Arjohuntleigh Malibu Contour Maintenance And Repair Manual Download Page 32 | Manualshive

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Service Procedures

MRM Malibu/Sovereign

32

the technician must state in the service notes
that the castors will remain safe until the
next scheduled service.

Replacement

1. Unscrew the castor (

c

) including washer (

d

)

2. Remove old Loctite (Refer to Loctite

instructions)

3. Apply new Loctite (type see page 47)

4. Assemble the new castor with bolt and

washer (torque see page 47).

5. Check the function of the new castor.

NOTE

All castors must be of the same brand. It´s not
permitted to use different versions of castors
on the same product.

c

d

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Summary of Contents for Malibu Contour

Page 1: ...Malibu Sovereign 2011 Maintenance And Repair Manual with people in mind XXX XXX Rev A 12 2014 For internal use only 09 AZ 03_4GB 08 2015 ...

Page 2: ...e Procedures 6 44 Lockings Lubrication and Torques 47 Tools 52 Trouble Shooting 53 NOTE Before using this Manual you must have taken part of and understood the Safety Precautions 09 NE 01 For technical data assemble and reassemble measurements and upgrades not found in this guide please refer to the Instructions for Use ...

Page 3: ...ean filters incoming water x Check expiring date for seat replace before expired x Replace the safety belt x NOTE All caregiver obligations according to Instructions for Use are to be checked when performing the Qualified personnel Service WARNING The points on this checklist are the minimum the manufacturer recommends In some cases due to heavy use of the product and exposure to aggressive enviro...

Page 4: ... moving parts x 11 21 Check the safety cut out switch x 12 22 Check the earth wiring connections x 13 23 Test control box batteries x 14 25 Perform full feature functionality test x 15 26 Check emergency stop x 16 27 Check replace safety catch on lift arm x 17 28 Perform a safe working load test Local requirement x 18 29 Check actuator lifetime x 19 30 Inspect castors on chassis for chair x 20 31 ...

Page 5: ...rocedures not included in PMS 5 Service Procedures not included in PMS SP26 Replaceactuator in lift arm page 38 SP 27 Replace PCB in outer profile page 42 SP 28 Replace MPA pump page 44 SP 29 Generic glue repair instruction page 45 ...

Page 6: ...to three parts mostly due to manufacturing problems at the same time the glass fibre was eliminated from the material due to the somewhat rough surface A few customers have perceived the Care Raiser as flimsy and thus uncomfortable We have therefore improved the Care Raiser by making a change in the material Field improvement We hereby offer the Carendo Care Raiser as a rebuilding kit to those cus...

Page 7: ...e product Check a Lift arm and hook b Safety catch c Top bushing d Control panel e Tub with legs attachments logos and warning sign f Shut off valves g Mixer unit h Drain overfill and floor drain assembly i Potential equalizer connection j Air Spa outlets option k Shower holder see page 19 All electrical cabling Labels c a b d e k g COLD HOT f h h j i ...

Page 8: ...to lift arm f Air jets with air spa g Chassis chair Shall not unhook from the catch even if it gets a hard stroke if this is the case replace See also Lockings Lubrication and Torques on page 47 and Tools on page 52 NOTE Screws and bolts attached with Loctite should not be checked by tools but manually to test if the jointing component is securely fitted If tightening is needed and Loctite is prev...

Page 9: ...es and Connections for Leaks and Damage This check is to preserve the safety and performance of the product Check a Inlet hoses and connection to mixer b Mixer c Hose connections MPA disinfection shower hose d Drain e Air Spa system option a b COLD HOT c d e ...

Page 10: ...ose the valves The handles red for hot water and blue for cold should be in a cross position 2 Remove the hex head lid with a wrench 3 Pull out the filter and clean it carefully 4 Open the valve for a while 5 Shut the valve 6 Fit the hex head lid Hex head lid Filter WARNING Make sure that the valve is closed before removing the lid especially important on the hot water supply NOTE When flushing th...

Page 11: ...nsition hole has to be clear of all obstacles and dirt to function satisfactory the hole has an inserted brass pipe very small to prevent lime build ups This pipe must not be removed or the result will be that the valve does not close Anchor seal The anchor seal on the anchor 6 is located under the anchor housing 7 and is reached by loosening and removing the solenoid 1 and the anchor housing Be c...

