protean 2&3 Service Manual Oct 2010

CONTENTS

Intended use of bed Maintenance Inspection Cycle Maintenance Checklist (Safety Audit) Replacement of Electrical Components Replacement Parts (Obtaining) How to change/repair Chains How to fit mini-fit plugs How to remove covers How to remove/change Control Box How to change Handset How to change Battery Backup How to install Mains Cable How to remove/replace Actuators How to remove/ replace Accessories • Extension Kits • Push Handle • Self Help Pole • IV Pole • Side Rails

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How to fit Side Rails Raise the bed to full height and install 4 x bed brackets using existing bolts on mattress platform rails Loosen handwheel on side rail brackets (2 brackets per side rail) and fit to the bed Pic 2. Make sure side rail brackets are seated correctly in bed brackets Pic 3. Tighten side rail hand wheels and test the side rails for correct function Reverse steps to remove side rails

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WARNING! Service work contained in this manual should only be undertaken by LiftCare trained and authorised service agents. Only LiftCare supplied parts should be used. Failure to comply with the above two items will void warranty and could result in further unnecessary damage to the bed and possible extreme safety hazard to the person occupying the bed and/or caring staff.

LiftCare strongly recommends against the use of side rails as they are known to cause death and injury.

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PURPOSE How to fit Push Handle to foot end of bed Pic 1-Push Handle Kit parts Remove footboard Remove both end caps Remove the ‘snap latch’ lug Remove the small plastic strips on the inside of both pedestal legs. Position the push handle using the bottom two screw holes and secure with 3 x 15mm button head screws and washers Secure 1x25mm screw through the ‘snap latch’ lug back into its original position. Replace end caps and footboard

This document will be made available to LiftCare staff, distributors, agents and authorised LiftCare service providers. It is not for publication or distribution to the public or clients who may use the information to allow other companies or individuals to repair or modify LiftCare products. This document and its contents are intended to be used in the performance of service on LiftCare produced products, i.e. Protean range series products. This document also serves as a reference for office and sales staff in the performance of their duties, i.e. collecting service call information to facilitate the expedient diagnosis of any problems and problem solutions. This document should be read in conjunction with LiftCare’s Operating and Assembly Guides, Instruction Manuals and Spare Parts Catalogues. This document is copyright to LiftCare Beds and must not be reproduced in any form without written permission of LiftCare.

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How to fit Self Help Pole Pic 1. Slide Self Help Pole Nut plate Bracket up into accessory slot in pedestal extrusion Pic 2. Tighten the hex head bolts. Only LiftCare self help poles will fit LiftCare beds

APPLIED STANDARDS

Protean 4 with CPR Quick Release Floor Level Folding Electric Bed with its mechanical and electrical adjustment devices complies with the regulations of the EC Directive 93/42/EEC for Medical Products

This bed is categorised as a Class 1 Medical Product. Applied Harmonized Standards

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Fitting an IV Pole The bed is fitted with four brackets for IV Poles. They are located at each corner of the bed, behind the head and footboards. Only LiftCare IV Poles will fit LiftCare Beds.

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AS/NZS 3200.2.38:2007 Medical Electrical Equipment-particular requirements for safety-Electrically and manually operated medical beds for adult use (IEC 60601-2-38, Ed.1.0(1996) MOD) EN6061-2-38:1998 Medical Electrical Equipment-Part 2 Particular Requirements for the Safety of Electrically Operated Hospital Beds.

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INTENDED USE OF THE BED This bed is designed for use in hospitals, aged care, community care and private homes for the purposes of providing comfort and care for any adult person being ill, frail, disabled or in need of care. The Safe Working Load (SWL) of this bed is 250kg/550lbs/39 stone. Due allowance must be made for the mattress, bedding, accessories or visitors or carers sitting or putting extra weight on the bed, when considering normal maximum patient weight. It is not recommended to use this bed for patients over 200kg/440lbs/31 stone for which LiftCare has other suitable beds with up to 455kgs/1000lbs/71 stone Safe Working Load. This bed may only be operated by persons who have received instructions in its safe operation.

