Arjohuntleigh Maxi 500 Maintenance And Repair Manual Download

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5001-00553-EN rev 5 • 1/2018

Maxi 500

Maintenance and Repair Manual

Summary of Contents for Maxi 500

Page 1: ...1 5001 00553 EN rev 5 1 2018 Maxi 500 Maintenance and Repair Manual ...

Page 2: ...rjoHuntleigh group of companies ArjoHuntleigh 2014 As our policy is one of continuous improvement we reserve the right to modify designs without prior notice The content of this publication may not be copied either whole or in part without the consent of ArjoHuntleigh ...

Page 3: ...dure 10 Adjusting the Legs 25 Service Procedure 11 Replacing the Base Assembly 26 Service Procedure 12 Replacing the Mast 27 Service Procedure 13 Replacing the Handle 28 Service Procedure 14 Replacing the PCB 28 How to Open the Control box 28 How to Close the Control Box 29 Fuse Replacement 29 Removing the Circuit Board 29 Service Procedure 15 Replacing the Battery Discharge Indicator PCB 32 Servi...

Page 4: ...f any warranty on it ArjoHuntleigh 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 D Dangerous substances If using hazardous substances be sure of how to handle these and refer to applicable information In doubt refer to t...

Page 5: ...ude Immediate stop reset switch Overload circuit Overload current limit protection in the PCB Lower and upper limit switches Anti crush Control panel on the unit Emergency lowering device Audible and visible low battery warning The raising and lowering mechanism comprises an electromechanical linear actuator powered by a 24 VDC motor The leg opening and closing mechanism comprises a 24 VDC motor a...

Page 6: ... 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 Do not perform maintenance tasks on equipment with live electrical connections unless absolutely necessary Isolate the power supply before removing plugs sockets or disc...

Page 7: ...553 EN rev 5 Suggested Tools Standard tool kit Socket Allen key 4 mm ST82 5 mm ST274 6 mm ST55 8 mm ST87 Sling clip gauge ST331 Load test equipment Recommended Spares Casters Fuse Hand Control Fig 1 LEFT RIGHT ...

Page 8: ...05 mm Install the threaded components and where known torque to the applicable torque value If the torque value is not known tighten so that it is firmly secured Clean off any unwanted adhesive Allow the Loctite 243 to cure before subjecting to load Where the cure time is unacceptably long or large gaps are present applying Loctite Activator N or T to the surface will reduce the cure time For gene...

Page 9: ...g 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 Fig 2 Loctite 243 1 P OEI IW Loctite 243 1 P OEI IW Loctite 243 1 P OEI IW Loctite 243 1 P OEI IW Loctite 243 1 P OEI IW 0RGHOV ZLWK EROWV 0RGHOV ZLWK FOHYLV SLQV ...

Page 10: ...ite 243 40 N m 29 5 lbf ft 2 Loctite 243 40 N m 29 5 lbf ft 2 Loctite 243 22 N m 16 lbf ft Loctite 243 35 N m 26 lbf ft 2 Loctite 243 16 N m 12 lbf ft 2 Loctite 243 40 N m 29 5 lbf ft 2 Loctite 243 50 N m 37 lbf ft 2 Food grade grease ...

Page 11: ...y that the safety latches on the spreader bar are present and move freely 28 29 Lubricate pivot points if necessary Check the function of the emergency lowering device by applying weight to the lift and activating the lowering device 30 Make sure that the legs are at a 91 angle from the base see SP10 31 32 Ensure that there is no irregular deflection in the spreader bar DPS Verify that the hole fo...

Page 12: ...12 001 00553 EN rev 5 Technician Inspections Fig 4 ...

Page 13: ...13 001 00553 EN rev 5 Fig 5 22 19 18 17 16 15 14 12 13 23 28 29 9 9 42 42 ...

Page 14: ...k is installed correctly and fully charged Test with a new fully charged battery pack Check if the hand control is connected Check if the actuator is connected to the control box Audible beep is heard from the control box Batteries are low Replace with a fully charged battery pack Actuator stalls during lift Batteries are low Replace with a fully charged battery pack Make sure you are not exceedin...

Page 15: ...acing Back Wheel SP7 Replacing Leg Actuator SP8 Replacing Legs SP9 Replacing Base SP11 Replacing Mast SP12 Replacing Handle SP13 Replacing PCB SP14 Replacing Battery Discharge Circuit SP15 Replacing Boom Actuator SP16 Replacing Boom SP17 Replacing Scale SP18 Scale Calibration SP19 Replacing DPS Spreader Replacing Hand Control SP21 Bar from a Load Safe Working Load Test SP22 Verifying the Sling SP2...

