on the right Ji e Tighten the nuts with 3 3 or 3 5 Nm es 1 Strip fuse 2 Spade terminal 3 DIN 6923 nut Requirements e 3 mm socket spanner Note If the fuseholder is damaged you can replace this complete with the battery cables Dismantling the main fuse e Remove the battery compartment cover disconnect the battery plugs and pull the batteries out of the battery compartment as described in chapter 7 3 1 e The fuseholder 1 is located on top of the batterie e Open the fuseholder cover 49 SERVICE MANUAL Invacare STORM MAX 50 e You see the strip fuses 2 once the fuse holder 1 is open e If the strip fuse has blown you must first ascertain and rectify the cause of the fault e The main fuse may only be replaced once the fault has been rectified e Remove the strip fuse nuts 3 with an 8 mm socket spanner e Replace the strip fuse Fitting the main fuse e Refit all the parts again in reverse order e To conclude check all the mobility aid functions Inv
2. e Use the following illustration and table to determine which holes must be utilized for the desired seat depth Additionally a sticker is attached to the frame that indicates the appropriate holes for the three seat depths Sitztiefe Verwendete Locher in incm Sitzrahmen 56 3 amp 4 59 5 2 amp 3 63 1 amp 2 80 Invacare STORM MAX SERVICE MANUAL Uninstalling the backrest e Loosen and remove the hexagon socket head screws 1 which hold the backrest unit e Swing the backrest unit 2 towards the rear e Loosen and remove the hexagon socket head screws 3 including the washers the cover plate 4 and the bearing plate 5 e The sticker 6 indicates the holes for the adjustment of the seat depth Installing the backrest e Assemble the parts in reverse order e Utilize the holes for the desired seat depth 81 SERVICE MANUAL Invacare STORM MAX 7 11 Back unit 7 11 1 Adjusting the belt back The belt back can be individually adapted to the back shape of the user e 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 e Open Velcro straps of the back straps 2 and set it to the desired length e Refit the back cushion and fasten with Velcro 82 Invacare STORM MAX SERVICE MANUAL 7 11 2 Adjusting a sling backrest Yd Requirements W e 5 mm Allen key e Loosen the hexagon socket
3. REM 550 Can be connected to power module ACS 2 PMAQOL 21 SERVICE MANUAL Invacare STORM MAX 5 Service plan 1x annually Component Check Remedy Notes Safety belt Damage to safety belt Replace belt if See chapter 7 9 damaged Belt lock function Replace belt if See chapter 7 9 damaged Damage to armrests Replace covering if damaged Armrest fixings Tighten screws Side panels Damage to side panels Replace side panels if damaged Side panel fixings Tighten screws Po Seat angle Tight fit of the bolt If necessary replace adjustment retainer clips the bolt retainer clips Power backrest Damage to backrest Replace parts if if fitted Seams damaged ixi Tighten screws Fixing Check cable Replace cable motor if necessary Check function Frames Carry out a visual check Tighten screws chassis of the fasteners rivets battery and battery receptacle Replace components if necessary i H mounting 22 Invacare STORM MAX SERVICE MANUAL Component Check Remedy Notes Wheel bin drive wheels for Adjust replace wheel See chapters suspension and tight fit and side play hubs 7 18 1 and 7 18 3 wheels Check steering wheels Replace wheels See chapter 7 17 for tight fit float and wheel fork or wheel side play bearings Tyres Repair or replace if See chapter 7 18 2 damaged Check suspension Repair or replace if See chapter 7 21 damaged Check straight running Replace wheels S
4. Refitting the rear light cover e Refit the parts in reverse order e Now tighten all the screws finger tight again 37 SERVICE MANUAL Invacare STORM MAX 7 1 5 Replacing the splash guard 4 Requirements aie e 5mm Allen key e The following splash guards are installed on the wheelchair Splash guard long RH Order Number SP1530557 Splash guard long LH Order Number SP1530558 Removing the splash guard e Remove the seat e Loosen and remove both hexagon socket head screws 1 together with the washers e Remove the splash guard 2 from the gearbox holder 4 e Pay attention to the distance wedge 3 e Replace the splash guard according to the table see above Refitting the splash guard e Refit the parts in reverse order 38 Invacare STORM MAX SERVICE MANUAL 0 7 2 1 7 2 2 4 oi Lighting unit Note There is only one LED lighting system Replacing the front LED LED lighting unit e Itis not intended for an individual LED to be replaced Replace the entire lighting unit as described in chapter 7 2 2 Replacing the complete front headlight LED lighting unit Requirements e 8 mm spanner e 4 mm Allen key e Diagonal pliers e Cable ties Removing the front headlight e Remove the rear and centre cover as described in chapters 7 1 1 and 7 1 2 e Carefully note the location of the cable and the connection locations of the various plugs Either mark each pl
5. e Remove the actuator for the seat tilt as described in chapter 7 6 6 e Remove the back part as described in chapter 7 6 6 Invacare STORM MAX SERVICE MANUAL a a a Heg 3 a s Fna ee a TAN Ea oe r sat oe amp H lt E z se I lt a p a r A p OE t a Ne 2 e Loosen and remove the hexagon socket head screws 1 and the washers 2 on the four frame supports 4 e Remove the four frame supports 4 and the corresponding flanged bushings 3 e Loosen both Phillips screws 5 which secure the armrests e Loosen the four fastening screws of the armrests 6 e Remove the armrests e Loosen and remove both of the fastening screws 7 and 8 of the front frame fixation e Loosen and remove both of the screws under the front of the frame 9 e Remove the seat frame e Tighten all screws again Installing the seat frame e Assemble the parts in reverse order e Adjust the restraining belt individually to the driver by modifying the clearance of both of the belt guides 79 SERVICE MANUAL Invacare STORM MAX 7 10 2 Adjusting the seat depth iW id Note The seat depth can be adjusted to three different positions Requirements e 4 mm Allen key e 8 mm jaw spanner e Oblique pliers e Cable ties Note Certain holes in the 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
6. downwards out of the front wheel suspension 1 Pay attention to the washers 3 spacer rings 4 and Magneto bearings 5 when doing this 93 SERVICE MANUAL Invacare STORM MAX Refitting the wheel fork e Refit the parts in reverse order e When fitting the ball bearings please ensure that the wide inner ring faces outward in each case e Adjust the wheel fork as described in chapter 7 17 2 e To conclude check all the mobility aid functions 94 Invacare STORM MAX SERVICE MANUAL 7 17 2 Adjusting the wheel fork A WW WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Requirements e 19mm socket spanner e blade screwdriver e f necessary remove the cover cap 1 e Get help of a second person to tilt the mobility aid to the rear e Rotate the wheel forks 6 upwards e Let go of the wheel forks so that they can swing downwards again e Adjust the nut 2 with a 19mm socket spanner so that the wheel forks are not too loose but can still rotate freely The wheel forks should oscillate to the opposite side a maximum of once and then come to rest facing downwards e Place the mobility aid on all four wheels again e Test the mobility aid s manoeuvrability e Repeat the adjustment steps if necessary until the castors are correctly adjusted e Refit the cap 1 95 SERVICE MANUAL Invacare STOR
7. min 14 x 14 x 30 cm e Tyre pump or compressor e Talcum powder Removing the tyres e Remove the wheel as described in chapter 7 18 1 A 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 e Always release the air from the wheel before you remove it Depress the small tappet in the centre of the valve A CAUTION Material damage hazard The valve can become blocked by the puncture protection gel and be unusable e During the following work you should always hold the valve up so that the puncture protection gel cannot enter the valve 102 Invacare STORM MAX SERVICE MANUAL e Remove the valve cover 2 e Press the release pin in the valve inwards and evacuate all the air from the tyre e Undo the five 6 mm Allen screws 4 on the inside of the wheel e Remove the inner 3 and outer 6 ring of the rim from the tyre 1 e Replace any defective or worn parts Refitting the tyres e Refit the inner tube in the tyre Note i If the old inner 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 e Refit rim rings 3 and 6 to the tyre Please ensure that the boreholes and thread for the screws are exactly above each other e Fill some air into the inner tube e Refit th
8. Standard motor ccc eeeeeeeeeeeeeeeeeeneeeeeenteeeeeeaas 108 7 19 3 Replacing Bowden cables and the CIULCH eceeeeeneeeeeeeeneeeeeeeeeeeeenaeeeeeenaeeeeneaas 110 Rear wheel SUSPENSION cceeeeeeeeeeeeeeeeeeeeeeeeeeeeeseseenee sea neneeeseseeeeeseseenenseseeeenseseeneeeeseeneeeens 113 7 20 1 Replacing the rear wheel SUSPENSION 0 ccceeeeeeeeeeeceeeceeeeeceneaaeeeeeeeeeteesenaeeeees 113 Replacing the Struts icc ccciccs ccesteccccat ese cocscceseat tees coat inasai rias coseecesetnnece etennecesdvienecesvsenccustiaaeass 115 7 21 1 Removing the SUSPENSION strut eee eee teeter ee ee teat ee eeeaaeeeeeeaaeeeeeeeaeeeeeenaeeeeeeaas 115 SERVICE MANUAL Invacare STORM MAX 1 1 1 2 Introduction 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
9. all electrical components for correct function Please note that incorrect polarity can result in damage to the electronics e 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 e 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 13 SERVICE MANUAL Invacare STORM MAX amp 14 CAUTION Any changes to the drive program can affect the driving characteristics and the tipping stability of the vehicle e Changes to the drive program may only be carried out by trained Invacare specialist dealers e 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 stabil
10. between modules except for the power module and the remote Replace the modules one after another in order to ensure which the one was causing the fault 11 x blink Drive motors overloaded Switch remote on and off overheated wait if necessary 12 x blink Compatibility problems Remove incorrect module See chapter 7 4 2 between modules 31 SERVICE MANUAL 6 3 32 Diagnosis of charging device faults SYMPTOM No LEDs illuminating on battery charger POSSIBLE CAUSE Charging device not connected to mains supply Invacare STORM MAX SOLUTION Ensure that the battery charger has been plugged in No mains supply 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 An internal fuse might be burnt 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 7 3 4 Battery charger not connected to mobility aid Ensure that the battery charger has been connected to the mobility aid No mains supply Check the mains supply with a voltmeter Defective mains supply cable Check the mains supply cable Replace damaged cable
