ARJO MAXI MOVE Maintenance and Repair Manual rev 0 July 2008

© ARJO International AB 2008 ARJO products are patented or patent pending. Patent information is available by contacting ARJO International AB. Our policy is one of continous development, and we therefore reserve the right to make technical alterations without notice. The content of this publication may not be copied either whole or in part without the consent of ARJO International AB.

Table of Contents Safety Instructions ...5 General ... 5

Product and Technical Description ...6 Introduction ... 6 Features ... 6 Combi Feature ... 6 Risk Assessment Checklist for Engineers ... 7 Suggested Tools ... 8 Recommended Spares ... 8 Loctite Application ... 9 Torque Data and Consumable Materials ... 10

Preventive Maintenance Schedule ...12 Service Procedures ...17 Procedures not Included in the PMS ... 17 Service Procedure 1 ... 18 Check that the latest updates have been implemented ... 18 Service Procedure 2 ... 19 Check the battery ... 19 Battery test ... 19 Check the battery charger ... 20 Service Procedure 3 ... 21 Check all vital parts for corrosion and damage ... 21 Painting ... 21 Service Procedure 4 ... 22 Full Feature Test ... 22 Service Procedure 5 ... 23 Safe Working Load Test (local Requirement) ... 23 Service Procedure 6 ... 26 Scale Calibration Check ... 26 Verified Scale ... 26 Verified Scale and Non-Verified Scale ... 26 Service Procedure 7 ... 27 Wheel Replacement ... 27 Front ... 27 Back ... 28 Service Procedure 8 ... 29 Changing the Leg Assembly/Actuator ... 29 Chassis opening ... 29 Legs ... 29 Legs Actuator ... 29 Reassembly ... 30 Service procedure 9 ... 31 Legs opening adjustment ... 31 Verification ... 31 Adjustment ... 31 Service Procedure 10 ... 32 Control box (PCB, Fuse, Switch, Keypad) ... 32 Opening the Control box ... 32 Fuse change ... 32 Main board changes ... 32 DIP Switch Settings ... 34 Configuration procedure ... 34 Changing the Brake board ... 36

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Table of Contents Changing the Switch ... 36 Closing the control box ... 37 Service Procedure 11 ... 39 Replacing the Handset ... 39 Service Procedure 12 ... 40 Replacing the Maxi Move Strap ... 40 Strap removal ... 41 Top Cover reassembly ... 44 Verification ... 45 Service Procedure 13 ... 46 Replacing the Mast Actuator ... 46 Removing the Mast ... 46 Removing the Actuator ... 47 Installing the Mast ... 48 Service Procedure 14 ... 49 Replacing/Adjusting the Handle ... 49 Removing the Handle ... 49 Replacement ... 50 Adjustment ... 50 Service Procedure 15 ... 51 Changing the Limit Switch ... 51 Anti-crush / Lower Limit ... 51 Upper limit ... 52 Service Procedure 16 ... 54 Slider Adjustment Replacement ... 54 Adjusting Sliders ... 54 Upper slider ... 54 Lower slide ... 55 Replacing Sliders ... 55 Service Procedure 17 ... 56 Jib / Jib roller / Jib cover ... 56 Jib removal ... 56 Jib Reinstallation ... 56 Jib roller change ... 56 Changing the Jib Top Cover ... 57 Service Procedure 18 ... 58 Combi Attachment ... 58 Inspection ... 58 T-Bar removal ... 59 T-Bar installation ... 59 Service Procedure 19 6... 0 Scale Removal/Installation ... 60 Removing the Scale ... 61 Installing the Scale ... 61 Service Procedure 20 ... 62 Combi Spreader Bars ... 62 Stretcher ... 62 Four-Point DPS Pivot Point ... 63 Four Point DPS (Combi) ... 63 Four-Point Powered DPS Spreader Bar ... 64 Sling Checks ... 66

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Safety Instructions General A. ARJO strongly advise that only ARJO designated parts, which are designed for the purpose, should be used on equipment and other ARJO supplied appliances to avoid injuries attributable to the use of inadequate parts. ARJO’s conditions of sale make specific provision confirming no liability in such circumstances. Our policy is one of continuous development, and we therefore reserve the right to change specifications without notice. B. Unauthorized modifications on any ARJO equipment may affect its safety and are in breach of any warranty on it. ARJO will not be held responsible for any accidents, incidents or lack of performance that occur as a result of unauthorized modifications to its products. C. If the terms listed below are used in the text their meaning is as follows: DANGER

Means: Electrical hazard warning, failure to understand and obey may result in electrical shock. WARNING

Means: Failure to understand and obey may result in injury to you or to others. CAUTION

Means: Failure to follow these instructions may cause damage to all or parts of the system or equipment. NOTE

Means: This is important for the correct use of this system or equipment.