Page 16: ...the battery that includes the fuse to prevent this component from blowing and making battery unusable Battery tester 8662950 can also be used on the battery without fuse The battery tester will load the battery with a high current for a short time This will show the battery Check if there are any field correction bulletins safety notices or technical bulletins that have been published since the la...

Page 17: ...ster refer to SEE201204 1 The battery to be tested must be charged for at least 12 hours before the test 2 Connect the tester to the battery When the tester is fully connected press and hold the button for 1 2 seconds and take a quick reading on the meter 3 The meter will show the battery s condition NOTE The battery power tester will become hot and there is a potential risk of fire Make sure the ...

Page 18: ... 16V Add an 80 ohms resistance 10 W min between both charger output prongs and measure voltage at resistor Status indicator LED on charger should be YELLOW Voltage reading should be between 28 71 V and 29 29 V Measure charger maximum output current by connecting an ammeter directly on output socket prongs Light indicator on charger should be OFF Current reading should be between 1 3A and 1 7A Char...

Page 19: ... of the product Fig 11 Floor Lift Paint If the paint is damaged scratches marks add paint in matching color to prevent further corrosion NOTE Before applying the paint the surface must be clean and dry To Verify 1 Front caster 2 Legs 3 Braked caster 4 Base 5 Mast 6 Battery 7 Control box 8 Handle 9 Hand Control 10 Boom 1 2 3 4 5 6 7 8 9 10 ...

Page 20: ...d closing No abnormal noises legs open fully on each side see the Instructions for Use Rotation and swiveling of casters Manual Move on short distance rotating the lifter No pulling no abnormal noises or vibrations Braked caster Manual Engage the brake on each rear caster Easy engagement disengagement lift immobile when brakes are engaged Hand control Buttons Press each button check display All li...

Page 21: ... wheel make sure you have all the items as illustrated below Insert the M10 cap screw into the M10 flat washer then into the caster the top cap and the top sleeve Mount the new front caster wheel assembly along with the new M10 cap screw Make sure that the cap screw is properly aligned to prevent any damage to the threads Use a torque wrench to tighten the M10 cap screw to between 35 40 N m 26 30 ...

Page 22: ...ction see Fig 13 3 Install the new caster with thread locker Fasten the flat head socket screw in the caster thread securing it by its hexagonal section Caution Ensure proper tightening of the caster by torquing it by its hexagonal section with the appropriate wrench Fig 13 4 Check that the caster spins freely over the stem 5 Verify that the brake is working properly i e easy engagement disengagem...

Page 23: ...asher on the pivots that holds the leg actuator ends and put new cotter pins to secure the assembly The cotter pin must be installed according to Fig 17 10 Connect the actuator Connect the cable to the leg actuator cable Make sure it does not interfere with the installation of the base cover 11 Leg opening must be verified adjusted after installation as per the Adjusting the Legs service procedure...

Page 24: ... see Fig 18 Dispose of the stover nut Fig 18 4 Put the new leg in place and fasten the leg pivot bolt and stover nut 5 Reinstall the tie rod end using a new nylon nut 6 Put the base cover in place 7 Leg opening must be verified adjusted after installation 8 Fully open and close the legs 9 Perform a safe working load test as per service procedure 22 Warning If one or both legs are disassembled it i...

Page 25: ... that the next application of loctite will adhere properly facilitating the leg adjustment later on 4 Reinstall the tie rod ensuring that the tie rod ends are both only slightly threaded onto it one thread or two 5 Adjust the legs so that they are 91 relative to the base Minimize any looseness in the legs by pushing them inwards Then rotate the tie rods until you get the dimensions as shown in Fig...

Page 26: ...eassemble the mast and boom and DPS spreader bar assembly on the new base assembly according to assembly instruction for each component 5 Check and adjust the legs if necessary as per the Adjusting the Legs service procedure SP10 6 Perform a full feature test as per service procedure 4 7 Perform a safe working load test as per service procedure 22 Warning If the base assembly is disassembled it is...

Page 27: ...eature test as per service procedure 4 13 Perform a safe working load test as per service procedure 22 4 Dismantle the actuator from the mast see Service Procedure 16 Replacing the Boom Actuator 5 Remove base cover and disconnect the mast section from power supply The connector is located under the base cover on the left side of the lift see Fig 15 6 Unscrew the two screws at the lower end of the ...

Page 28: ...l the new handle Fasten the three screws along with the cable clamp for the hand control Warning If the handle is disassembled it is essential that all components are reinstalled correctly If not the consequence may be later disengagement which can lead to death or serious injury Fig 22 1 Lock the rear casters to make sure the lift stays stable during maintenance 2 Remove the battery pack 3 Remove...