11. bracket Replace the defective components Install Bowden cables lever unit and fixation bracket in reverse order Adjust the clutch by loosening the counter nut 1 and turning the adjustment nuts 2 on the lever unit The last step is to test all functions of the vehicle Invacare STORM MAX SERVICE MANUAL 7 20 7 20 1 A WH Rear wheel suspension Replacing the rear wheel suspension WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges Requirements 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 e Remove the rear and the centre battery compartment cover as described in chapters 7 1 1 and 7 1 2 e Remove the rear light cover as described in chapter 7 1 4 e Pull the motor plug out of the power module e Open the cable clamps and expose the motor cable e Remove the drive wheel as described in chapter 7 18 1 e Remove the wheel hub as described in chapter 7 18 3 e Remove the splash guard as described in chapter 7 1 5 e Remove the motor transmission u
12. head screws 1 e Shift the position of the cross braces 2 together with the sliding nuts in the channels e Re tighten the hexagon socket head screws again 83 SERVICE MANUAL Invacare STORM MAX 7 11 3 Replacing the cross braces Yd Requirements al e 5mm Allen wrench e Loosen and remove the hexagon socket head screws 1 of the cross brace to be replaced 2 e Remove the cross brace 2 and replace it e Install the new cross brace in reverse order 84 Invacare STORM MAX SERVICE MANUAL 7 11 4 Replacing a standard backrest Wd Requirements e 5mm Allen wrench Uninstalling the backrest unit e Remove the backrest cushion 1 e Loosen the hand wheels 2 and the hexagon socket head screws 4 on the left and right side of the chair e Remove the backrest tube 3 from the channels 5 e Remove the channels Installing the backrest unit e Assemble the parts in reverse order e The last step is to test all functions of the vehicle 85 SERVICE MANUAL Invacare STORM MAX 7 12 Fitting the headrest 7 12 1 Fitting the headrest to the standard back 18 Requirements BaSS e 5 mm Allen key e 10 mm socket spanner e Gripping it at the base hold the lower section of the headrest mounting 4 with the clamp block against the handlebar 3 e Attach the clamp cover 2 e Insert the four Allen screws 1 from above through the boreholes e Fit the four cap nut
13. illustration above you see the power module 3 and the positions of the optional lighting circuit board 2 of the optional actuator module 1 and of the optional G Trac sensor 4 e Remove the rear cover as described in chapter 7 1 1 e Press both locking bolts inwards and open the battery box cover 59 SERVICE MANUAL Invacare STORM MAX e Disconnecting the cable of the G Trac sensor from the electronic module e Loosen and remove the hexagon socket head screw 2 e Remove the G Trac sensor 1 Installing the G Trac sensor e Assembly of the G Trac sensor is carried out in the reverse order e The G Trac sensor must be installed with the cable pointing upwards e Test all functions of the vehicle 60 Invacare STORM MAX SERVICE MANUAL 7 4 6 i 7 4 6 1 Drive program selection after component replacement The drive program is saved in the remote and in the power module If one of these two components is replaced the system must be told which of the components has not been replaced so that it knows which contains the current controller profile Note The system allows normal usage of the mobility aid after component replacement only if the profile is selected afterwards Profile selection with remote REM A or REM B e Insert the plug into the remote or into the power module respectively e Switch the remote on e LEDs 1 and 4 blink e Use the bottom rocker switch 5 to select where the r
14. support is very heavy Injury hazard to hands and feet e You should seek help from a second person Requirements e 6mm Allen key e Leta 2 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 e Loosen and remove the two Allen screws 6 with a 6 mm Allen key e Tilt the seat to the desired gradient e Place the two parts of the strut on top of each other e Refit the Allen screws and tighten them e To conclude check all the mobility aid functions Invacare STORM MAX SERVICE MANUAL 7 6 3 Replacing the seat frame with a manual tilt module from Dec 2010 A CAUTION Danger of crushing The seat seat support are very heavy You should seek help from a second person who can secure the seat and help when carrying Requirements a T40 torx wrench oblique pliers cable ties Dismantling the seat support Remove 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 the headlight mountings using an 8 mm jaw spanner see chapter 7 2 3 Put the headlight and the mounting in a safe place on the rear part of the battery compartment cover Remove the connecting cable to the chassis from the remote or form the optional actuator module Remove
15. upper or lower holes the seat can be adjusted to two different heights e Attach the cover plate 1 e Install the screws 2 in such a way that the cover plate is flush fitted or is somewhat elevated depending on the desired seat height e Refit the other parts in reverse order e To conclude check all the mobility aid functions Invacare STORM MAX SERVICE MANUAL 7 9 Replacing the safety belt Requirements sil e 10mm socket spanner e 4mm Allen key WENI Dismantling the safety belt e Pull the end of the belt out of both belt guides 1 e Pull the restraining belt 2 out of the loop on the wheelchair e Pull the complete restraining belt 2 out of both of the belt guides 1 e Remove the nut including the washer e Replace the restraining belt 1 Refitting the safety belt e Refit the parts in reverse order e Adjust the restraining belt individually to the driver by modifying the clearance of both of the belt guides 77 SERVICE MANUAL 7 10 Seat support 7 10 1 Adjusting the seat width il WW a 78 Invacare STORM MAX Note The seat width can be adjusted by installing one of three different seat frames Requirements e Phillips screwdriver size 2 e 6 mm Allen wrench e 8mm Allen wrench b r i A Uninstalling the seat frame e Remove the seat cushion 1 e Loosen both Phillips screws 3 and remove them e Remove the cover plate 2
16. version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software Note The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs Pre requisites e Dynamic Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the download area on http Awww dynamiccontrols com 63 SERVICE MANUAL Invacare STORM MAX 7 6 7 6 1 A WH 64 Seat support and tilt module Replacing the seat support with manual tilt module till Dec 2010 WARNING Danger of crushing The seat seat support is very heavy Injury hazard to hands and feet e You should seek help from
17. EERTE IEEE EAEE AT EEOAE E EEA ARA 93 7 17 4 Replacing the wheel fork sessssesesrrinrsrresrrinesisunnarnrrnnninnnesnnnaneteantannnnananuwadnaanneiea nnana 93 TL2 Adjusting the wheel TOK eperen ieena A KEENE A ARI Ee RENAA EE FEA KRSR 95 3917 3 Changing afront WNSEls arrere aa RA ERA ARAA LEENA 96 7 17 4 Replacing a tire or inner tube in the front eee ceeeeeeeeeeneeeeeeeeeeeeeeeeeeeeseeeaeeeeeeaaees 97 Drive wheels Saneren Senee an sn ereet aaa aaa ah cauenneteiieeeecicaneadentuuendes Ceusareteeeconetde 99 7 18 1 Replacing the drive wheel 0 eee ceeeeeeeeeeeeeeeeceeeeeeeseeeeeeeseaaeeeseeeaaeeeseeeaeeeseeaaeeeeeeaaees 99 7 18 2 Replacing a tyre or inner tube eee ee een ee eeente ee eeeeaeeeeeeaaeeeeeeeaaeeeeeeaeeeseenaeeeeeeaas 100 7 18 2 1 Replacing pneumatic tyres 0 eee eeeeeeeeeeenneeeeeeaeeeeeeeaeeeeeeaeeeeeedaeeeeeenaeeeeeeaas 100 7 18 2 2 Replacing puncture protected tyres ccccccceceeeecseceeceeeeeeeseceaeaeeeeeeeseeseesenneeeees 102 7 18 2 3 Replacing puncture proof tyres 0 0 2 ececccceeceeeeeeeeeececcaeceeeeeeeseccaeaeeeeeeeeeeseesecaeeeeees 104 7 18 3 Replacing the drive wheel NUD eee ceeneeeeeenneeeeeeaeeeeeeeaeeeeeeeaeeeeeeaeeeseenaeeeeeeaas 105 Drive UNI xine i Tee re cued ste erae ae ee et ei tea e a ea a Pa tee eee eana aaeeea sanaaa Ea eana da aaah Enean 106 7 19 1 Replacing the motor transmission unit Standard Storm sae ratte faite Sra Siete Coot Sat t G 106 7 19 2 Replacing the carbon brushes
18. IN Fagerstagatan 9 sweden invacare com S 163 91 Spanga finland invacare com Sverige WWW www invacare se Tillverkare M LNDAL Invacare Deutschland GmbH T 46 0 31 86 36 00 KleiststraRe 49 Fax 46 0 31 86 36 06 D 32457 Porta Westfalica ginvacare invacare com Deutschland LANDSKRONA T 46 0 418 2 85 40 Fax 46 0 418 1 80 89 linvacare invacare com OSKARSHAMN T 46 0 491 1 01 40 Fax 46 0 491 1 01 80 oinvacare invacare com Eastern European Distributor a 49 0 5731 75 45 40 peace Organisation EDO Fax 49 0 5731 75 45 41 WelsiSirans a9 edo invacare com D 32457 Porta Westfalica www Avinvatareide Deutschland Invacare STORM MAX SERVICE MANUAL Contents Chapter Page 1 Introduction 8 1 1 General informat ny a r r ear a ra a a a aa eaa a ea aaae aa ae D a adaa deiae aaa 8 1 2 Notes on transport sssssunsessnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnnnnn nnmnnn nn nnn nnmnnn nanna nnmnnn nna 8 1 3 Definition and representation of information and safety information in this manual 9 1 4 Hazard symbols and symbols used ccceeeccceeeeeeeeeeneee seen nena seen sees seen seeeeeeeseeeeeenseeeeeenseeeeeens 10 1 5 IMAGES IN this MANUA cece ceeeee cece eee ee eeeeee eee eeee eee neeee eee iren eee neee see akra seen aeaeeeenseeeeensneeeeeees 11 2 Safety and fitting instructions 12 2 1 Before any inspection or repair WOPK c eccceseeeeeeeseeeeeeeseeeeeenseeeeeen
19. Invacare STORM MAX SERVICE MANUAL CE Edition 16 11 11 SERVICE MANUAL Invacare STORM MAX These instructions contain information about Testing work Repair Instructions This manual is part of the instructions for use Service addresses CAD Invacare Austria GmbH T 43 6232 5 53 50 Herzog Odilostrasse 101 Fax 43 6232 5 53 54 A 5310 Mondsee info invacare austria com Austria WWW www invacare at r i Invacare n v T 32 0 50 83 10 10 Autobaan 22 Fax 32 0 50 83 10 11 CLD B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Invacare AG T 41 0 61487 70 80 BenkenstraRe 260 Fax 41 0 61487 70 81 CH 4108 Witterswil switzerland invacare com Switzerland WWW www invacare ch D Invacare Aquatec GmbH a 49 0 7562 70 00 Alemannenstra e 10 Fax 49 0 7562 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de ne Invacare A S Kundeservice 45 0 36 90 00 00 _ Sdr Ringvej 37 Fax Kundeservice 45 0 36 90 00 01 DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk Ee Invacare SA T 34 0 972 49 32 00 o Areny s n Fax 34 0 972 49 32 20 Pol gon Industrial de Celr contactsp invacare com E 17460 Celr Girona WWW www invacare es ESPA A Ee Invacare Poirier SAS T 33 0 247 62 64 66 Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fondettes contactfr inv
