ARJO HUNTLEIGH Malibu Sovereign Operating instructions

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

Index MRM Malibu/Sovereign
2
Index
Preventive Maintenance Schedule (PMS).................................... 3
Service Procedures, not included in PMS ................................... 5
Service 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 theSafety 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.

MRM Malibu/Sovereign Preventive Maintenance Schedule (PMS)
3
Preventive Maintenance Schedule (PMS)
The US-version of Sovereign is namedMalibu Contour.
Caregiver obligations
PMS Malibu/Sovereign
Action/check Every
day Every week Every month
Every
second
year
Cleaning/Disinfection x
Visually check all exposed parts x
Visually check hoses, pipes and connections x
Perform functionality test x
Check castors on chassis x
Check neckpillow x
Check hand control and cable x
Visually check mechanical attachments x
Visually check the safety belt x
Exercise thermostat mixer x
Check/clean 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 environment, more frequent
inspections should be carried out. Continuing to use this product without conducting regular
inspections or continuing to use this product when a fault is found will seriously compromise
the user and residents safety. Local regulations and standards may be higher than the
manufacturers. Preventive maintenance specified in this manual can prevent accidents.

Preventive Maintenance Schedule (PMS) MRM Malibu/Sovereign
4
Qualified personnel actions
PMS Malibu/Sovereign
Action/check Every
year
Every
2:d
year
Every
3:d
year
Every
5:th
year
Service
Procedure Page
Check that the latest updates have been
implemented x 1 6
Check all vital parts for corrosion and dam-
age x 2 7
Check mechanical attachments x 3 8
Check hoses and connections for leaks
and damage x 4 9
Check/clean filters, incoming water x 5 10
Check valves replace if necessary x 6 11
Check/replace flow restrictors x 7 12
Check/adjust mixer incl. seal kit/complete
thermostatic unit x 8 13
Check dosage disinfection x 9 17
Check shower/disinfection handle x10 19
Lubricate moving parts x11 21
Check the safety cut-out switch x12 22
Check the earth wiring connections x13 23
Test control box batteries x14 25
Perform full feature functionality test x15 26
Check emergency stop x16 27
Check/replace safety catch on lift arm x17 28
Perform a safe working load test
(Local requirement) x18 29
Check actuator lifetime x19 30
Inspect castors on chassis for chair x20 31
Replace safety belt x21 33
Replace filter air-blower (Air-Spa) x22 34
Replace air jet caps and diaphragms (Air-
Spa) x23 35
Replace all pressurized hoses x24 36
Replace control box batteries x25 37
Mixer check (Local requirement, GB only) 813
Replace seat on chair x- -
WARNING
The following actions must be carried out by qualified personnel, using correct tools and
knowledge of procedures.Failure to meet these requirements could result in personal injuries
and/or unsafe product.

MRM Malibu/Sovereign Service Procedures 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

Service Procedures MRM Malibu/Sovereign
6
Service Procedures
SP 1. Check That the Latest
Updates Have Been
Implemented
Check if there are any Field Safety Notices or
Technical Advisory Notices (FSN:s and
TAN:s) that have been published since the last
service.
Field Safety Notice: information notice
informing of what actions must be taken in a
Field Safety Corrective Action.
Technical Advisory Notices are divided in
three classes:
•A:FieldSafety CorrectiveAction (FSCA)
Information about what technical
interventions to be made in order to remedy
safety related issues described by the Field
Safety Notice (FSN)
•B: Information about non-safety related
changes
•C: Information about administrative issues
The check must be done to keep the product up
to date according to safety and product im-
provements.
TECHNICAL ADVISORY NOTICE B
Carendo - Care Raiser
Date: 2007-08-31 Case No: 611
Author: Marie Masseck,
[email protected]
Issue: 1
Subject Care Raiser Document number: SE1507
Product group: Carendo
Background
The Care Raiser was changed in May 2006, the Care raiser was divided into
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 customers who perceive the Care
Raiser as flimsy.
Actions in production
The improved Care Raiser was implemented February 26th 2007, SEE0708193.
Warranty
The new Care Raiser is available as rebuilding kit with article number S8557970-014, for products
manufactured between SEE0620105 (May 23rd 2006) and SEE0708193 (February 26th 2007).
Complaints will be handled through the Complaint Handling System as per procedure.
Carendo - Care Raise
r
ARJO strongly advise and warn that only ARJO company designated parts, which are
designed for the purpose, should be used on equipment and other appliances supplied
by ARJO, to avoid injuries attributable to the use of inadequate parts.
Arjo Hospital Equipment AB
Box 61
S-241 21 ESLÖV
MEMBER OF THE GETINGE GROUP
2007-11-30http://www.ar
j
o.nu/popUp.aspx?x=C%2fHosK
gyy
d
j
t9EIfd4br
g
rOeNk7sNYq0nUPdu...
Example of a published Technical Advisory
Notice B