Materials in the bed–the bed is built for the most part from steel, the surface of which has been finished with an electrocoated powder-coating. The head and foot end pedestal covers of the bed are ABS plastic. None of the surfaces are harmful to skin contact. Structural Design-the mattress platform is divided into a back rest, split seat section and on some models, a thigh and calf lift section (Kneebreak or Knee Gatch). The mattress base can be horizontally adjusted in height. The bed can be adjusted to a head-low or feet low (Trendelenburg and Reverse or Tilt position). Chassis– the chassis is constructed of welded steel and features four individually locking castors (3 brake-red) and 1 directional lock (usually green).

ANY OTHER USE OF THIS BED SHALL BE REGARDED AS NONCOMPLIANT WITH THE REQUIREMENTS AND MAY INVALIDATE WARRANTY.

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A handset for use by the patient. The handset consists of a robust, easy-care, wash-down plastic casing with membrane keypad.

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Motors for controlling the adjustment of the backrest and Kneebreak (if fitted) the height of the bed

The central control box unit and battery backup (if fitted), are located underneath the covers at the head end of the bed.

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Electrical Adjustment system– the electric adjustment system of this bed comprises: •

The bed may only be operated under the conditions of duty described in the LiftCare Instruction Manual which is provided with every bed. (Extra copies can be obtained from LiftCare).

fit to the inside face of the platform beams. Pic 9. Fit the extra mattress platform panel supplied with the button head screws and Nyloc nuts. Pic 10. Using two people replace the extended mattress platform, foot end first, ensuring that the nylon bushes are in the hooks-do not over-tighten the locking bolts. Replace the backrest and kneebreak cables into the actuator connectors. Pic 11. Place the mattress and bolster on the bed and check all functions. **NOTE: The standard length brackets which are removed when extending the bed should always be kept in a safe place so the bed can be returned to its original shorter length if required.

THIS MANUAL MAY NOT BE REPRODUCED IN PART OR IN WHOLE WITHOUT THE WRITTEN PERMISSION OF THE PUBLISHER.

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How to remove a mains cable Remove ‘P’ clips (Pic 1#) with a Phillips head screwdriver Lift Control Box up, then out to remove it-then carefully place it on the floor beside the bed to ensure no damage to cables. Remove the cable retainer from the Control Box with a small flat screwdriver Pic2 Remove the mains cable from the Control Box (refer to plug assignment Pic 3) Reverse these steps to install a mains cable

Here a transformer provides a safe low voltage of 24v which is non-harmful for both the patient and user. Connected to central control unit, via dust and moister proof plugs, are all the electric motors and the handset which work on a safe low voltage of 24v.

tions by users (See checklist page 6) As a guideline, it is recommended that regular preventative maintenance occurs and an annual inspection be carried out on all LiftCare Beds.

Baery backup

Handset

Mains

Actuators*

How to fit Extension Kit Check contents of box (Box should contain 1 x mattress bolster; 1 x mattress platform panel; 2 x extension brackets; 4 x button head cap screws; 4 x Nyloc nuts. If any parts are missing please notify LiftCare or your authorised Distributor immediately.) Remove head and footboards and release backrest and kneebreak cables from the actuators by removing the plastic circlip in the connector Pic 1. Loosen mattress platform locking bolts Pic 2. Swing the link brackets away at the head end of the bed and lower mattress platform onto lower beams at the head end. Pic 3. Using two people, remove the mattress platform and place it on a work bench or table. Pic 4. Remove the two circlips on the foot end of the lower beam saddle then remove all 4 pins. Pic 5. Extend the lower beams and replace the four pins in the outermost holes, replace the circlips. Pic 6. Repeat Step 5 at the head end of the saddle (the lower beams are now extended). Pic 7 Remove the mattress platform locking bolts and fit them to the extension brackets. Pic 8. Remove the mattress platform “standard brackets”** at the foot end and replace them with the “extension brackets” supplied. Tabs go underneath the beams; brackets

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Battery backup allows for off-mains power emergency operation (for a limited period of time).

Contact LiftCare for information on the Safety and Condition Audit program

MAINTENANCE Operators of hospital beds are obligated to keep medical products in a safe state throughout their entire service life. This also includes regularly carrying out expert, LiftCare authorised maintenance and safety checks.