Page 12: ...valve a and the pump valve b must be replaced follow the replacement procedure below Replacement procedure 1 Shut off water and mains 2 The fill valve is reached in the front of the tub while the pump valve is reached from the side of the tub 3 Disconnect the hoses from the fill valve and unscrew it from the holding plate When assembling check the cable connection according to picture top right an...

Page 13: ... incoming flow pressure and temperature is OK and the procedures above are made but the temperature regulation stability or flow still is poor replace the regulation cartridges as follows All cartridges with springs a shall be replaced if maintenance is required These are included in a repair kit together with o rings and internal check valves The three pushers b and the shaft transmission must be...

Page 14: ...ings k included in kit Position of check valve shall be according to picture on bottom of this page Check that no remains of the old check valve is left inside Lubricate all o rings Assembling 1 Tighten the screws f in diagonal order to make the cartridges fit correctly 2 Hold the mixer in place and position the mixer shaft c 3 Attach an tighten screws holding mixer a b 4 Attach PEX pipes 5 NOTE A...

Page 15: ... in Service mode set DIP 3 and 4 in OFF position see Technical Manual 6 Activate scalding protection by switching to Normal mode 7 Drain tub 8 Use internal thermometer to measure at what water temperature the scalding protection is deactivated The temperature will fall below 45 C within one minute 9 If the scalding protection does not work check Sensor and connections to sensors for fill g positio...

Page 16: ...und 3 C below the fill setting 4 Leave the water on for 30 seconds so the water temperature is stable For Malibu without shower go to 6 5 Now activate the shower make sure the shower temperature has the correct maximum value If exceeded the regulation cartridges need to be replaced see page 13 6 Push the knob in position The stop peg on the knob c shall be placed just above the stop peg of the sto...

Page 17: ...sinfection flow and keep it activated until the flow is stable and you no longer have any air bubbles in the fluid 8 Check the set value on the flow meter c according to the recommended value see table below release the handle trigger 9 Top up the graduated cylinder completely without removing the bottle connection 10 Use a graduated 2000 ml container to collect the disinfection mixture 11 Start t...

Page 18: ...igher Example 30ml 1 77l 17 ml l 15 If the concentration is too low according to table check disinfection line for air leaks If no leaks Primary Replace injector Secondary Replace flow meter Low level alarm 1 Lift up the bottle connection a so there is no contact with the disinfectant in the bottle 2 Start disinfection by pressing the disinfection button b for 5 seconds 3 A warning with flashing g...

Page 19: ...or d fully clockwise 7 Carefully screw the spray plate b onto the flow divertor d There should be a gap between the edge of the spray plate and the flow divertor 8 Make sure the green dot e is according to the picture and align inner teeth f with outer teeth g 9 Clip the adjuster ring a in position With auto flush shower holder Check handle holder for cracks leaks and or sharp edges Check fastenin...

Page 20: ...ction and pull out the plastic insert e replace the two o rings f 5 Unscrew the shower strainer replace the big o ring g and the plastic valve h Strainer kit B 6 In addition replace the small o ring i and shower strainer j with screw k and plug l 7 Reassemble c d b a e f g h i j k l A Repair kit B Strainer kit A A B ...

Page 21: ...d down a couple of times and let the grease spread Lift Arm 1 Remove screws b holding the lift arm 2 Remove screws c holding top bushings 3 Lift up remove arm and bushings d from tub 4 Lubricate surface of arm e 5 Lubricate inside the outer profile f 6 Lubricate rotation bearings through small holes on the bearings g 7 When assembling use Loctite for screws b NOTE Check that the screws b are prope...

Page 22: ...is still possible to raise the lift arm Activation of the switch can be checked on LED 2 in Normal Mode showing green light c Procedure 1 Lower the liftarm while resisting the move ment down by hand the safety cut switch shall stop the movement down 2 If the lift arm movement is not stopped check the switch with connections connected to the control box position J13 3 If replaced check function of ...

Page 23: ...on connection point in the building a certified electrician must make the installation NOTE Verification Test of Equalization connection point 1 A cable from the earth equalization con nection point in the building is plugged into the test instrument The measurement is then done with a probe between the instru ment and the specified parts of the tub see next side 2 Test at 25A 3 Measure on clean m...