MRM Malibu/Sovereign Service Procedures
7
SP 2. Check all Vital Parts for
Corrosion and Damage
This check is to preserve the safety and
performance of the 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

Service Procedures MRM Malibu/Sovereign
8
SP 3 Check Mechanical
Attachments
This check is to preserve the safety and
performance of the product.
Check:
(a) Lift arm and hook
(b) Safety catch
(c) Drain, overfill cover
(d) Tub foots, floor attachment
(e) Internal framework and actuators,
especially the swing actuator connection 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
ScrewsandboltsattachedwithLoctiteshouldnot
be checked by tools but manually to test if the
jointing/component is securely fitted.
If tightening is needed and Loctite is previously
used new Loctite must be applied. Proceed ac-
cording to the Loctite manufacturers instructions.
ab
c
d
e
f
g

MRM Malibu/Sovereign Service Procedures
9
SP 4 Check Hoses 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)
ab
COLD
HOT
c
d
e

Service Procedures MRM Malibu/Sovereign
10
SP 5. Check/Clean Filters
Incoming Water
The shut-off valve has a hex lid covering the
filter. Thevalve isdesignedtolet thewaterpass
the filter from inside to outside to avoid
clogging. The same shut-off valve is used on
System 2000, Freedom Bath.
1. Close 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
removingthelid,especially importantonthe hot
water supply.
NOTE
When flushing the valve use a hose to lead out
thewaterina vesseloutsidethebathto catchup
the waste water.

MRM Malibu/Sovereign Service Procedures
11
SP 6. Check Valves, Replace if
Necessary
RPE SOLENOID VALVES These valves are
replacedcompleteifnotfunctioning. Theyhave
an expected lifetime of 100000 openings and
closings. See page 50.
OLD SOLENOID VALVE (Fill valve)
The solenoid valves has a membrane as well as
an anchor seal.
Membrane
The membrane (4) is located underneath the
brass lid (2) and is accessed after removing the
four Allen head screws.
When removing the lid; note the position of the
membrane as there is a small bleed hole and
brass pipe in the membrane (A) that has to be
assembled correctly to function.
The membrane is also equipped with a pressure
transition hole (B), allowing the pressure to
build up on top of the membrane thus keeping
the valve closed.
As the transition 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
looseningandremoving thesolenoid(1)andthe
anchor housing. Be careful not to loose the
anchor spring on the anchor.
The service kit for this valve includes position
4, 5, 6 and 7.
Membrane condition
Focusshouldbe onthemembranerubberstatus:
it should not stain your fingers when touching it
or show signs of deterioration. Clean off all
surfaces with a rough cloth or similar before
reassembling the valve.
NOTE
Before replacements and service, shut off all
water supply.
RPE MPA valve
RPE Fill valve
1. Solenoid (24VDC 50/60Hz)
2. Valve lid
3. Valve body
4. Membrane
5. Return spring
6. Solenoid anchor
7. Solenoid anchor housing
1
6
54
3
7
2
A
B