20. 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 Refitting the centre panel e Refit the parts in reverse order e Now tighten all the screws finger tight again 35 SERVICE MANUAL Invacare STORM MAX 7 1 3 Opening the front panel Wd 36 Requirements e 4mm Allen key Dismantling the front cover panel e Remove the seat as described in chapters 7 6 1 and 7 6 5 e Remove the rear and the middle covers as described in chapter 7 1 1 and 7 1 2 e Loosen the two Allen screws 1 concealed by the motor in the picture using a 4 mm Allen key e Pull the motor cable and the guide bushes 2 out of the lateral recesses e Pull the connecting cable to the seat out of the recess 3 e First lift the front cover up so that the retaining clips 4 are exposed e Then pull the cover off towards the front Refitting the front panel e Refit the parts in reverse order e Make sure that the retaining clips 4 snap securely into the openings of the cover e Now tighten all the screws finger tight again Invacare STORM MAX SERVICE MANUAL 7 1 4 Opening the rear light cover Requirements ida e 4 mm Allen key e socket spanner 13 mm Dismantling the rear light cover e Remove the rear and centre cover as described in chapters 7 1 1 and 7 1 2 e Loosen the nut 1 using a 13 mm socket spanner
21. M MAX 7 17 3 Changing a front wheel A i La 96 Ja ir WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges Requirements e 5mm Allen wrench e Oblong wooden blocks at least 14 x 14 x 30 cm ha ZOON m 0 9 M Yw e Prop up the wheelchair on multiple wooden blocks with the help of a second person Removing the wheel e Use the 5 mm Allen wrench to loosen and remove the hexagon socket head screws 1 e Pull the axle 5 out laterally e Remove the complete wheel 3 from the front wheel fork 4 Assembling the wheel e Assemble the parts in reverse order e When installing the wheel pay attention to the correct direction of rotation Invacare STORM MAX SERVICE MANUAL 7 17 4 Replacing a tire or inner tube in the front A WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under th
22. Oblique pliers e Cable ties Dismantling the tilt actuator e Remove the e egrests e Pull the tilt actuator plug out of the actuator module under the seat e Unclip the cable Remove any cable ties which are fitted e Remove the upper pin retainer 1 e Remove the upper bolt 2 e Swing the tilt actuator 6 forwards e Remove the lower pin retainer 5 e Remove the lower pin 4 and remove the entire tilt actuator e Replace the tilt actuator Refitting the tilt module e Refit the parts later in reverse order e To conclude check all the mobility aid functions 72 Invacare STORM MAX SERVICE MANUAL iW Lifting column WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e You should seek help from a second person WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Save the vehicle laid on its side against overturning Requirements e 4mm Allen key e T40 torx wrench e Oblique pliers e Cable ties Dismantling the lifting column e Remove the rear battery compartment cover as described in chapter 7 1 1 e Remove the centre battery compartment cover as described in chapter 7 1 2 e Remove the front battery compar
23. a second person Requirements e T40 torx wrench e oblique pliers e cable ties Dismantling the seat support e Remove the legrests e Remove the armrests e Remove the seat cushion e Remove any existing cable ties holding the cables on the remote or lighting Remove the cables from the stuck on clamps e Loosen the cap nuts of the headlight mountings using an 8 mm jaw spanner see chapter 7 2 3 e Put the headlight and the mounting in a safe place on the rear part of the battery compartment cover e Remove the connecting cable to the chassis from the remote or from the optional actuator module e Remove the cable or cables so that there is no longer any cable connection between the seat and the chassis Invacare STORM MAX SERVICE MANUAL e Remove the pin retainer 1 e Remove the pin 2 e Swing the brace 6 forwards e Remove the bolt retainer clip 5 e Remove the bolt 4 e Remove the brace e Fold back the entire seat e Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 e Lift the seat and the seat support from the vertical column Refitting the seat carrier e Refit the parts in reverse order e To conclude check all the mobility aid functions 65 SERVICE MANUAL Invacare STORM MAX 7 6 2 Adjusting the seat tilt on a seat with a manual tilt module till Dec 2010 66 WARNING Danger of crushing The seat seat
24. acare STORM MAX SERVICE MANUAL 7 3 5 Checking the cable Wd Requirements e 4mm Allen key e oblique pliers e cable ties e Remove the rear and the centre cover as described in chapters 7 1 1 and 7 1 2 Pull the batteries out of the battery compartment as described in chapter 7 3 1 e Check the fuse cable 1 and battery cable 2 for visible damage and crushing points e Replace any damaged cables e Check all cables for visible damage and crushing locations Replace any damaged cables e Pull each plug 1 carefully The plug should not come out of the socket e f one of the plugs is loose press it back into the socket with light pressure The plug must engage e Checked to ensure that the plug is now firmly in its socket If not repeat the previous operation e Refit the parts in reverse order e Check all vehicle functions 51 SERVICE MANUAL Invacare STORM MAX 7 3 6 Cable routing Requirements e 4mm Allen key e oblique pliers e cable ties e Remove the rear and the centre cover as described in chapters 7 1 1 and 7 1 2 e Guide the cables inside of the cover over the cable link 1 e Secure the cables with the cable clamps 2 e The motor cables are fitted with protection covers 2 and are guided out of the front cover through recesses on the side e Cables that lead to the seat upper actuator module remote headlight are guided out of the front cover through an
25. acare com France WWW www invacare fr Invacare STORM MAX SERVICE MANUAL GB Invacare Ltd Customer services 44 0 1656 77 62 22 a Pencoed Technology Park Fax Customer services 44 0 1656 77 62 20 Pencoed uk invacare com Bridgend CF35 5HZ WWW www invacare co uk United Kingdom Cm Invacare Mecc San s r l T 39 0445 38 00 59 yia dei Pini 62 Fax 39 0445 38 00 34 36016 Thiene VI italia invacare com Italia WWW www invacare it CE Invacare Ireland Ltd T 353 18 10 70 84 Unit 5 Seatown Business Campus Fax 353 18 10 70 85 Seatown Rd Swords ireland invacare com County Dublin WWW www invacare ie Ireland ar Ti Invacare AS T Kundeservice 47 0 22 57 95 00 Grensesvingen 9 Fax Kundeservice 47 0 22 57 95 01 Postboks 6230 norway invacare com Etterstad island invacare com N 0603 Oslo WWW www invacare no Norge CNL Invacare B V T 31 0 318 69 57 57 Celsiusstraat 46 Fax 31 0 318 69 57 58 NL 6716 BZ Ede nederland invacare com Nederland csede invacare com WWW www invacare nl P gt Invacare Lda T 351 225 10 59 46 Rua Estrada Velha 949 T 351 225 10 59 47 P 4465 784 Le a do Balio Fax 351 225 10 57 39 Portugal portugal invacare com WWW www invacare pt SERVICE MANUAL a 3 Aterforsaljare M Invacare AB Kundtjanst Fax Kundtjanst Invacare STORM MAX 46 0 8 761 70 90 46 0 8 761 81 08 F
26. ace if necessary Drive lever function Replace drive lever if necessary Replace remote if necessary Power supply Tighten cables and connecting plugs replace if necessary Check drive electronics Update software if See chapter 7 5 program version newer version available CE Eee E s Invacare STORM MAX SERVICE MANUAL 6 Operational faults Different power modules can be installed in the mobility aid in connection with different remotes The rectification of operational faults depends on the installed power module in each case The power modules used are described in chapter 4 2 Note i 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 If you have problems with the mobility aid please proceed as follows e First assess the possible cause of the problem using the following table e Check the remote status display Evaluate the error code e Carry out the necessary checks and repairs as recommended in the following table 25 SERVICE MANUAL 6 1 26 Drive fault diagnosis PROBLEM OTHER Mobility aid will not start Invacare STORM MAX POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE The remote Drive motors Engage drive See operating manual status display disengaged motors illuminates normally and displays blink code 5 6 Remote status B
27. atteries Replace batteries See chapter 7 3 2 display does not defective Mnetiee Completely Pre charge See instruction manual for discharge batteries charger battery Power supply to remote interrupted Remote defective Check master fuse See chapter 7 3 4 Check cables between the modules for loose connections and damage Replace remote See chapter 7 3 5 See chapter 7 4 1 Remote status display blinking Various causes Assess error code See chapter 6 2 defective resistance of brakes replace motor if defective Mobility aid None Batteries Replace batteries See chapter 7 3 2 judders in defective drive mode unstable voltage Drive motor s Replace motor s See chapter 7 19 1 dete Gils Replace carbon See chapter 7 19 2 brushes Mobility aid None Drive motors Change See chapter 7 5 pulls to left running programming to or right asymmetrically synchronise motors Tyre visibly Not enough air Check air See chapter 7 18 2 dented in the tyre pressure replace inner tube and or valve if necessary Error None Bad connections Check all See chapter 7 3 5 message connecting cables not go Motor brake Measure internal See chapter 7 19 1 Invacare STORM MAX SERVICE MANUAL PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Motors stop None Voltage decline Stop journey and and start all
28. batteries e Refit the batteries in reverse order e Ensure that the battery cage sockets plugs have been correctly refitted A polarity diagram is located in the rear cover 47 SERVICE MANUAL Invacare STORM MAX 7 3 3 Correct handling of damaged batteries A O Wd 48 WARNING BURN HAZARD Injury hazard due to discharged acid e Always wear acid proof protective gloves when handling batteries e Always wear protective goggles when handling batteries What to do if acid is discharged e Always take clothing which has been soiled by or dipped in acid off immediately e Rinse any areas of your skin which has come into contact with battery acid off immediately with plenty of water If contact with eyes is made e Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements e protective goggles e acid proof gloves e acid proof transport container e f handling damaged batteries always wear suitable protective clothing e Always deposit damaged batteries in suitable acid proof containers immediately after removal e Only transport damaged batteries in suitable acid proof containers e Always wash any objects which were contacted by acid in plenty of fresh water Always dispose of used or damaged batteries correctly Used and damaged batteries will be taken back by your medical equipment supplier or Invacare