Page 24: ... with the probe from the test equipment on the following parts 1 Potential equalization connector on chas sis foot end 2 Chassis lift end both movable a and fixed part b 3 Chassis foot end both movable a and fixed part b 4 MPA pump metal housing 5 Field wiring box PE cable to chassis 6 Control box earth connection point on PCB 1 2a 2b 3b 3a 4 5 6 ...

Page 25: ... 2 Check the colour of the LED a 3 If the LED shows green light when disconnecting from mains run a complete lift cycle with the maximum load 130 kg on the chair If the LED before during or after this test shows yellow light replace the batteries Replacement procedure see SP 25 page 37 4 If the batteries can manage a complete cycle ending up with steady green LED they are OK and need no replacemen...

Page 26: ...plus trigger pulled on handle With autodisinfection Flow can be shut off by pressing the button Flow min 120 sec when interrupted on button max 155 sec without interruption With manual disinfection only Flow can be shut off by pressing the button Flow time out 5 minutes LED indication on tub con trol panel Connected to mains A Steady green or flashing green Connected to mains B steady green Lock b...

Page 27: ...ncy stop button is securely fit to the tub A rotation stop washer is used here since september 2010 b 3 If no function check the emergency stop with connection connected to the control box position J4 Replace if not functioning WARNING When the mains is shut off by the emergency stop there is still power connected in the con trol box That s why the mains indicator on the control panel still shows ...

Page 28: ...ch removal 1 Remove the plastic plugs a 2 Drive out the slotted pin b and remove the spring c 3 Replace the safety catch d 4 Insert the new safety catch spring with assembly pin Push down on the spring to get it in under the transfer casting 5 Drive the slotted pin against the assembly pin to replace Stabilize the spring when doing this 6 Check that the new safety catch moves smoothly 7 Attach the...

Page 29: ...s place a suitable lightweight cover on the chair e g cloth plastic or paper sheet 5 Load the barrels on the Malibu chair 6 Raise the lift to apply and sustain the test load of 130 kg for a period of approximately ten seconds 7 Lower the lift and unload the barrels check for any permanent deformation or damage Recommend the replacement of any defective parts 8 Clean down the chair 9 Document the t...

Page 30: ...ttom to top The picture to the right shows that this actuator has performed between 10000 and 11000 strokes 3 Make a read out and make a note of the interval shown a b c Actuator Lifetime Mode DIP 3 ON and DIP 4 OFF LED 7 6 5 4 3 2 1 0 Lift Arm Actuator Life Time R Y Y Y G G G G R red Y yellow G green On 0 strokes On On 1000 strokes On On On 3000 strokes On On On On 5000 strokes On On On On On 700...

Page 31: ...nue to rotate when released and without excessive bearing noise b 4 Check the wheel tread Check for splits cracks flat spots missing sections or any visible damage Replace if any of the before mentioned is found 5 Place the product upright for further testing 6 Check function of brakes if applicable by applying the brakes and push the product forward The brakes must lock the wheels and the brake l...

Page 32: ...cement 1 Unscrew the castor c including washer d 2 Remove old Loctite Refer to Loctite instructions 3 Apply new Loctite type see page 47 4 Assemble the new castor with bolt and washer torque see page 47 5 Check the function of the new castor NOTE All castors must be of the same brand It s not permitted to use different versions of castors on the same product c d ...

Page 33: ...orrect position and tighten the two slide buttons firmly by hand New version 2013 replacing all old belts as spare part Pull off the old belt and push the new in place over the two slide buttons a with the label towards the seat as shown The two slide buttons can also be removed if fitting is difficult In this case be sure to tighten the two slide buttons firmly by hand a b Old version New version...

Page 34: ...slightly 4 Disconnect the blower from the air line b 5 Unhook the blower from the bracket c 6 Remove two screws d to separate the top of the air blower from the base 7 Replace the filter e 8 Refit the base and attach the screws d 9 Connect the blower to the air line b 10 Hook up the bracket 11 Tighten the two screws a holding the bracket 12 Attach the tub front a c b e d ...

Page 35: ... old cap with diaphragm from the air jet do not scratch the tub surface 2 Fit the new rubber diaphragm to the pin on the underside of the new chrome cap and push it fully into position 3 Be careful not to break the tap 4 Fit the new cap with diaphragm 5 Fill the bath with water and check the airjets 1 2 3 ...