Service Procedures MRM Malibu/Sovereign
12
SP 7. Check Flow Restrictors
If the water regulation of the MPA is disturbed
check:
1. That the flow and pressure of incoming wa-
ter is sufficient.
2. If the flow and pressure of the incoming
water is OK then measure the flow from the
shower, (default 4,9-5,7 l/min) by filling a
vessel with known volume
3. Calculatethe flowbydividing thevolume of
the vessel with the time to fill the complete
vessel e.g. 20 l /4 min=5 l/min
4. Perform the test twice
5. Ifthe averageflow is4-5l/minormorethere
is no need to replace the flow restrictors
6. If the average flow is less than 4 l/min both
the fill 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 and fit the
hoses
4. Pump valve, bottom view right:
Disconnect the hoses from the valve and
unscrew it from the hose nipple (c).
Note. With auto flush cabling for valve 1 (d)
is not connected and line (e) is plugged.
5. When assembling the pump valve, note
positioning; back outwards
3
3
2
1
1
2
Front view
Back view
Yellow
Brown
Red
Green
Orange
Black
Orange
Black
Brown Yellow
Red
Green
Cable connections for 3-way valves
c
de
b)Pump valve
a)Fill valve

MRM Malibu/Sovereign Service Procedures
13
SP 8. Check/Adjust Mixer
Including Seal Kit/Complete
Thermostatic Unit
For mixers installed in any UK National
Health Service Installation. Please refer to
document 10.AR.03.
If the mixer does not provide sufficient
amount of water or if the temperature
regulation/stability is poor:
• Check incoming flow, pressure and
temperature
• Check that hot water (stable 40°C) is shut off
if incoming cold water check valve is closed
• Cleanfiltersincoming water according toSP
5
• Check shower handle flow according to
SP 10
• Check fill flow using the tub filling times in
Instructions for Use.
If 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 well lubricated or it
will be difficult to adjust the temperature.
(Lubrication see page 50)
As the mixer is difficult to serve in place it´s
recommended to start with disassembling the
mixer.
Disassembling the mixer from the tub
1. Reaching the mixer from the short side will
simplify the procedure but is not necessary
2. Shut off the water supply
3. Raise the tub to top position
4. Remove the front panel and inner cover
b
a

Service Procedures MRM Malibu/Sovereign
14
5. Unscrew the PEX pipes to the mixer.
6. Slightly loosen the two screws (a) holding
the mixer to the u-bar and remove the screw
(b) holding the bracket (e) to the chassis
7. Pull out the mixer
8. The mixer shaft (c) will pop out of the mixer
hub (d) and can be left hanging.
Removing the adjustment plate and
cartridges
• Remove the four screws (f) holding the
adjustment plate (g).
• Use repair kit with three cartridges -
replacing single cartridges or o-rings will
not restore to full performance
• Replace check valves (j) and o-rings (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. Attachantightenscrewsholdingmixer(a,b)
4. Attach PEX pipes
5. NOTE: Adjust the mechanical scalding
protection (see page 16)
6. Test function
7. Attach inner cover and front panel
NOTE
Hot water may come out of the mixer
NOTE
The cartridges (h) are spring loaded (i) and can
pop up very hard when all screws are removed.
Only cartridges with a white top should be used.
f
g
i
Cartridges and adjustment plate
h
j
k
Mixer
a
b
e
c
d