29. cabling and See chapters 7 3 5 and being charged cable defective replace fuse 7 3 4 Batteries Replace batteries See chapter 7 3 2 defective LEDs blinking Charging unit Replace charging See instruction manual for oncharging defective unit charger unit Short None One of the Replace batteries See chapter 7 3 2 charging batteries could period be defective Mobility aid None Remote Replace remote See chapter 7 4 1 runs too defective slowly Batteries Replace batteries See chapter 7 3 2 defective 29 SERVICE MANUAL PROBLEM OTHER Electrical adjustment motor does not react Invacare STORM MAX POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Remote shows Lighting Replace lighting See chapter 7 4 4 blinking E or actuator module actuator module blink code 2 defective Status diode on lighting actuator module does not go out even if the remote has been switched off or disconnected None Cable Safeguard cable See chapter 7 3 5 disconnected or connection damaged replace cable if necessary Electrical Check adjusting adjusting motor motor defective Remote Replace remote See chapter 7 4 1 defective 1 Only applies to remote SD24 2 All remotes except SD24 30 Invacare STORM MAX 6 2 REM remotes Error codes and diagnostic codes SERVICE MANUAL The drive electronics can automatically rectify some faults In this case the status display w
30. chapters 7 1 1 and 7 1 2 e 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 e In the illustration above you see the power module 3 and the positions of the optional lighting circuit board 2 of the optional actuator module 1 and of the optional G Trac sensor 4 57 SERVICE MANUAL Invacare STORM MAX 58 e Pull the plug 1 out of the lighting PCB e Undo the two Allen screws 2 with a 4 mm Allen key e Lift off the lighting PCB together with the retaining bracket e 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 e Replace the lighting PCB Refitting the lighting PCB e Refit the parts in reverse order e Plug all the plugs into their old positions e To conclude check all the mobility aid functions Invacare STORM MAX SERVICE MANUAL 7 4 5 Wd Replacing the G Trac sensor Requirements e 5 mm Allen key e 10 mm socket wrench Uninstalling the G Trac sensor e Remove the seat as described in chapters 7 6 1 and 7 6 5 e Switch the electronics of the wheelchair OFF e Remove the rear cover as described in chapter 7 1 1 Ee e 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
31. d or material damage if they are not avoided e 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 e 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 SERVICE MANUAL Invacare STORM MAX 1 4 9 FP PRP P PB mt lt ci X 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 e 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 e 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 e 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 e Always follow the instructions to a
32. d the centre battery compartment cover as described in chapters 7 1 1 and 7 1 2 Remove the drive wheel as described in chapter 7 18 1 Loosen and remove the nut 1 from the hexagon socket head bolt 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 Allen screw 4 together with the cover plate 3 Remove the pin 2 In doing so please pay attention to the washers and spacers Remove the strut Refitting the strut Refit the parts in reverse order To conclude you should always carry out a trial run to test the vehicle functions
33. de check all the mobility aid functions 107 SERVICE MANUAL Invacare STORM MAX 7 19 2 Replacing the carbon brushes Standard motor Note i Always replace all the carbon brushes on both motors A WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Requirements _ 5 mm Allen key 6 mm Allen key 10 mm socket spanner 19 mm socket spanner blade screwdriver long wooden blocks min 14 x 14 x 30 cm Removing the carbon brushes e Switch off the mobility aid e Remove the drive wheels as described in chapter 7 18 1 e Disengage the motor 1 by setting the engaging lever to Push e Loosen and remove all four plastic caps 3 using a blade screwdriver e Note the fixing position and location of the carbon brushes Note i Used carbon brushes need to the refitted exactly in the same position from which they were taken in order to guarantee optimum contact to the collector 108 Invacare STORM MAX SERVICE MANUAL Make a marking on the motor and the carbon brushes in order to guarantee correct refitting Remove the carbon brushes completely from the mounting 2 Check the carbon brush and spring for the level of wear broken components or discolouration Refitting the carbon brushes Depending on the condition of the brush and the spring either replace the brushes in exactly the same p
34. e placed exactly above each other e Place the joiner s clamps in position e Tighten the joiner s clamps alternately in small stages until the rim rings are precisely aligned e Tighten the Allen screws 2 to 18 Nm Invacare STORM MAX SERVICE MANUAL 7 18 3 Replacing the drive wheel hub LY CAUTION Possible material damage to mobility device Collisions can be caused if the adjusting washers are removed during fitting work to the drive wheels Adjusting washers are often fitted between the drive shaft and the wheel hub to even out tolerances If these adjusting washers are removed and not replaced again collisions can be caused e Always replace the adjusting washers exactly as they were before you started dismantling Y Requirements BIL e 19 mm socket spanner Removing the drive wheel hub e Loosen and remove the nut 3 with a 19 mm socket spanner e Remove the washer 2 e Take the wheel hub 1 off the axle 4 e Take the feather key 5 off the axle Refitting the drive wheel hub e Refit the drive wheel hub parts in reverse order e Use a thin film of lubricant to make pushing the wheel hub onto the axle easier 105 SERVICE MANUAL 7 19 7 19 1 A WW 106 Drive unit Replacing the motor transmission unit Standard Storm Invacare STORM MAX WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help f
35. e five Allen screws on the inner side of the wheel and tighten them e Check the exact fit of the tyre on the rim e Inflate the tyre to the prescribed air pressure e Re check the exact fit of the tyre on the rim e Screw the valve cap back on e Refit the wheel 103 SERVICE MANUAL Invacare STORM MAX 7 18 2 3 Replacing puncture proof tyres WW L 104 Requirements e 6mm Allen key Two long wooden blocks min 14 x 14 x 30 cm Three joiner s clamps with plastic caps Torque spanner 5 25 Nm or similar Talcum powder Removing the tyres e Remove the wheel as described in chapter 7 18 1 ATTENTION Explosion hazard There is considerable pressure in the tyre Danger of injury Parts can be thrown out and injure you if you do not secure the rim rings e Secure the rim rings with joiner s clamps e Secure the rim rings against unexpected discharge with three joiner s clamps When doing so ensure that you do not scratch the rims e Undo the five 6 mm Allen screws 2 on the inside of the wheel e Now loosen the joiner s clamps carefully and alternately until you can remove the rim rings without danger e Remove the inner 3 and outer 1 ring of the rim from the tyre 4 e Replace any defective or worn parts Refitting the tyres e Refit the tyres to the rim in the reverse sequence e When fitting the rim rings together ensure that the drillholes and threads for the bolts ar
36. e grid The user can carry out the final adjustment following the operating manual 41 SERVICE MANUAL Invacare STORM MAX 7 2 4 Replacing the complete rear light LED lighting unit Requirements da e 4 mm Allen key e 13 mm socket spanner Removing the rear light e Remove the rear and the centre cover as described in chapters 7 1 1 and 7 1 2 e 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 e Loosen the cable leading to the lighting PCB from the rear light affected 2 oO e Loosen the nut 1 with a 13 mm socket spanner e Lift off the plastic casing 2 42 Invacare STORM MAX SERVICE MANUAL 7 2 5 Wd e Open the rear light plug 3 that is to be replaced e The rear lights are only clamped in the plastic casing Replace the red rear light 1 or the indicator 2 as required The cables are marked correspondingly Refitting the rear light e Refit all parts in reverse order e Now tighten all the screws finger tight again e Check all vehicle functions Replacing the rear bulb holder LED lighting unit Requirements e 4mm Allen key e 13mm socket spanner Dismantling the bulbholder e Remove the rear lights as described in chapter 7 2 4 e Replacing the rear bulb holder LED lighting unit Refitting the bulbholder e Refit all parts in reve
37. e wheels i Requirements aie e 5mm Allen wrench e Two oblong wooden blocks at least 14 x 14 x 30 cm e Repair kit for inner tube tires or a new inner tube e Air pump or compressor e Talcum powder it 1 x lA 6 j f Y F E 4 Removing a tire inner tube e Uninstall the wheel as described in chapter 7 17 3 A CAUTION EXPLOSION HAZARD On a vehicle with pneumatic tires the wheel will explode if you do not let the air out of the tire before removing the wheel e Always allow the air to escape from the wheel before you remove it Press the spring pin in the middle of the valve e Unscrew and remove the valve cap 2 e Press the spring pin in the middle of the valve and allow the air to completely escape from the tire e Uninstall the wheel as described in chapter 7 17 3 97 SERVICE MANUAL Invacare STORM MAX 98 e Use a5 mm Allen wrench to loosen the five hexagon socket head screws 4 e Remove the inner ring and outer ring 3 of the rim from the tire 1 e Remove the inner tube 2 from the tire e Replace defective or worn parts or repair these parts Installing a tire e Insert the inner tube back into the tire NOTE If the old tube is to be repaired and re fitted and has become wet during repair work powdering the hose with some talcum powder can simplify the fitting procedure e Re position the rim halves 3 in the tire again Make sure tha
38. ee chapter 7 17 wheel fork or wheel bearings Drive units Motors Check motors See chapter 7 19 clutch mechanism Check functions during Check carbon See chapters drive operation and brushes replace if 7 19 1 and 7 19 2 when pushing necessary Check the clutch Replace motor if mechanism necessary Tighten screws nuts adjust or replace if necessary Legrests Check welded seams Tighten replace if interlocking screws necessary footplates Power legrests Check cable Replace cable if if fitted Check contacts necessary check functions Lighting if Check cable Replace lamp or See chapter 7 2 fitted Check function cable if necessary Battery Check battery support Replace if necessary mounting and mounting belts for damage 23 SERVICE MANUAL Component Batteries Invacare STORM MAX Check Remedy Notes cs batteries for Replace batteries if See chapters 7 3 2 damage necessary and 7 3 3 Check battery voltage Charge batteries Co Fl Check battery voltage Charge batteries See operating manual Check contacts and Clean contacts and Please refer to the terminals terminals safety information in chapter 7 3 2 and 7 3 3 for handling batteries Remote electronics modules Drive program 24 Remote status display Evaluate error blink See chapter 6 blinking code Fixings Tighten fixings replace if necessary Cables and connecting Tighten cables and connecting plugs repl