Page 29: ...k and test all features controlled by this device to confirm that it works properly as per service procedure 4 1 Insert the top end of the cover under the switch panel see Fig 24 2 Carefully position the wires Be sure not to pinch a wire behind a screw or the edge of the control box 3 Fasten both screws Phillips 2 near the bottom end see Fig 23 Insert the nylon washers between the control box cove...

Page 30: ...nt them from moving freely OLD STYLE BOARDS a Safe working load By actuating the hand control make sure that the lift raises the safe working load on its entire stroke between 227 238 kg 500 525 lb If not adjust the current limiter with the potentiometer VR1 see Fig 28 Keep the safe working load raised for the next step b Opening and closing the legs The safe working load hoisted open and close th...

Page 31: ... limiter with the potentiometer RV1 Turn the potentiometer counterclockwise to decrease the force d Emergency stop When completing a full stroke press the emergency stop button red The actuator must stop immediately Press the on button green to reactivate the hoist and finish its course e Check that hour meter and battery charge indicator are working properly Fig 29 RV1 CAUTION Respect the 10 duty...

Page 32: ...rge indicator PCB in place as shown in Fig 30 fastening the two nuts and flat washers securely Do not over tighten the nuts holding the circuit as too much torque could damage the board Screw in the cover 5 Plug J5 and J7 connectors as shown on electric diagram on battery discharge indicator PCB 6 Install control box cover Fig 30 Warning If any component of the electrical system is disassembled it...

Page 33: ... too tight Install the new cotter pin see Fig 32 Install the bolt end caps 1 Lock the rear casters to make sure the lift stays stable during maintenance 2 Disconnect the actuator from the power supply The connector is located under the base cover together with the connector for the leg actuator on the left side of the lift see Fig 15 From SN300155061 the actuator cable must be unpinned from the ma...

Page 34: ... safe working load test as per service procedure 22 12 Perform the anti crush system test as per the Verifying the Anti Crush System service procedure SP5 NOTE If the boom is reassembled using an attachement with a shoulder bolt make sure to secure the shoulder bolt with Loctite 243 and the stover locknut Tighten securely to 20 N m 15 lbf ft Warning If the boom is disassembled it is essential that...

Page 35: ...e 2 Remove the battery pack 3 Dismantle the scale display cover by removing the four screws behind the box see Fig 33 Put aside the cover and remove the two screws that hold the box to the boom 4 Unplug the scale display from the socket Fig 33 NOTE From SN300155061 the scale is sold with the accessory and cannot be separated Socket 1 2 3 Scale cover display ...

Page 36: ...ary use soap and water to ease displacement Remove the cotter pin from the clevis pin slide it out and dispose of it see Fig 32 6 Pull out load cell wire from boom 7 If necessary remove the DPS or spreader bar from the load cell as per Service Procedure 20 Replacing the DPS SpreaderBar from the Load Cell Fig 34 Warning If the scale or any other parts necessary to achieve the task are disassembled ...

Page 37: ...scale reads the correct value Check scale at maximum weight All readings must be within 0 1 of NIST traceable standard Process 2 CAL MENU Press the calibration button see Fig 35 to put system in CAL mode The button on the right allows you to toggle through the menus without saving any parameters The button on the left permits a menu item to be selected or a parameter saved NOTE Allow scale to stab...

Page 38: ...ave or right button to toggle to quit Select quit by pressing the left button to quit without saving changes e Press the left button again to save and the display will show SAV d 4 Set the Full Scale value a Select the Full Scale from the CAL menu by pressing the left button when the display shows FULL b The display will show only the five digits XXXX X with the thousand place flashing 1 Toggle to...

Page 39: ...lay will show HALF apply the predetermined half scale value on the scale and press the left button d Display will show FULL apply the predetermined full scale value on the scale and press the left button e Display will show SAVE press the left button to save display will show SAV d or right button to toggle to quit Select quit by pressing the left button to quit without saving changes 7 Save the p...

Page 40: ...s critically low Over range display Excessive load on scale Low data input to electronics Excessive load on scale CALIBRATION MODE ERROR CAL TO LOW Calibration slope is lower than expected Recheck unit of measure and value input at Half and Full scale ERROR CAL TO HIGH Calibration slope is higher than expected Recheck unit of measure and value input at Half and Full scale ...

Page 41: ... 36 NOTE From SN300155061 the scale is sold with the accessory and cannot be separated Warning If the DPS Spreader bar is disassembled it is essential that all components are reinstalled correctly It is essential that the pivot bolt and the load cell extension block are fastened in a manner that the hole in the threaded end and the hole in the load cell extension block are aligned It must be assem...

Page 42: ...t side of the control box Fig 37 3 Remove the top screw of the handle with a 4mm Allen key and slide out the wire from the bracket see Fig 38 Fig 38 4 Install the new hand control and attach the cable to the hand control clip see Fig 38 5 Replace the battery pack 6 Test if the hand control is working properly as per service procedure 4 Hand Control socket ...