D. Dangerous substances. If using hazardous substances be sure how to handle these and refer to applicable information. In doubt refer to the local authorities for health and safety requirements.

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Product and Technical Description Introduction The Maxi Move is a mobile patient lifter and is used for transferring patients from bed or chair to the toilet or bath. The floor lift has a maximum safe working load (SWL) of 227 kg (500 lb). NOTE: The SWL will depend on the lift’s configuration and attachments. Always refer to the maximum SWL of the lowest rated attachment.

Each Maxi Move is supplied with two 24V rechargeable batteries and a charging unit.

Features The features of the Maxi Move floor lift include: • Immediate stop/reset switch • Overload circuit • Overload current limit protection in the PCB • Upper limit switch • Lower limit switch/anti-crush • Control panel on the unit • Emergency manual wind down • Handset LCD display • Audible low-battery warning The raising and lowering mechanism comprises an electromechanical linear actuator powered by a 24VDC motor. The leg opening and closing mechanism comprises a 24VDC motor and a double-ended actuator (legs open independently).

Combi Feature The Maxi Move with the ‘Lock & Load’ (combi attachment) has the facility to accommodate: • A two-point spreader bar for use with a loop sling to support patients with contracted (restricted movement) or ‘windswept’ (deformed) limbs and walking slings. • A two-point loop small. • A two-point loop medium. • A four-point loop large. • A four-point spreader bar Dynamic Positioning System (DPS) for general lifting (small, medium and large). • A 4 point powered spreader bar Dynamic Positioning System (DPS) for general lifting (medium and large). • A stretcher system for handling dependent, fragile patients with a minimum of disturbance (SWL 160kg (350 lb)).

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Product and Technical Description Risk Assessment Checklist for Engineers WARNING: IF IN DOUBT, CONTACT YOUR LOCAL ARJO REPRESENTATIVE. DO NOT TAKE UNNECESSARY RISKS.

The following assessment MUST be made before carrying out servicing, repair work or installations: • Make sure the work area is adequately sized, suitably lit and at a reasonable temperature. • The floor surfaces must be free from clutter, unevenness and non-slip. • Use good engineering and manual handling practices to keep risk of injury at its lowest level. • Tools and equipment must be kept in good condition. • Wear protective clothing and eye protection where necessary. • You should be adequately trained to perform the task. • Do not manually lift items that could cause personal injury, that is too heavy, hot or sharp. • You must comply with all local site safety rules, report any incident or accident to the site safety supervisor or equivalent. Use the ARJO reporting procedure. • If necessary use Hard Surface Wipes (Alcohol Impregnated) to decontaminate a machine before carrying out any work. NOTE: The above wipes should be of the type that has proven bactericidal action for disinfecting hard surfaces against MRSA & E.COLI.

• Load tests must only be applied as instructed in the relevant procedure. • If it is necessary to work from a platform (i.e. scaffold, ladders etc.) to perform a service or installation task make sure the platform is secure and suitable for the task. DANGER – Electrical Shock can kill.

• Do not perform maintenance tasks on equipment with ‘live’ electrical connections unless absolutely necessary. • Isolate the power supply before removing plugs, sockets or disconnecting cables. • Be alert at all times to the dangers of working on electrical equipment that operates on mains supply voltage. Where possible, visually inspect electrical cables and plugs etc. for damage or deterioration before working on equipment. • Dispose of all waste in appropriate containers.

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Product and Technical Description Suggested Tools • Standard tool kit. • Special Tool ST252. • 2 x 20kg weights ST219. • Socket Allen key: (4mm ST82) (5mm ST274) (6mm ST55) (8mm ST87). • Drift ST288. • Ball-end Allen key (4mm) ST292. • Starlock Washer Installation Tool (ST295). • Sling Clip Gauge ST331. • Load Test Equipment: refer to Section 11.0.

Recommended Spares Refer to PARTS LIST 001.25070.EN NOTE: This manual is intended to be used in reference to the Maxi Move manufactured in Canada (Serial number KMCXXXXX). For the Maxi Move manufactured in the UK or in Sweden, please refer to: 09.MKM.00/3GB

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Product and Technical Description Loctite Application Refer to the manufacturer instructions on the container before use, in addition to the following information: Procedure for the correct use of Loctite 242 and Loctite 243 (Colour blue) Threadlocking: - Clean both of the joint faces with Loctite 7063 Cleaner or a lint-free cloth moistened with Acetone or another suitable volatile solvent. NOTE: Because Loctite 243 is oil-tolerant, it is not necessary to meet the same standard of oil-free cleanliness as for Loctite 242.