39. eeenes 32 7 Repair work 33 7 1 Oo Ep SS eR soo SoS a E SP A SE aD eR SS AOR SPE 33 7 1 1 Opening the rear cover panel cccceceesececceceeeeeeeeceeaneeceeeeeseceneaeeeeeeeeeeeesesnanaeeeeees 33 7 1 2 Opening the centre panel c cccccecceeeeecenccceeeeeeeececeeeaeeeceeeeeseeeneaeeeseeeeeeeeeenenaeeeeees 34 7 1 3 Opening the front panel ccececcceeece cece ee eecencae cece cess see eaaaaeaeeeeeeesecceaaeceeeeeeesessisaeeeeees 36 7 1 4 Opening the rear light cover 2 c iicceceseeleseeece ences deleceedecceneveeseeneusebessadedeseseeesenesnatdebeneeds 37 TS Replacing the splash Guard isa c cccsets eects cee etic atten eel nett edited 38 SERVICE MANUAL Invacare STORM MAX 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 Agta UI ences secs cease eee ia ses ecccc at ec ces shee cana Aaa aa aTa dectadceststacacadsctecddecanes 39 7 2 1 Replacing the front LED LED lighting Unit 0 cece ee eeeeeeeeteeeeeeeeeaeeeeeeneaees 39 7 2 2 Replacing the complete front headlight LED lighting Unit 0 0 eeeeeeeeeeeeneees 39 7 2 3 Replacing the front bulb holder LED lighting Unit ec eeeeeeeeeeeeeeeeeeeneeeeeeeeaees 41 7 2 4 Replacing the complete rear light LED lighting Unit eee eeeeeeeeeeeeeeeeeeaeees 42 7 2 5 Replacing the rear bulb holder LED lighting Unit ec eeeeeeeeeeeeeeeeteeeeeeeeaees 43 Batteries cables amp battery charger ccsecccceeeeeeeeeeseeeeeenseee
40. eeenneeeeeenseeeeeenseaeeeenseeeeeeenseneeeenas 44 7 3 1 Making the batteries accessible ee eeeeeeeeceeeeeeeeeeeeeeeeeeeaeeeeeeeaeeeseeeeaeeeseeaaeeeeeeaaees 44 03 2 Replacing baterio niyen by heacse hectic creche A AA EAEEREN 46 7 3 3 Correct handling of damaged batteries 0 0 0 ecceeeeeeeeeeeeeneeeeeeeeeeeeteeeeeeeseeaeeeeeeenaees 48 7 3 4 Checking and replacing the main fuse 000 0 eeeeeceeeeeeeeeeeeeeeeeeeeeeeeteeeaeeeteeaaeeeeeeaaees 49 23 9 oGhecking the Cable ss i522 e cse atic eens esti ie tite een nit eit aA 51 13 6 Cable roving ea E ee ee bet eee aie 52 Electronics module ccccseecccesseeeeeeenseeeeeensneeeeenseeeeeenseeeeeensneeseenseeeeeeenseeeeeenseeeeeenseeeeeesseeeeesans 53 TAN R place remote eena e aa e at aa ee aaa alae aaia 53 T4 2 Replacing the power mod le sieri iaaa aa aaee eai iaaa aaa e a a a aaa 53 7 4 3 Replacing the actuator module under the Seat eee eceeeeeeeeeeneeeeteeeeeeeeeeaeeeeeeeeaees 56 TAA Replacing the lighting PCB ecserin eA AAAA EANET eA AnA E DAEA PERRA 57 7 4 5 Replacing the G Trac SCNSOM cccceeeeececeeeeeeeeeeeeeeeeeeeeeeeeseeeaeeeseeeaeeeeeeeeaeeeteeaeeeseeaaees 59 7 4 6 Drive program selection after component replacement cccceeeeeeeeeeetteeeeeeeees 61 74 6 1 Profile selection with remote REM A or REM B cc cccceeeeeeeeeeenneeeeeeneeeeeeneeeeeeaaes 61 74 6 2 Profile selection with remote REM 550 eeeecceeeeeeeeeeeeneeeeeeneeeeeenaeeeees
41. eel 2 off the wheel hub Refitting the drive wheel NOTE Please ensure that the wheel is re fitted on the same side and in the same running direction as removed e Refit the wheel in reverse order 99 SERVICE MANUAL Invacare STORM MAX 7 18 2 7 18 2 1 Wd 100 Replacing a tyre or inner tube Note There are three different types of tyres or inner tubes and specific points must be observed for the replacement of each type It is easy to tell the difference between the tyre or inner tube types e Pneumatic tyres have black valve caps e Puncture protected tyres have red valve caps e puncture proof tyres have no valves Please proceed in accordance with the appropriate chapter e Replacing pneumatic tyres see chapter 7 18 2 1 e Replacing puncture protected tyres see chapter 7 18 2 2 e Replacing puncture proof tyres see chapter 7 18 2 3 Replacing pneumatic tyres Note Pneumatic tyres have black valve caps Puncture protected tyres have red valve caps Requirements e 6mm Allen key Two long wooden blocks min 14 x 14 x 30 cm Repair kit for inner tube tyres or a new inner tube Tyre pump or compressor Talcum powder Invacare STORM MAX SERVICE MANUAL Removing the tyres e Remove the wheel as described in chapter 7 18 1 e Unscrew the valve cap 2 A ATTENTION Explosion hazard If the wheelchair is fitted with pneumatic tyres the wheel can expl
42. eneeeeeeaas 62 Updating the driving Program ccccceeecccceseeeceeeeeeeeeenseeeeeensneeseenseeeeeensneaeeeenseeeeeenseeeeeenseeeeeents 63 Seat support and tilt MOCUIC ccs seeceeeee este ee eeeeeneeeeeeeeeeeaaeseseeeeneaeeesaaesaseeeeneeeeseeeseseaeenseeeeees 64 7 6 1 Replacing the seat support with manual tilt module till Dec 2010 0 eee 64 7 6 2 Adjusting the seat tilt on a seat with a manual tilt module till Dec 2010 66 7 6 3 Replacing the seat frame with a manual tilt module from Dec 2010 sses 67 7 6 4 Adjusting the seat tilt on a seat with a manual tilt module from Dec 2010 69 7 6 5 Replacing the seat support with electric tilt module 0 cceee eset eeeeeeeeeeetteeeeeeeees 70 7 6 6 Replacing the tilt ACtUAtON issii aaa a aa ea iN AA e ARR T AER 72 LAPIN Kesel LET iT a PRA E E EE E E E E EE E EE ES 73 Seat height adjustment 00 2525 6c sees eetecte ce ceck sleet eck aena te deea aaea aa Se aeaa a es ean aaae adana iaaa Eik 75 7 8 1 Adjusting the seat height with a manual lifter pillar oo ee eects eeeeeeeeeeeeeeeeeeeeaees 75 Replacing the Safety belt c sccccesseeeceeeeeeeeeeeeneeeeenseeeeeeeseeeseenseeeeeensneeeeeenseeeeeenseeeeeenseeeeeenes 77 DCA SUPPOM PPE tate era ee ee ocr eee ee ocr a et esd ss alee ans 78 FAOT Adjusting He seat wid oiii ea a ER 78 7 10 2 Adjusting the seat depth 00 eee ceeen re eeenne ee eeeae eee eeeaeeeeeeaeeeeeeaeeeseeaeeeseenaeeeeeenaees 80 Bea CK U
43. equired controller profile is saved LED 1 power module LED 4 remote Only LED 1 or 4 blinks now depending on the selection e Press the Horn 2 and 3 buttons on the speed selection and hold them down for 3 seconds to confirm the selection The system will switch itself off and restart automatically In the process the selected profile is saved in the remote and in the power module 61 SERVICE MANUAL Invacare STORM MAX 7 4 6 2 Profile selection with remote REM 550 62 Insert the plug into the remote or into the power module respectively Switch the remote on The display 2 shows that you need to select a profile Use the bottom rocker switch 3 to select where the required controller profile is saved remote Il power module The display shows which profile you have selected Press the Horn 4 and 1 buttons on the speed selection and hold them down for 3 seconds to confirm the selection The system will switch itself off and restart automatically In the process the selected profile is saved in the remote and in the power module Invacare STORM MAX SERVICE MANUAL 7 5 WW Updating the driving program The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections If a newer
44. h plenty of water If contact with eyes is made e Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements e No tools are required Note When disassembling take care of small parts such as screws and washers Put all small parts down so that they can be reassembled in the right sequence Invacare STORM MAX SERVICE MANUAL e Remove the rear panel as described in chapter 7 1 1 e Press both catches 1 inwards and open the battery box cover e Pull the quick release catch 1 to the left and place the power module on top of the battery box e Pull on the strap 3 to move the batteries 1 and the battery support 2 forward see below 45 SERVICE MANUAL Invacare STORM MAX 7 3 2 A gt Seer p gt 46 Replacing batteries ATTENTION Injury hazard and possible material damages if batteries are handled improperly e The installation of new batteries may only be carried out by authorised specialists e Observe the warning information on the batteries e Only use battery versions stated in the specifications ATTENTION Fire and burns hazard if battery terminal is bypassed e Please take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts e Ensure that the battery terminal caps have been replaced if you are not wo
45. id driving behaviour especially tipping stability for unaltered standard drive programs Note All power modules are delivered with a standard drive program If you have made any customer specific modifications to the drive program these must be adapted after the installation of the new power module Requirements e 83 mm socket spanner e To adapt the drive program programming software or hand programming device and system installation manual available from Invacare Dismantling the power module e Remove the rear panel and the centre panel as described in chapters 7 1 1 and 7 1 2 53 SERVICE MANUAL Invacare STORM MAX e 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 e In the illustration above you see the power module 3 and the positions of the optional lighting circuit board 2 of the optional actuator module 1 and of the optional G Trac sensor 4 e Pull the plug 1 out of the power module e Use a4 mm Allen wrench to loosen both of the hexagon socket head screws 2 e Remove the washers and the black intermediate pieces e Remove the power module by pulling it backwards from the guides e Replace the power module Refitting the power module e Refit the parts in reverse order e Plug all the plugs into their old positions e Select the drive program as de
46. ies Replace batteries See chapter 7 3 2 defective Cabling to power check cabling See chapter 7 3 5 module or remote defective Power module Replace power See chapter 7 4 2 defective module Corroded Water salt or Check cabling See chapter 7 3 5 contacts urine has replace if penetrated necessary Motor None Bearing Replacing the See chapter 7 19 1 makes defective motor clicking Collector Replacing the See chapter 7 19 1 noise defective motor Scraping None Bearing Replacing the See chapter 7 19 1 noise or defective motor motor Transmission Replace See chapter 7 19 1 blocked at defective transmission Transmissi None Transmission Replace See chapter 7 19 1 on makes defective transmission cliekmg Drive wheel Tighten drive See chapter 7 18 1 noise loose wheel secure bolts with Loctite if necessary Invacare STORM MAX SERVICE MANUAL PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Transmission None Sealing ring on Replace See chapter 7 19 1 losing oil drive shaft transmission if defective sealing ring defective Check carbon See chapters 7 19 1 and brushes for oil 7 19 2 wetting replace motor if brushes wet Irregular None Drive shaft Check drive shaft See chapter 7 19 1 running movable or bent replace transmission if defective Parts lost None Parts lost Reattach parts once found Batteries not None Fuse burnt out Check