Page 36: ... Procedures MRM Malibu Sovereign 36 SP 24 Replace All Pressurized Hoses Every fifth year the 5 8 pressurized water connection hoses a before the shut off valve shall be exchanged in order to prevent a burst a ...

Page 37: ...top of the control box 5 Replace battery pack and strap together with the cable 6 Attach to J14 on PCB b and tighten cable skin top on box 7 Check that the LED on the control panel c is flashing green loading with mains connected When the LED changes to a steady state the battery is fully charged 8 Attach control box lid and front panel To protect the PCB from static electricity ESD Ground yoursel...

Page 38: ...support the PCB inside when the screw on the bushing has been removed 6 Raise the tub to top position If no Hi lo actuators raise 30 cm 7 Remove screw and nut d holding the top attachment e 8 Pull off the o ring f and take it off so it will not fall down 9 Remove the bearing as one piece g 10 Put plastic tape h on outer profile according to picture to protect it from being scratched when later pus...

Page 39: ...cotter pin r holding the actuator to the attachment 18 Lower the actuator gently together with the outer profile s down to the floor and the divided rotation bearing t in the top attachment will fall out making it possible to recline the outer profile 19 The actuator can be removed by gently lifting the outer profile s reclining it to be able to pull out the actuator The attached tape prevents the...

Page 40: ... Locate the actuator attachment d and fasten clevis pin and cotter pin e together with microswitch f use Loctite on screws for microswitch 3 Attach the actuator attachment with three long 16mm screws g use special tool 4 Fasten the lower attachment h with six short 12 mm screws i together with the guide plate j use torque 5 Fasten the swing actuator k note position of rotation plate l with wings u...

Page 41: ...ape holding PCB and attach screws w holding top bushings and PCB 14 Attach screws x holding the lift arm use Loctite 15 Lower the tub 16 Attach the chair on lift arm 17 If out of position the actuator will find the correct position if operated to the lowest position inside tub When searching for the correct zero position the movement may be slow but it will always reach their zero position 18 Atta...

Page 42: ... the lower screw is removed 6 Raise the tub to top position If no Hi lo actuators raise 30 cm 7 Release the swing actuator e from the lift arm 8 Rotate the pillar so the lower screw for the PCB f is in front of you and remove it 9 Disconnect cabling from lift arm PCB g cut the straps holding the cable 10 Attach a thin wire h to the PCB cabling making it easier to pull down the new PCB see below 11...

Page 43: ...bottom screw using Loctite Remove the wooden pin gently 6 Fasten the swing actuator p Note position of rotation plate q with wings upward against actuator Nut r is a locking nut 7 Attach cable to lift arm PCB and strap it 8 Gently lower the liftarm into the outer profile 9 Remove tape i holding PCB use a small screwdriver to get the top of the PCB s in correct position attach bushings c and finall...

Page 44: ...11 Disconnect cable j Assembly 1 Connect cable d to new pump and attach lid with screws i 2 Attach pump to plate f 3 Attach new pipe sealant in both ends to hose nipple g and attach to pump all the way down Attach valve in other end and note position of valve facing inwards pump 4 Attach cabling e according to picture 5 Attach pump with plate f to tub 6 Connect angles and hoses c 7 Fasten T connec...

Page 45: ...vers and or panels 2 Locate the loose bracket s 3 Identify the earlier position of the bracket using old glue and mark out the position by scratching or felt tip marker 4 Remove loose glue 5 Determine how you could fixate the item in the correct position for 1 hour before going to point 6 quick clamp support bracing tape etc This does not require much force only enough to fixate the bracket withou...

Page 46: ...shown right 10 Do not over do the adhesive it must be allowed to spread over entire surface when compressed but not so much that it spills over 11 Fixate according to point 5 12 Let dry for minimum of 45 minutes but preferably one full hour allowing the adhesive to cure 13 While the adhesive is curing remove all cardboard paper towels used as drip protection 14 Remove fixations when time has elaps...