- Apply Loctite 243 sparingly but sufficient to fill all engaged threads. (This product performs best in thin bond gaps [0.05 mm]). - Install the threaded components and where known, torque to the applicable torque figure. If the torque figure is not known tighten to a firm fixing. - Clean off any unwanted adhesive. - Allow the Loctite 243 to cure before subjecting to load. NOTE: The cure time will depend on the materials used, the ambient temperature and the bond line gap.

- Where the cure speed is unacceptably long, or large gaps are present, applying Loctite Activator ‘N’ or ‘T’ to the surface will improve the cure speed. For general Loctite specifications and application details: refer to Loctite manufactures instructions.

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Product and Technical Description Torque Data and Consumable Materials Thread retaining: Apply Loctite 243 when no threadlocking patch has been pre-applied. When replacing a part with pre-applied threadlocking, the part should be replaced by a new part using pre-applied threadlocking.

NOTE: Grease 005.00031: Lenson white grease or equivalent can be used.

Fig.1

10

Product and Technical Description

Fig.2

11

Preventive Maintenance Schedule

Visually inspect the condition of all sling attachment points for damage. If any is found, replace with new unit.

X

X

X

X

Make sure all instruction labels are attached and readable. Replace as required. See “Operating Instructions” for location of labels.

X

X

X

X

Check the condition of the friction discs and bushes within the pivot points. If found worn and/or damaged, parts must be replaced.

S

S

When the friction discs and bushes have been checked/replaced, reset friction assembly to support a 5.4 kg (12 1b) load at the handle.

S

S

Visually inspect all external parts, making sure no damage has occurred during use. Replace parts as required.

S

S

Make sure the unit can be powered through the full range smoothly. Examine all exposed parts, especially where there is close contact with the patient’s body. Make sure no cracks or sharp edges have developed that could cause injuries or become unhygienic. Replace where necessary.

KEY:

S

X

S

X = Action required on the part of the customer

X

S

X

S

S = Action required on the part of a qualified service technician 12

X

S

Every 2 Years

Every 12 Months

Before Every Use

Stretcher Every 2 Years

Every 12 Months

Every Week

Before Every Use

2-4 Point Every 2 Years

Every 12 Months

Every Week

Before Every Use

Powered Every 2 Years

Every 12 Months

Every Week

Action

Before Every Use

Manual

Loop Spreader Bars

Every Week

DPS Spreader Bars

Preventive Maintenance Schedule

X

X

X

X

X

X

X

X

Accessories

X

Examine for damage/fraying to sling, straps and clips; replace as required. Visually examine the battery charger for loose connectors, cut wires, damaged casing etc. Do not use if damaged in any way.

Before Every Use

Battery Charger Every 2 Years

Every 12 Months

Every Week

Before Every Use

Every 2 Years

Every 12 Months

Every Week

Action

Before Every Use

Slings

X = Action required on the part of the customer

Every 2 Years

S

Maxi Move

KEY:

Every 12 Months

Before Every Use

Every 2 Years

Every 12 Months

Every Week

Before Every Use

Every 2 Years

Every 12 Months

Every Week

Before Every Use

Every 2 Years

Stretcher

S X

S = Action required on the part of a qualified service technician 13

S

Every 2 Years

Visually inspect to make sure the leaf spring within the locking clip is correctly installed.

X

2-4 Point

Every 12 Months

Visually inspect that the spreader bar correctly installs on the jib, i.e. that the plastic clip latches into the groove on the “T” part on the jib.

Powered

Every Week

Inspect the condition of the leaf spring and locking clip at the attachment point. Replace if damaged.

Every 12 Months

Action

Every Week

Before Every Use

Manual

Loop Spreader Bars

Every Week

DPS Spreader Bars

Preventive Maintenance Schedule Accessories

X

Operate the lift through its full range from both the control panel and the control handset in a normal and smooth manner.

X

With the jib in the fully lowered position, visually examine the exposed lifting straps on each side of the mast for any cuts or fraying. If damaged in any way, withdraw lifter from use immediately and have lift straps replaced with new ones.

X

Open and close the chassis legs and check for full range of motion and smooth movement.

X

Visually check the condition of the handset and its cable. If damaged, withdraw from service immediately and replace with new cable and handset assembly.

X

Visually check that all external fittings are secure, and all screws and nuts are tight.

X

Make sure all castors rotate freely and that the two rear brakes lock. Replace as required.

X

Make sure all castor-mounting pins are tight on the chassis and chassis legs, and that the castor tread is not damaged. Replace as required.

X

Make sure all instruction labels are firmly attached and readable. Replace as required. See “Operating Instructions” for location of labels.

X

X = Action required on the part of the customer

S

S = Action required on the part of a qualified service technician 14

X

Every 2 Years

Every 12 Months

Every Week

Every 2 Years

Every 12 Months

Every Week

Before Every Use

Battery Charger

S

Recharge battery for a minimum of 15 hours once every seven days. See “Operating Instruction’s” for battery charging procedure.