47. ill stop blinking Switch the remote on and off again several times Wait around 5 seconds each time before switching the remote on again If this does not rectify the fault determine the cause using the blink codes from the following table BLINK CODE POSSIBLE CAUSE SOLUTION DOCUMENTATION 1 x blink Module defective Replace defective module See chapter 7 4 2 2 x blink Accessory error e g short Check accessory See chapter 7 3 5 circuit in adjusting motor connections check accessory 3 x blink Fault on left hand motor Check connection plug See chapters 7 3 5 M2 Connection check motor and 7 19 1 loose defective or motor defective 4 x blink Fault on right hand motor Check connection plug See chapters 7 3 5 M1 Connection check motor and 7 19 1 loose defective or motor defective 5 x blink Fault brake fault on left Check connection plug See chapters 7 3 5 hand motor M2 check motor and 7 19 1 Connection loose defective or motor defective 6 x blink Fault brake fault on right Check connection plug See chapters 7 3 5 hand motor M19 check motor and 7 19 1 Connection loose defective or motor defective 7 x blink Completely discharge Pre charge battery See operating manual battery 8 x blink Battery voltage too high Switch lighting to low See instruction battery voltage manual for charger Check battery charger 9 or 10 x blink Faulty data transmission Remove electronic modules See chapter 7 4 2
48. is very heavy Danger of injury to the hands e Pay attention to the heavy weight Requirements e 5mm Allen wrench e 6 mm Allen wrench e 13 mm socket wrench e Oblong wooden blocks at least 14 x 14 x 30 cm Uninstalling Bowden cables Loosen the locking nuts 1 of the Bowden cables on the clutch lever Loosen the adjustment nuts 2 of the Bowden cables on the clutch lever Pull the Bowden cables out of the lever unit Invacare STORM MAX SERVICE MANUAL e Loosen the screw of the pull out protection 1 e Remove the pull out protection from the Bowden cable e Loosen the locking nut 2 of the Bowden cable on the motor e Loosen the adjustment nut 3 of the Bowden cable on the motor e Pull the Bowden cable out of its holder on the motor e Repeat the procedure on the other motor Uninstalling the lever unit of the clutch e Loosen the screw of the clutch lever 1 e Remove the clutch lever e Loosen the 4 screws 2 and 4 of the lever unit e Remove the lever unit from the fixation 111 SERVICE MANUAL Invacare STORM MAX 112 Uninstalling the fixation bracket of the lever unit Loosen the hexagon socket head screws underneath the seat frame One hexagon socket head screw is screwed into the nut 1 The other hexagon 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
49. ity for this standard drive program Invacare STORM MAX SERVICE MANUAL 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 3 Nm 6Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 A CAUTION Damage can be caused to the mobility device due to improperly tightened screws nuts or plastic connections e Always tighten screws nuts etc to the stated tightening torque e Only tighten screws or nuts which are not listed here fingertight 15 SERVICE MANUAL Invacare STORM MAX 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 e Actuator module 1 The actuator module is optional If present it controls the electrical tilt module as well as the electrical backrest adjustment Under the rear cowling e Light terminal module 2 The lighting distributor module is located on top of the battery box The lighting distributor module is optional It is only present if the wheelchair is equipped with a lighting system e Power module 3 The power module is located in the rear i
50. moving unintentionally during repair work e Switch the power supply off ON OFF key e Engage the drive e Before jacking up secure the vehicle by using chocks to block the wheels Invacare STORM MAX SERVICE MANUAL A ATTENTION Fire and burn hazard due to electrical short circuit e The mobility device must be completely switched off before removal of voltage carrying components To do this remove the batteries e Avoid short circuiting the contacts when carrying out measurements on voltage carrying components CAUTION Danger of burns from hot surfaces on the motor e 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 e Use only undamaged tools in good condition e Some moving parts are mounted in sockets with PTFE coating Teflon Never grease these sockets e Never use normal nuts instead of self locking nuts e Always use correctly dimensioned washers and spacers e When reassembling always replace any cable ties which were cut during dismantling e After completing your work before renewed start up of the mobility device check all connections for tight fitting e After completing your work before renewed start up of the mobility device check all parts for correct locking e Only operate the vehicle with the approved tyre pressures see technical data e Check
51. nit as described in chapter 113 SERVICE MANUAL Invacare STORM MAX 114 e Loosen and remove the nut 1 from the hexagon socket head bolt 6 on the spring e Remove the washer 9 e Remove the hexagon socket head bolt 6 In doing so please pay attention to the washer 8 and the spacer 7 e Remove the plastic cover 4 e Loosen and remove the torx screw 3 e Remove the spacer 2 e Remove the entire wheel suspension 5 from the axle Refitting the wheel suspension e Refit the parts in reverse order e Toconclude you should always carry out a trial run to test the vehicle functions Invacare STORM MAX SERVICE MANUAL 7 21 7 21 1 0 A WW Replacing the strut Removing the suspension strut Note Invacare always recommends replacing both struts in order to ensure that the mobility aid works perfectly WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges Requirements e 4mm Allen key e 6mm Allen key e 13mm socket spanner e long wooden blocks min 14 x 14 x 30 cm 115 SERVICE MANUAL Invacare STORM MAX 116 Dismantling the strut Remove the rear an
52. niten cccte ct tcce leet sce tenccctbecteited eat cendewes see dtee eet eetante dete eee wc pen deteenete de ceecedeetecsne 82 Adel Adjusting the bet Pakoren edie atti edited de eal itlad ie dees 82 7 11 2 Adjusting asling backrest 000 ccses sed deniece tence deeiieeedeldnneeeetaneedeeliieeetsieeedetianedaes eines 83 Invacare 7 12 7 13 7 14 7 15 7 16 7 17 7 18 7 19 7 20 7 21 STORM MAX SERVICE MANUAL 7 11 3 Replacing the CroSs DraCe Sinine anae eaaa aaa aaa aaa 84 7 11 4 Replacing a standard backrest occitanie S A E 85 Fitting the headrest ssssnsssnunnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nn nnnn nnmnnn nnmnnn nnmnnn nnna 86 7 12 1 Fitting the headrest to the standard back sssesesssssrssesrrsseesrrssetrrssrtrnssenrssrrnnssrennne 86 Installing ArMTeSts meeaiinineoei iiei aeon nien en AR EAER EREINA AANO AERE ERNE ATEREA R i 87 Installing a footrest susssssseunnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn nnmnnn nnmnnn nnmnnn naa 89 Installing calf SUPpottS sssssssnnenunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn nnmnnn nnmnnn nannaa 90 Replacing the front wheel carrier ccccssecceceseeeeeeeeeeeeeennneeeeenneaeeeensneeeeeenseeeeeeeseeeeeenseeeeeenas 91 7 16 1 Replacing the front Wheel Carriel eee ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeaeeeseeeaeeeseeaeeeeeeaaees 91 Front WHOSLIOTKS oraire ioanen aa EE
53. ns are intended to prevent accidents at work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information 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 e 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 e 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 e Always wear acid proof safety gloves when working on any defective or possibly defective batteries 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 e 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
54. nside of the battery box e G Trac 4 The G Trac sensor is located inside of the battery box directly next to the power module 16 Invacare STORM MAX 4 2 Electronics modules SERVICE MANUAL 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 The following remotes can be connected Power module ACS 2 PMA9SOL Actuator module ACT 2 ACT 4 Lighting PCB G Trac sensor REM 24 SD REMA REMB REM 550 The actuator module is optional The lighting PCB is optional The G Trac sensor is optional 17 SERVICE MANUAL Invacare STORM MAX 4 2 1 4 2 2 4 2 2 1 ACS 2 PMAQOL electronics module Connections 1 Battery 24V 2 Cable to G Trac module GYRO 3 Bus cable to remote or ACT T pis 4 Motor M1 LA gt asm 3 iy 5 Light 6 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 ACT 2 actuator module Connections AL E a 1 ACI eo oa pal f 2 Bus cable to remote or ACT 3 Bus cable to remote or ACT 7O T 4 Adjusting motor ac
55. ode if the air is not released from the tyre before removing the wheel e Always release the air from the wheel before you remove it Depress the small tappet in the centre of the valve e Press the spring pin on the valve and remove the air completely from the tyre e Undo the five 6 mm Allen screws 4 on the inside of the wheel e Release the inner 3 and outer rim ring 6 from the tyre 1 e Remove the inner tube 5 from the tyre e Replace defective or worn parts or repair the parts Refitting the tyres e Refit the inner tube in the tyre NOTE ED If the old inner tube is to be repaired and used again and has become wet during repair installation can be facilitated by applying some talcum powder to the inner tube e Refit rim rings 3 and 6 to the tyre Please ensure that the boreholes and thread for the screws are exactly above each other e Fill some air into the inner tube e Refit the five Allen screws on the inner side of the wheel and tighten them e Check the exact fit of the tyre on the rim e Inflate the tyre to the prescribed air pressure e Re check the exact fit of the tyre on the rim e Screw the valve cap back on e Refit the wheel 101 SERVICE MANUAL Invacare STORM MAX 7 18 2 2 Replacing puncture protected tyres Note gd Pneumatic tyres have black valve caps Puncture protected tyres have red valve caps 4 Requirements ia e 6mm Allen key e Two long wooden blocks
56. osition from which they were taken or fit new brushes Refit the plastic caps and tighten them firmly Refit the drive wheels as described in chapter 7 18 1 Note i The following procedure is necessary to run the carbon brushes in after replacement and thus guarantee maximum performance A WARNING Risk of accidents Hazards to workers surroundings and mobility device Do not leave the mobility device unattended during the following procedure Secure the area Lift the mobility aid up on one side and get a second person to place a wooden block around 14 cm high underneath it so that the drive wheel is suspended freely Also repeat this on the other side of the mobility aid Allow the motors to run for an hour in forward direction Allow the motors to cool down for 30 minutes Allow the motors to run for an hour in reverse direction Lift the mobility aid off the wooden blocks 109 SERVICE MANUAL Invacare STORM MAX 7 19 3 Replacing Bowden cables and the clutch A Wd 110 WARNING Danger of crushing The wheelchair is very heavy Danger of injury to the hands and feet e Leta second person help you Danger of injury due to uncontrolled movement of the wheelchair e Switch the vehicle s power system off ON OFF key e Engage the drive motors e Secure the vehicle against rolling away by placing wedges under the wheels CAUTION Danger of crushing The motor gearbox unit