As a result of improper operation as well as long-time use, damage, defects, and signs of wear may occur. Such defects can present hazards if not promptly recognised and eliminated.

If damage or a malfunction is suspected, the bed must be withdrawn from service immediately until repairs have been carried out or the defective parts have been replaced. LiftCare suggests regular inspec-

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LiftCare RECOMMENDS REGULAR USER CHECKS OK

Checked

NOT OK

Descrip on of fault

Visual check of the electrical components

Using the two locating pins on the Battery Backup bracket connect the Battery Backup to the Control Box. Pic 6. Relocate the Control Box by sliding the moulded guides of the Control Box into the grooves in the actuator. Actuators

Handset cable

Damage, routing

Mains cable

Damage, routing

Handset

Damage, membrane

Baery backup

Handset Visual check of the mechanical components

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Mattress Platform is parallel to floor (ie level)

Mains

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Damage

Bolts, fasteners, screws

Check & tighten regularly

Chassis

Damage, deformations

Mattress Platform, covers

Damage

Pic 5 Check for rust or corrosion.

Damage

Castors

Damage

Bed Extension

Damage

NOTE: Always number the actuator plugs with black pen on the cables before removing actuators from the control box. Some bed are not fitted with Kneebreak so third port may be empty.

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How to remove a handset

Performance check of the electrical components Backrest

Adjustment, secure retention

Kneebreak (if fitted)

Adjustment, secure retention

Platform Hi/Lo

Adjustment, secure retention

Battery Backup ( if fitted)

Check fully charged & operational

Handset

Adjustment, secure retention

Accessories (eg: Self Help Pole, side rails)

Fastening, damage

Signature of the Inspector:

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Name of Inspector:

Inspection result:

Date:

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Pic 1. Remove ‘P’ clips with a Phillips head screwdriver Pic 2. Lift Control Box up, then out to remove it-then carefully place it on the floor beside the bed to ensure no damage to cables. Pic 3. Remove the cable retainer from the Control Box Pic 4. Remove the handset plug from the Control Box (see Plug Assignment Pic 1 top of this page ) Reverse these steps to replace/install a handset

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MAINTENANCE CHECKLIST - EXPLANATORY NOTES How to remove main bed lift actuators (Hi/Lo) Head and foot end. Remove plastic inner cover (See page 12 Pics 2,3,4) Pic 1. Lower pedestal end onto two blocks of timber (not supplied) approximately 250-300mm in length Pic 2. Remove ‘P’ clips (cable retainers) with a Phillips head screwdriver. Pic 3 & 4. Lift Control Box up and out to remove it - then carefully place it on the floor beside the bed to ensure no damage to cables. Pic 5 Remove circlip and pin from base of actuator anchor point Remove counter-sunk screw from the top of the actuator Reverse these steps to replace or install an actuator

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How to remove a Control Box Pic 1. Remove ‘P’ clips (cable retainers) with a Phillips head screwdriver Pic 2. Lift Control Box up, then out to remove it-then carefully place it on the floor beside the bed to ensure no damage to cables. Pic 3. Remove the cable retainer from the Control Box with a small flat screwdriver

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How to add a battery backup-(if bed is fitted with Charge Circuit Control Box (see Page 15 Pic 1). Pic 2. Remove ‘P’ clips (cable retainers) with a Phillips head screwdriver Pic 3. Lift Control Box up, then out to remove it-then carefully place it on the floor beside the bed to ensure no damage to cables. Pic 4. Remove the cable retainer from the Control Box Pic 5. Feed the Battery Backup plug behind the actuator and into the lower Control Box port. Lock the cable retainer back into position on the Control Box.