KEY:

Every 2 Years

X

Every 12 Months

Make sure the battery is in a good state of charge. See “Operating Instructions” for the battery charging procedure.

Every Week

Action

Before Every Use

Slings

Before Every Use

Maxi Move

Preventive Maintenance Schedule Accessories

Examine all exposed parts, especially where there is close contact with the patient’s body. Make sure no cracks or sharp edges have developed that could cause injuries or become unhygienic. Replace where necessary.

S

Test the “Immediate Stop” facility.

S

Mechanically test the “System Failure Wind Down” facility.

S

Where a scale is installed, check the accuracy of the unit and recalibrate if required.

S

Examine the two lifting straps over the entire length. Replace the straps if there is evidence of wear or damage.

S

Perform a torque tightening check.

S

Check the 2.5 kg force required to rotate the jib pivot. Adjust screw if required.

S

Check the gap between the “T” piece flange and jib. If more than 2 mm, replace jib bushes (minimum gap is 1 mm).

S

Verify the width of the legs. First, remove the leg covers. With the legs closed, measure centre to centre at the ends near the front castors. Adjust only if dimension “A” is shorter than 650 mm (25 1/2”).

S

X = Action required on the part of the customer

S = Action required on the part of a qualified service technician 15

Every 2 Years

Every 12 Months

Every Week

Every 2 Years

Every 12 Months

Every Week

Before Every Use

Battery Charger

X

Test the “Automatic Cut-out” function.

KEY:

Every 2 Years

Every 12 Months

Every Week

Action

Before Every Use

Slings

Before Every Use

Maxi Move

Preventive Maintenance Schedule Accessories

It is recommended to replace the two lift straps every 2 years if they are used. If the straps appear damaged or worn before then, replace the straps immediately. Lubricate the two top strap rollers.

S

Check and lubricate the upper and lower mast sliders. Replace if worn or damaged. If necessary, adjust to remove excessive gap in the column.

S

Check and replace as necessary the 4 off jib rollers and 2 off guide blocks if they show signs of wear or damage.

S

Check the combi “T” piece and attachment contacts if fitted. Clean and replace as required.

S

X = Action required on the part of the customer

S = Action required on the part of a qualified service technician 16

Every 2 Years

Every 12 Months

Every Week

Every 2 Years

Every 12 Months

Every Week

Battery Charger

S

Check the Usage Counter and reset if required.

KEY:

Before Every Use

Every 2 Years

Every 12 Months

Every Week

Action

Before Every Use

Slings

Before Every Use

Maxi Move

Service Procedures Procedures not Included in the PMS

Jib/Jib roller- SP 17 Limit switch replacement- SP 15

Scale calibration- SP 6 Scale - SP 19

Strap replacement- SP 12

Combi T-bar attachment- SP 18 Combi spreader bars- SP20

Handset replacement- SP 11 Handle replacement- SP 14

Mast slider replacement- SP 16 Control box- SP 10 Mast actuator replacement- SP13

Leg opening adjustmentSP 9

Battery and charger-SP 2

Wheel replacementSP 7 Leg actuator replacementSP 8

Fig.3

17

Service Procedures Service Procedure 1 Check that the latest updates have been implemented • Check if there are any field correction bulletins, safety notices or technical bulletins that have been published since the last service. (These replace the previously used Technical Advice Notices (TAN) with status A (i.e. safety issue, requiring some form of recall) or B (non-safety issue). • This verification must be done to keep the product up to date according to safety and product improvements. Bulletins and notices can be generated as a result of an engineering change note, a safety incident report or a change to form/fit etc. Example of a Technical Bulletin

Fig.4

18

Service Procedures Service Procedure 2 Check the battery The battery power tester will load the battery with a high current (up to 60 A, depending on battery condition) for a short time and this will show the battery condition on a meter.

WARNING! • The battery power tester will become hot and there is a potential risk of fire. • Make sure the battery power tester is kept away from inflammable material during tests and for several minutes following the test. • Beware of touching the metal casing for several minutes following the test.

Battery test 1) The battery to be tested must be charged for at least 12 hours before test. 2) Connect the tester to the battery. DO NOT operate the test switch! When the tester is connected, switch the test switch right or left for 1-2 seconds and take a quick reading on the meter. 3) The meter will show the battery’s condition. 4) If the battery is OK, place the tested battery back in the charger. Battery tester

Fig.5

19

Service Procedures Check the battery charger 700.24250 1) Connect the cable from the test rig to the charger. • Measure the voltage in the banana plug outlet of the rig. The voltage should be between 27.6 and 28 VDC. 2) Measure the current in the banana plug outlet of the rig. • Turn the knob until the amber led indicator starts blinking. • The current should now be between 0.9 and 1.1A. Battery charger

Fig.6

20