57. ow electronics again to cool down Motor runs None High motor load Stop journey and but loses allows the power allow electronics power module to lower to cool down the voltage Motors stop None High motor load Leave mobility aid and do not allows the power switched on and start again module to lower let the power the voltage module operate Charge batteries overnight with mobility aid switched on None Fuse burnt out Check cabling and See chapters 7 3 5 and replace fuse 7 3 4 None Motor defective Check carbon See chapter 7 19 2 brushes and replace if necessary Replacing the See chapter 7 19 1 motor None Power module Replace power See chapter 7 4 2 defective module Motors lose None Bad connections Switch mobility aid See chapter 7 3 5 power off wait 10 during seconds switch journey mobility aid on again Check all cabling Motor None Carbon brushes Check carbon See chapter 7 19 2 judders or worn brushes and runs replace if irregularly necessary or T one Bearing Replacing the See chapter 7 19 1 ern defective motor Collector Replacing the See chapter 7 19 1 defective motor 27 SERVICE MANUAL 28 Invacare STORM MAX PROBLEM OTHER POSSIBLE SOLUTION Documentation SYMPTOMS CAUSE Motors do None Bad connections Check all cabling See chapter 7 3 5 notrun Fuse burnt out Check cabling and See chapters 7 3 5 and replace fuse 7 3 4 Batter
58. rews 1 into the fixation tubes and tighten them 89 SERVICE MANUAL Invacare STORM MAX 7 15 Installing calf supports i Requirements palais e 5mm Allen wrench e T30 Torx wrench e 10 mm socket wrench e Install the calf supports as shown in the illustration above e Attach the fixation bracket 1 of the calf support to the wheelchair using the hexagon socket head screws 2 e The angle of the calf supports can be adjusted by loosening the screws 3 The cover 4 has openings so that the screws are accessible 90 Invacare STORM MAX SERVICE MANUAL 7 16 7 16 1 A iW Replacing the front wheel carrier Replacing the front wheel carrier WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle 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 i n a hz ot f ee Fa y B F j oF A om a i i I i La H n ir lf o aa P r p Dismantling the front wheel carrier e With the aid of a second person jack up the mobility aid using several
59. rking on the battery terminals ATTENTION Danger of crushing The batteries are extremely heavy This results in injury hazards to your hands e Bear in mind that the batteries are sometimes very heavy e Please handle the batteries with care WARNING BURN HAZARD Injury hazard due to discharged acid e Always wear acid proof protective gloves when handling batteries e Always wear protective goggles when handling batteries What to do if acid is discharged e Always take clothing which has been soiled by or dipped in acid off immediately e Rinse any areas of your skin which has come into contact with battery acid off immediately with plenty of water If contact with eyes is made e Rinse the affected eye under running water for several minutes You should also consult an eye specialist immediately afterwards Requirements e 11mm socket spanner Removing the batteries e Make the batteries accessible as described in chapter 7 3 1 Invacare STORM MAX SERVICE MANUAL e Remove the pole caps 1 on the accessible battery 3 e Remove the pole screws located under the pole caps using an 11 mm socket spanner e Remove the connecting cable 4 and the fuse cable 2 e Lift the battery from the battery carrier e Pull on the strap of the second battery to move it forward e Dismantle the cables on the second battery as well e Lift the second battery from the battery carrier Refitting the
60. rom a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges ATTENTION Danger of crushing The motor gearbox unit is extremely heavy Injury hazards to hands e Please note the high weight Requirements e Smm Allen key e 6mm Allen key e 19mm socket spanner e long wooden blocks min 14 x 14 x 30 cm Removing the motor transmission unit e Remove the rear and the centre battery compartment cover as described in chapters 7 1 1 und 7 1 2 e Pull the motor plug out of the power module e Open the cable clamps and expose the motor cable e Remove the drive wheel as described in chapter 7 18 1 e Remove the wheel hub as described in chapter 7 18 3 e Remove the splash guard as described in chapter 7 1 5 Invacare STORM MAX SERVICE MANUAL Pid e Undo the four Allen screws 1 with a 5 mm Allen key e Remove the screws together with the Nord Lock lock washers e Undo the Allen screw 4 with a 5 mm Allen key e Remove the screws together with the washers e 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 unit Refitting the motor transmission unit e Replace the defective parts e Refit the motor transmission unit in reverse order e Toconclu
61. rse order e Check all vehicle functions 43 SERVICE MANUAL Invacare STORM MAX 7 3 7 3 1 A A Ser p gt iW 44 Batteries cables amp battery charger Making the batteries accessible ATTENTION Injury hazard and possible material damages if batteries are handled improperly e The installation of new batteries may only be carried out by authorised specialists e Observe the warning information on the batteries e Only use battery versions stated in the specifications ATTENTION Fire and burns hazard if battery terminal is bypassed e Please take great care to ensure that the battery terminals are never short circuited with tools or mechanical mobility device parts e Ensure that the battery terminal caps have been replaced if you are not working on the battery terminals ATTENTION Danger of crushing The batteries are extremely heavy This results in injury hazards to your hands e Bear in mind that the batteries are sometimes very heavy e Please handle the batteries with care WARNING BURN HAZARD Injury hazard due to discharged acid e Always wear acid proof protective gloves when handling batteries e Always wear protective goggles when handling batteries What to do if acid is discharged e Always take clothing which has been soiled by or dipped in acid off immediately e Rinse any areas of your skin which has come into contact with battery acid off immediately wit
62. s 5 to the screws from underneath e Use a 5mm Allen key and a 10mm socket spanner to tighten the screws and the cap nuts e Fit the headrest in the guide bar 86 Invacare STORM MAX SERVICE MANUAL 7 13 Installing armrests i Requirements e 4mm Allen wrench e T30 Torx wrench e 10 mm socket wrench e Rubber hammer a W ai ee w i at 5 0 Li e Install the armpad as shown in the illustration above e Install the armrest as shown in the illustration above e Attach the armrest along with the holder 1 to the mounting bracket 2 Utilize the screws 3 for this purpose By selecting different holes in the mounting bracket 1 the depth of armrest can be adjusted e Insert the armpad into the armrest and secure it using the screw 4 87 88 SERVICE MANUAL Invacare STORM MAX a j R T i J a 3E E 4 gG r t s i a A oy d ta Se 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 armrests and tighten them Invacare STORM MAX SERVICE MANUAL 7 14 Installing a footrest Requirements da e 5 mm Allen wrench e T30 Torx wrench e 10 mm socket wrench e Insert the braces 3 of the footrest 2 into the fixation tubes Pay attention to the correct height while doing so e Insert the four hexagon socket head sc
63. s or send the battery charger to Invacare Service for repair 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 mobility aid Replace the batteries See chapter 7 3 2 Invacare STORM MAX SERVICE MANUAL 7 Repair work 7 1 Covers 7 1 1 Opening the rear cover panel Refitting the front cover panel e Loosen and remove the two knurled thumb screws 1 on the left and right side of the rear casing e Carefully raise the rear cover The front part of the cover is held at the top by means of a Velcro strip You must also release this Refitting the rear cover panel e Refit the parts in reverse order e Tighten the knurled thumb screws hand tight 33 34 SERVICE MANUAL 7 1 2 Opening the centre panel Invacare STORM MAX Requirements y e 4 mm Allen key 7 ee e am f 3 Wis r j lt i M Dismantling the centre panel e Remove the rear cover as described in chapter 7 1 1 e f possible use the lifter to move the seat to the uppermost position e Loosen the two Allen screws 1 using a 4 mm Allen key Invacare STORM MAX SERVICE MANUAL e Liftthe rear part of the cover carefully and remove the two spacers that are underneath the cover on the Allen screws e
64. scribed in chapter 7 4 6 e If anew software version is available update the drive program as described in chapter 7 5 54 Invacare STORM MAX SERVICE MANUAL e Adapt the drive program using the programming software if necessary e To conclude check all the mobility aid functions 55 SERVICE MANUAL Invacare STORM MAX 7 4 3 MW 56 Replacing the actuator module under the seat The actuator module is optional Requirements e 4mm Allen key Removing the actuator module e Remove the seat as described in chapters 7 6 1 and 7 6 5 e 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 e Pull the plug 1 out of the actuator module e Loosen both hexagon socket head screws 2 e Replace the actuator module Refitting the actuator module e Refit the parts in reverse order e Plug all the plugs into their old positions e To conclude check all the mobility aid functions Invacare STORM MAX SERVICE MANUAL 7 4 4 Replacing the lighting PCB Replacement is described in the following section based on the example of a mobility aid with an optional lighting PCB Requirements cal e 4mm Allen key e 8mm socket spanner Dismantling the lighting PCB e Remove the seat as described in chapters 7 6 1 and 7 6 5 e Remove the rear and the centre cover as described in
65. seeeeeeenseaeeeenseeeeeenseeneeenas 12 2 2 Personal Safety CQUIPMENL cceeeeeceeeseeeeeeenneeeeenneee seen seen eeeesneeeeeenseeeseenseeeeeenseeeeeenseeeeeenees 12 2 3 General safety information and information about fitting removal csseeeeeeees 12 3 Tightening torques 15 4 Layout of components and componentry 16 4 1 010 2 ese eo iO ee ee eee 16 4 2 Electronics modules cceccecsseeeceenseeeeeeensneeeeenseeeeeensneeeeensneeeeensneeeeenseeeeeeenseeeeeenseeeenenseeeeeeans 17 4 2 1 ACS 2 PMAQ0L electronics MOdUIe eren a aa a aa ESE Eaa 18 A22 AGT actuator Mod le en eaa a a a a a aea a 18 4 2 2 1 ACT 2 actuator MOdUIe c ccccccecceceeecceeceece cece seeseaeeeceeeeesesneaeeeseeeeeeeeseesinaeeeeees 18 4 2 2 2 ACT 4 actuator module sccciee set e ied Sei ae ee eas 18 4 2 3 Lighting PCB 222nnin ee wea lie ane aed ete lve ate 19 4 3 Joystick DOXCS wicieteciche cee ie cel cetctte venta ce leet antec catieas ene tnaitdetdets euzaceeetetdeusrezaceeueeuvacuestdundousrandeuzees 20 5 Service plan 1x annually 22 6 Operational faults 25 6 1 Drive fault diagnosis ceeeceeeeeee cece eee ee eeneee eee nnee eee nena sees neee see neee see seeeseenseaeeeenseeeeeenseeeeeenees 26 6 2 REM remotes Error codes and diagnostic codes cccseeececeeeeeeeeeeeeeeeeeeseeeeeenseeeeeenseeeeeeenes 31 6 3 Diagnosis of Charging device faults ceecccceceeeeeeeeeeeeeeenseeeeeenseeeeeenseeeeeeenseeeeeenseeeeeenseen