Page 47: ...ed once and must be replaced with new Loctite 2701 on locking pin Loctite 243 on screws 25 Nm Shell Cassida RLS2 on this surface Loctite 243 Loctite 243 Loctite 243 Locking nuts on both sides Loctite 243 Loctite 243 Shell Gadus S3 A1300C Dri Loc 64 Nm Loctite 243 Tape KS5669 1 Clean with isopropanol 2 Apply one stripe of tape along the whole length and into the tube 3 Apply tape around the whole c...

Page 48: ...Loctite 243 Locking nuts on both sides Elecrolube HTC on tub temperature sensor Shell Gadus S3 A1300C Tape KS5669 1 Clean with isopropanol 2 Apply one stripe of tape along the whole length so it enters the tube 3 Apply tape around the whole circumference opening of handle 4 Remove protection and apply water 5 Push handle in place 2 3 ...

Page 49: ...and nut can be replaced by clevis pin and cotter pin All screws within circles use torque 12 17 Nm Lift end Shell Gadus S3 A1300C on these surfaces Shell Gadus S3 A1300C inside along profile Locking nut Locking nuts Tighten with max 5Nm in order not to damage the attachment Locking nuts Locking nuts Loctite 243 Loctite 243 Shell Gadus S3 A1300C on the rotation bearings Screw and nut can be replace...

Page 50: ... Sihaf 2 is used on all o rings Berulub Sihaf 2 on o rings inside the mixer Berulub Sihaf 2 on the cartridge pushers COLD HOT Berulub Sihaf 2 on threads for shut off valve 20 35Nm for all nipples Coupling must be hold still when tightening nut to pipe Use special tool Conex 303 ...

Page 51: ...bu Sovereign Lockings Lubrication and Torques 51 Air Spa Disinfection MPA Locking nuts Tighten airjet with 2 7 Nm Locking nuts Loctite 5776 Locking nuts 9 Nm 10 Berulub Sihaf 2 on o ring Control Box Locking nut ...

Page 52: ...Tools MRM Malibu Sovereign 52 Tools For specification of tools refer to the Parts List Service Articles and Special Tools ...

Page 53: ... tub work ing Note No el scalding protection shower Shortcut no connec tion of fill shower cabling sensor or no connection from con trol box Check sensor cable to J11 fill in or Check sensor cable to J12 shower in Check cable to J10 Replace thermometer Both temperature dis plays black Note No el scalding protection No connection ther mometer defect Check connection J8 in Control box replace ther m...

Page 54: ...IFT ARM LED 0 in Normal Mode shows if lift arm is in lowest position LED 2 in Normal Mode shows if the safety cut out switch is active LED 1 in Normal Mode shows if lift arm is in inner rotation position LED 6 in Normal Mode shows if lift arm is in highest position Lift arm up down and in out does not work Hand control not working Check hand control and connection to control box J15 Lift arm up do...

Page 55: ...ntrol box J27 Check swing actuator SP 26 Lift arm is not in top position Check LED 6 Check cabling to lift arm PCB J1 SP 26 Lift arm out does not work Tub is not in the low est position Lower the tub Check LED 5 Lift arm is not in top position Check LED 6 Check cabling to lift arm PCB J1 Electric fault Check hand control and cables to J15 Check control box J27 Check swing actuator SP 26 Check that...

Page 56: ...ter but no hot water External hot water supply shut off Check hot water supply check valve FILLING LED 0 in Service Mode shows if fill valve gets signal from PCB No or bad flow Water supply Check incoming water flow Check clean filters SP 5 Mixer clogged limed Check replace cartridges and filters SP 8 Fill button defect Replace control panel Solenoid valve does not open Check filling valve power s...

Page 57: ...gnal from PCB Blower not working Control panel fault Check function of control panel See Control panel No connection Check control box J18 power supply to blower and J17 speed regulation Blown fuse Check fuse inside blower ELECTRONIC SCALDING PROTECTION LED 6 in Service Mode shows if there is a scald signal from thermometer Scalding protection not working Temp display No connection to sensor or Se...

Page 58: ...e black No connection ther mometer defect Check connection J8 in Control box replace ther mometer Scalding protection active without water fill shower tub LED on panel flashing DIP switch set to Ser vice mode No fault Short cut in fill shower or tub sensor Replace sensor Before starting to trouble shoot check Power supply Water supply LED s on Panel and in Control box and emergency stop Problem Ca...

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