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VISUAL CHECKS • Handset Cable – Check for cracks in plastic insulation, check for breaks in casing, cable holder and plugs. • Mains Cable – as above • Handset – Check that all functions work and ensure there is no damage to casing or faceplate. • Chassis – Check the bed frame for bent or corroded pieces; ensure that all bolts and screws are tight. • Head & Foot Covers/boards/caps – Check ABS covers have no cracks and are secured tightly, head and Foot boards are in place and ABS caps have no cracks and are secure. • Castors – Check that each wheel will turn, test the brake and directional locking. Ensure that each castor is tightly secured. • Paintwork/Corrosion – Ensure all metal parts have no flaking paint or signs of rust. • Bed Extension (If Fitted) – Check that this has been installed correctly and all bolt s are tight. • Accessories correctly fitted – Check that all accessories fitted to the bed have been correctly installed and that all the bolts are tight. • Serial No. Label – Each bed has its own Serial Number and the label is found on the rail running underneath the mattress platform. Check that this in place. MECHANICAL CHECKS • Bed to maximum low/high measurements – Check the height of the mattress platform (at all 4 corners) to ensure that they agree with the correct specifications for this product. • Platform level – Measure from mattress platform to the floor at each corner and ensure that each measurement is the same • Kneebreak Maximum up/down – Operate kneebreak to fullest height and check for any damage. • Backrest Maximum up/down – Operate backrest to fullest height and check for any damage. • Trendelenburg Maximum forward & reverse – Operate Trendelenburg to fullest height

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MECHANICAL CHECKS CONTINUED •

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Quiet smooth Hi/Lo Function – Operate bed up and down checking that it is quiet and goes smoothly up and down End covers and fittings – Check all covers are fitted correctly and secured to frame of bed. Castors tight and lockable – check castor fixing bolts are tight, check directional castor (Green tab) x 1 and locking castors x 3 for correct function. Hilo drive mechanism – Check raise/lower actuators for excess noise or slow operation. Check nylon bushes for wear or damage. Side Rails – Check condition of side rails and brackets, ensure that the screws are tight. All bolts, screws, fasteners must be checked regularly before putting the beds into service and between patients/residents.

STRUCTURAL • Visible distortion of frame – Check frame for bent or cracked metal parts. • Visible serious client damage – Check for damage caused by bed lifters etc. and report to client. • Structural Fractures – Check for cracks or tears in steel frame • Hinges/mounts not bent – Check all the hinges on platform, actuator fixing points & platform fixing points for damage.

How to remove an Actuator Protean 2 Remove headboards Raise bed to maximum height Remove inner cover (See page 12 Pics 2,3 & 4) Lower bed onto chocks (under pedestal ends) Remove top and bottom bolts and pins Support actuator and remove from bottom anchor point-lay carefully on the floor Disconnect actuator lead from control box. How to replace Actuator Protean 2 Connect power lead on new actuator to control box Fit actuator to bottom anchor point Align with top anchor point (inside square tube) and raise actuator until holes are aligned Fit covers and headboards Check all bed operations

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ELECTRICAL • Battery backup working/condition (if fitted) – Disconnect mains cable from power point and operate bed. • Handset buttons all working – Check all functions on handset • Cables secure and in good condition – Check that all cables are secured correctly, not hanging loose. • All Actuators secured & working – Check for excessive noise, vibration or cracks in casing.

How to remove an Actuator Protean 3-Backrest and Kneebreak Raise the bed to a comfortable working height Remove mini fit plug using a small flat blade screwdriver to release the plastic circlip locking tabs and separate the male and female mini fit plugs. (See Page 12 Pic 4) Remove actuator circlip washer and pin at bottom of actuator only. (see Page 13 Pic 9) While supporting the weight of the actuator (with chocks) Pic 1. remove the circlip washer and pin from the other end. Reverse these steps to replace or install an actuator

REPLACEMENT PARTS In order to maintain operational safety and the right to claim under warranty, only original LiftCare replacement parts may be used! Please quote part numbers for each item as per the LiftCare Spare Parts Catalogue.

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ELECTRICAL COMPONENTS

HOW TO FIT A MINI PLUG WHEN ASSEMBLING BED Pic 1. Lightly lubricate seal on the plug and insert firmly into the socket ensuring that the key and keyways are aligned (Pic 2.) Pic 3. Fit the plastic circlip and ensure that the two locking tabs lock into the slots of the socket.

Pic 1 ’O’ ring seal

Pic 3

Pic 2 Keyway

Pic 4 Locking tabs

How to remove covers Step 1. Inner cover (Protean 2 only) Remove headboard/footboard; Pic 1. Pull cover inward at the base Pic 2. Pull inner cover inward at the top (there are no screws on this cover) and Pic 1 remove from bed. Step 2. Outer cover (Protean 2 only) Raise bed to maximum height Remove inner cover as above Pic 3. Undo and remove four screws Pic 3 Gently remove cover from bed.