66. t the holes and threads for the screws are positioned exactly on top of each other e Inflate the inner tube with a little bit of air e Insert the five hexagon socket head screws on the inner side of the wheel and tighten them firmly e Check that the tire is positioned correctly on the rim e Inflate the tire to the prescribed pressure e Check once more that the tire is positioned correctly on the rim e Screw the valve cap back on e Re install the wheel Invacare STORM MAX SERVICE MANUAL 7 18 7 18 1 A Vi L Drive wheels Replacing the drive wheel WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges Note In most cases 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 e 6mm Allen key e Long wooden blocks min 14 x 14 x 30 cm Removing the drive wheel e Lift the mobility aid up on one side and get a second person to place a wooden block around 14 cm high underneath it so that the drive wheel is suspended freely e Loosen the four or five 6 mm Allen screws 1 e Take the wh
67. the cable or cables so that there is no longer any cable connection between the seat and the chassis Remove the pin retainer 1 Remove the bolt 2 67 SERVICE MANUAL Invacare STORM MAX e Swing the brace 6 forwards e Remove the bolt retainer clip 5 e Remove the bolt 4 e Fold back the entire seat e Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 e _Lift the seat and the seat support from the vertical column Refitting the seat carrier e Refit the parts in reverse order e To conclude check all the mobility aid functions 68 Invacare STORM MAX SERVICE MANUAL 7 6 4 Adjusting the seat tilt on a seat with a manual tilt module from Dec 2010 A WARNING Danger of crushing The seat and frame are very heavy and can fall down without warning if the seat tilt adjustment assembly is screwed apart too far Danger of injury to hands and feet e Make sure that you only adjust the seat tilt to a maximum of 25 Requirements ald e 19mm open end wrench e Protractor e Apply the open end wrench to the hexagon bolt 6 of the tilt adjustment e Turn the tilt adjustment until the desired angle or a maximum of 25 is reached 69 SERVICE MANUAL Invacare STORM MAX 7 6 5 Replacing the seat support with electric tilt module A WW 70 CAUTION Danger of crushing The seat seat support are very heavy Yo
68. tment cover as described in chapter 7 1 3 e Remove the seat as described in chapter 7 6 1 or 7 6 5 respectively e Obtain the aid of a second person to place the mobility aid on its side and safeguard it against overturning 73 SERVICE MANUAL Invacare STORM MAX e Loosen and remove the four torx screws 3 on the underside of the chassis 2 e Remove the lifting column 1 Refitting the lifting column e Refit the parts in reverse order e To conclude check all the mobility aid functions 74 Invacare STORM MAX SERVICE MANUAL 7 8 Seat height adjustment 7 8 1 Adjusting the seat height with a manual lifter pillar A WARNING Danger of crushing The seat is very heavy Injury hazard to hands and feet e You should seek help from a second person A WARNING Danger of crushing Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive Requirements aan e 4 mm Allen key e T40 torx wrench e Oblique pliers e Cable ties Manual seat height adjustment e Remove the seat as described in chapter 7 6 1 or 7 6 5 75 SERVICE MANUAL Invacare STORM MAX 76 e Loosen and remove the four torx screws 2 on the underside of the column 3 e Lift off the coverplate 1 Note The cover plate has four flaps pointing downward There are two tapped holes on each flap for the screws 2 By selecting the
69. 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 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 Invacare STORM MAX SERVICE MANUAL 1 3 D 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 e 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 e 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 an
70. tuator Channel 2 5 Adjusting motor actuator Channel 1 The ACI connection is used for actuator limitation or speed reduction 4 2 2 2 ACT 4 actuator module 18 Connections E a a 1 ACI ore and arm jm om a 2 2 Bus cable m to remote or power module 3 Bus cable lt x z ae to remote or power module Actuator Channel 4 z 8 4 5 Actuator Channel 3 6 Actuator Channel 2 7 Actuator Channel 1 The ACI connection is used for actuator limitation or speed reduction Invacare STORM MAX SERVICE MANUAL 4 2 3 Lighting PCB Connections 1 Driving light amp I h indicator 1 2 Driving light amp I h indicator 2 3 Power module 4 Driving light amp r h indicator 1 5 Driving light amp r h indicator 2 The lighting PCB connections are printed directly on the circuit board 19 SERVICE MANUAL Invacare STORM MAX 4 3 20 Joystick boxes Various remotes can be used on the mobility aid Before you connect any mobility 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 pre pn pee ooo REM 24 SD Can be connected to power module ACS 2 PMAQOL Can be connected to power module ACS 2 PMAQOL Invacare STORM MAX SERVICE MANUAL pre pon pee ooo REM B Can be connected to power module ACS 2 PMAQOL
71. u should seek help from a second person who can secure the seat and help when carrying Requirements T40 torx wrench oblique pliers cable ties Dismantling the seat support Remove 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 the headlight mountings using an 8 mm jaw spanner see chapter 7 2 3 Put the headlight and the mounting in a safe place on the rear part of the battery compartment cover Remove the connecting cable to the chassis from the remote or form the optional actuator module Remove the cable or cables so that there is no longer any cable connection between the seat and the chassis Remove the pin retainer 1 Remove the bolt 2 Invacare STORM MAX SERVICE MANUAL e Swing the tilt actuator 6 forwards e Remove the bolt retainer clip 5 e Remove the bolt 4 e Remove the tilt actuator 6 e Fold back the entire seat e Keep a firm hold on the seat and the seat support whilst loosening and removing the four torx screws 3 e Liftthe seat and the seat support from the vertical column Refitting the seat carrier e Refit the parts in reverse order e To conclude check all the mobility aid functions 71 SERVICE MANUAL Invacare STORM MAX 7 6 6 Replacing the tilt actuator 4 Requirements all e
72. ug and socket or take a photograph with a digital camera e Loosen the cable leading to the lighting PCB from the front headlight affected 2 e Open the cable clamps 1 remove all cable ties and pull the cable out of the mobility aid 39 SERVICE MANUAL Invacare STORM MAX 40 e Loosen the Allen screw 1 using a 3 mm Allen key and remove the headlight from the mounting e Replace the headlight unit Refitting the front headlight e Refit the parts in reverse order e Lay the cables carefully and fasten them using the cable clamps and cable ties In doing so please pay attention to chapter 7 3 6 e Now tighten all the screws finger tight again e Check all vehicle functions e Adjust the headlight roughly using the grid The user can carry out the final adjustment following the operating manual Invacare STORM MAX SERVICE MANUAL 7 2 3 Replacing the front bulb holder LED lighting unit Requirements da e 4 mm Allen key e 8 mm spanner Dismantling the bulbholder e Loosen the Allen screw 1 using a 4 mm Allen key and remove the headlight from the mounting e Loosen the two cap nuts 2 using an 8 mm spanner and remove the headlight with the mounting from the rubber bumpers e Replace the mounting Refitting the bulbholder e Refit the parts in reverse order e Now tighten all the screws finger tight again e Check all vehicle functions e Adjust the headlight roughly using th
73. upper left recess 3 e Make sure the cable has enough play so that all movable parts can move freely without stretching clamping or abrading the cable e Lay the cables in the same way under the seat and to the remote Fasten the cables with the prescribed cable clamps or cable ties respectively 52 Invacare STORM MAX SERVICE MANUAL 7 4 7 4 1 id 7 4 2 iW Electronics module Replace remote Note Replacing the remote is very easy and is not described in detail However when replacing a remote in connection with the power module please take the final selection of the drive program into account as described in chapter 7 4 6 Replacing the power module Note When replacing the power module in connection with a remote please take the final selection of the drive program into account as described in chapter 7 4 6 Different power modules in connection with different remotes can be fitted to the mobility aid The possible power modules are described in chapter 4 2 Replacement is described in the following section based on the example 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 mobility aid e Changes to the drive program may only be carried out by trained Invacare specialist dealers e Invacare can only give a warranty for safe mobility a
74. void injury to the user or damage to the product Wear safety shoes The symbol refers to the requirement for wearing safety shoes e 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 e 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 e 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 e 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 Invacare STORM MAX SERVICE MANUAL 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 11 SERVICE MANUAL Invacare STORM MAX 2 1 12 Safety and fitting instructions These safety instructio
75. wooden blocks e Use a screwdriver to remove the plastic cap 6 e Loosen and remove the Allen screw 2 with a 5 mm Allen key e Loosen and remove the Allen screw 5 with a 17 mm Allen key e Remove the two Nord Lock lock washers 4 e Remove and replace the front wheel carrier 3 91 92 SERVICE MANUAL Invacare STORM MAX Refitting the front wheel carrier e Refit the parts in reverse order e Use Loctite locking varnish to secure the Allen screw 2 e Tighten the Allen screw 2 to 25 Nm e Tighten the Allen screw 5 to 200 180 Nm e To conclude check all the mobility aid functions Invacare STORM MAX SERVICE MANUAL 7 17 Front wheel forks 7 17 1 Replacing the wheel fork A WH WARNING Danger of crushing The mobility device is very heavy Injury hazard to hands and feet e You should seek help from a second person Injury hazard caused by uncontrolled movement of the mobility device e Switch the power supply off ON OFF key e Engage the drive e Before raising the vehicle secure the wheels by blocking them with wedges Requirements e 19mm socket spanner e blade screwdriver e long wooden blocks min 14 x 14 x 30 cm Dismantling the wheel fork e Prop up the wheelchair on multiple wooden blocks with the help of a second person e Remove the plastic cap 1 with a screwdriver e Use the 19 mm socket wrench to loosen and remove the nuts 2 e Pull the wheel fork 6
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