Page 43: ... to safe working load SWL Release the load and remove the load test equipment Check the hoist for any permanent deformation or damage Fig 39 WARNING OBEY ALL RELEVANT SAFETY PRECAUTIONS Two Point Spreader Bar With or Without Scale DPS With or Without Scale Tool No Description Qty Tool No Description Qty ST164 Hand Control and load cell 1 ST164 Hand Control and load cell 1 ST165 Load test strap sho...

Page 44: ...s a UK band It can be ordered outside UK as an example and should be changed to a country specifie layout Record the identity serial number from the DO NOT USE band on your service report sheet and make a note of the failure Use the indelible marker pen to discreetly write the identity serial number from the DO NOT USE band in a corner of the sling Inform the customer of your findings and the acti...

Page 45: ...4 Remove the cotter pin and dispose of it 5 Remove the clevis pin and pull down the DPS or spreader bar to slide out the anti sway rod from the collar 6 Apply the grease provided to lubricate the anti sway rod of the new accessory to install 7 From the open side of the top attachment align the anti sway rod in the collar fig 1 8 Align the accessory and boom holes and hold in place with the clevis ...

Page 46: ... to the ground as possible along the entire lifting stroke when no load is applied The purpose of the Anti sway is to prevent the DPS from freely swinging back and forth after an abrupt stop of an unloaded lift s forward movement The adjustment must be done to prevent the DPS from getting stuck while lifting A DPS that is stuck and suddenly comes free may hit the user patient It is acceptable that...

Page 47: ...mpliant to IEC 60601 1 series including applicable collateral standards and national deviations The MAXI 500 is compliant to ISO 10535 standard WARNING Radio transmitting devices such as mobile telephones two way radios etc should never be used near the MAXI 500 since they can interfere with the function of the lift Cables from potentially strong sources of electromagnetic fields should not be pla...

Page 48: ... cm 12 cm 55 cm 121 cm 22 cm 70 cm 60 cm CSP 16 cm 48 cm 56 cm 25 cm Height of Accessories 2 Hooks Spreader Bar 2 Hooks Spreader Bar with Scale DPS DPS with Scale CSP stands for Central Suspension Point a reference point on the lift for measurements On the Maxi 500 the CSP is the Accessory attachment point located at the boom end ...

Page 49: ...please consult the AMI TIR 18 1997 Guidance on Electromagnetic Compatibility of Medical Devices for Clinical Biomedical Engineers Electromagnetic Emissions Guidance and Manufacturer s Declaration Electromagnetic Emissions For all Equipment and Systems The Maxi 500 is intended for use in the electromagnetic environment indicated below The customer or the user of the Maxi 500 should assure that it i...

Page 50: ... at least 30 Electrical fast transient burst IEC 61000 4 4 2 kV for power supply lines 1 kV for input output lines Not applicable Mains power quality should be that of a typical commercial or hospital environment Surge IEC 61000 4 5 1 kV differential mode 2 kV for input output Not applicable Voltage dips shortinterruptions and voltage variations on power supply input lines IEC 61000 4 11 5 UT 95 d...

Page 51: ...ower of the communications equipment Rated maximum output power of transmitter W Separation distances according to frequency of transmitter m 150 kHz to 80 MHz 80 MHz to 800 MHz 800 MHz to 2 5 GHz 0 01 0 12 0 12 0 24 0 1 0 38 0 38 0 74 1 1 2 1 2 2 4 10 3 8 3 8 7 4 100 12 12 24 For transmitters rated at a maximum output power not listed above the recommended separation distance d in metres m can be...

Page 52: ...ffice G005 Nucleotide Complex Dubai Biotechnology Research Park P O Box 214742 Dubai United Arab Emirates Tel 971 0 4 447 0942 E mail Info ME getinge com NEDERLAND ArjoHuntleigh Nederland BV Biezenwei 21 4004 MB TIEL Postbus 6116 4000 HC TIEL Tel 31 0 344 64 08 00 Fax 31 0 344 64 08 85 E mail info nl arjohuntleigh com NEW ZEALAND ArjoHuntleigh Ltd 41 Vestey Drive Mount Wellington NZ AUCKLAND 1060 ...

Page 53: ...effective everyday care early mobilisation safe patient handling venous thromboembolism prevention pressure injury prevention hygiene routines bariatric care and diagnostics With extensive know ledge and experience we strive to improve efﬁciency and ensure a safer and digniﬁed environment for caregivers and their patients ArjoHuntleigh AB Hans Michelsensgatan 10 211 20 Malmö Sweden www arjohuntlei...

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