Pic 5 locking slot

Pic 2

Baery

Handset

Mains

Actuators

The corresponding replacement parts can be obtained from LiftCare or your local Linak office. When ordering please specify – TYPE & ITEM. The necessary details are found on the type plate (as shown below) on each electrical component. For further information contact LiftCare Service Department: [email protected] or phone +61 3 8773 1111 REPLACEMENT OF ELECTRICAL COMPONENTS Safety information on replacing electrical components This is a Class 2 electrical product. CAUTION! Before commencing any work on electrical equipment, always unplug the mains cable from the electrical socket. Any work and/or repairs to the electrical equipment may only be carried out by service engineers, qualified technicians or authorised electricians in compliance with all the relevant country of use safety standards. All electrical drive system components (actuators, handset, and control box) are maintenance-free and must not be opened.

Inner/Outer cover (Protean 3)

In the event of a malfunction, the corresponding component must always be replaced in full.

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When replacing individual components, always ensure that the plugs, outfitted with undamaged O-rings (seals), are inserted into the control unit as far as possible. Only then can reliable sealing and perfect operation be guaranteed.

Pic 1. Remove headboard/footboard and raise the bed to highest position Pic 2. Remove 2 outside Phillips head screws and 2 inside screws. (Note: some models may have different fastening method) Pic 3. Remove ‘snap latch’ lug with Allen Key and one end cap which allows the cover to be removed. LiftCare. A MEMBER OF THE HUMAN CARE GROUP. Protean 2 & 3 SERVICE MANUAL OCTOBER 2010 12

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The component plugs are connected to the corresponding port in control box. To prevent the plugs from inadvertently disconnecting, they are secured with a locking device. When necessary, this device can be carefully lifted off using a screwdriver. The locking device must always be properly refastened.

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HOW TO REPAIR/REPLACE CHAINS - PROTEAN 2 ONLY The most common cause of broken chains is a broken con link, usually through operator error ie the bed being operated up or down with the mattress platform operation being impeded by a window sill or piece of furniture etc. Pic 1. Cotter pin, circlip, split pin & con link Pic 2. Remove end cap with Phillips head screwdriver Pic 3. Remove chain retainer if fitted.

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Pic 14 Pic 1

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Pic 2

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Pic 7 Replace new chain assembly cotter pin and split pin (spread split pin legs to ensure it remains in position). Pic 10. Replace outside extrusion and loosely fit the top 6 screws and refit aluminium strip (Protean 2 models only) (Pic 13. )to lock extrusions then return the rubber strip (Pic 14.) into the slot. (with hanger bracket on the outside of the aluminium extrusion) Pic 18. Refit nylon rollers onto the roller pin on the hanger bracket and lower all the way into extrusion. NOTE: When repairing or replacing chains always take note of the assembly arrangements before removing from the bed so the same fitting can be repeated.

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Pic 4. Remove two Phillips head screws from underneath the extrusion. Pic 5. Remove the outside half of the extrusion with a 4mm Allan Key. Lower bed to floor to remove the weight from the chain assembly. CAUTION! Beware of exposed chain & sprocket. Pic 6. Support the mattress platform with chock between the top & lower beams Pic 7. Remove split pin and cotter pin from chain anchor point Pic 8. Remove 6mm button head (domed head) cap screws from mattress platform (See Page 11 Pic 13) with 5mm Allen Key then lift the chain assembly out. Pic 9. Fit the new chain assembly

Pic 6

Pic 11

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Pic 18

Pic 15. Raise bed, remove the chock to enable the refitting of the two lower cap screws into the extrusion and the Phillips head screws underneath the extrusion. Pic 16.Replace chain retainer Pic 17. Replace end cap and Check all bed functions How to repair a Chain When chains are jammed (Protean 2 only) If the chains are jammed under the sprocket. Remove the inner cover (See page 13 Pic 2, 3 and 4) Pic 1. Loosen the 8mm button head screws then lift the top rail assembly (Protean 2 only) to release the chain. Put 3mm spacer between cog and aluminium extrusion and press firmly down on the cog and retighten the 8mm button head screws

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Pic 2

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