MRM Malibu/Sovereign Service Procedures
15
Test of the electronic scalding
protection (fill, shower, tub)
1. Remove the plug (a), loosen the screw (b),
remove the knob (c)
2. Activate the filling
3. Turn the plastic part (v) anti-clockwise until
the fill temperature exceeds the scalding
protection temperature 45°C and shuts off.
(Use a calibrated thermometer ±0,5°C)
(see Technical Manual: Scalding protection
for temperature diagram)
4. Proceed according to 3 but activate the
shower.
5. For tub: fill tub with water above 45°C with
scalding protection off (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. Useinternal thermometer tomeasure at what
water temperature the scalding protection is
deactivated.(Thetemperaturewillfallbelow
45°C within one minute.)
9. If the scalding protection does not work
check:
Sensor and connections to sensors for
-fill (g), position J11 on the PCB
-shower (h), position J12 on the PCB
-tub (i), from thermometer
thermometer (connects to position J8/J12 on
the PCB), or replace the thermometer.
10.Proceed with Adjustment of the
mechanical scalding protection below to
set the stop ring.
NOTE
The scalding protection LED on the tub display
must flash yellow (f)
b
c
d
e
a
g
i
h
f

Service Procedures MRM Malibu/Sovereign
16
Setting of the mechanical scalding
protection.
1. Remove the plug (a) loosen the screw (b)
and remove the knob (c).
2. Activate fill.
3. Turn the plastic part (d) counterclockwise
until the correct temperature is measured.
(see page 26 for set values). Try to get as
close as possible to this temperature as over
temperature will activate the scalding
protection and shut off the hot water.
Remember that the fill water setting results
in a shower temperature around 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 stop ring (e). In this position
it shall be impossible to turn the knob
counterclockwise.
7. Turn the knob to cold and then back to
maximum heat to check the set temperature
values not exceeds the maximum allowed
temperatures for fill and shower.
8. Reassemble the screw (b) with plug (a).
b
c
d
e
a
e
c

MRM Malibu/Sovereign Service Procedures
17
SP 9. Check Dosage
Disinfection
Perform the procedure in a room temperature
between 20-25°C (68-77°F) to obtain correct
set values.
1. Open the panel lid and remove the disinfec-
tion bottle
2. Fill a graduated 50 ml cylinder with your
used disinfection fluid.
3. Place the cylinder where the disinfection
bottle was placed
4. Place the bottle connection (a) in the
cylinder
5. Hold the disinfection handle in tub rim level
and pointing downwards
6. Start the disinfection by pressing the
disinfection button (b) for 5 seconds
7. Press the handle trigger to get a disinfection
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 the disinfection, remember to hold the
handle in tub rim level
12.When the level in the 50ml cylinder passes
50 ml start to spray the disinfection mixture
into the container until the level reaches 20
ml
13.Shut off the disinfection by pressing the
disinfection button (b)
Disinfection agent Value ml/l
ArjoClean up to
VEPL00005449 70 16
ArjoClean from
VEPL00005450 50 16
80
70
60
50
40
30
20
c
a
b

Service Procedures MRM Malibu/Sovereign
18
14.Calculate the ratio in ml/l which is 30ml
dividedwiththe mixed volume, forexample
30 ml/1,86 l = 16 ml/l. Compare with
approved value in ml/l according to table.
The mixed volume must not give a too low
concentration but it is acceptable if the
calculated value is 5% higher. 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 green LED and
sound for 5 seconds shall be heard
If not check replace with new bottle connection
and test again.
b
a

Service Procedures MRM Malibu/Sovereign
19
SP 10. Check Shower/
Disinfection Handle
Shower handle
Check shower handle for bad flow, leaks/
damage and replace if necessary.
1. Turn the adjuster ring (a), fully anti clock-
wise
2. Unclip and remove the adjuster ring (a)
3. Unscrew the spray plate (b) anti clockwise.
The o-rings (c) will provide some resistance
4. Clean parts (a,b,c) with astiff brush inwater
or if necessary delime
5. Assembletheo-rings(c) and make sure they
are located correctly
6. Turn the flow divertor (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
• Checkhandle holderfor cracks, leaksand/or
sharp edges
• Check fastening of handle holder
• Repeat insertion and removal of shower
handle into holder for safe fit
Disinfection handle (Yellow)
Note, grey shower handle is illustrated.
Repair kit A:
1. Knock out two taps (a) holding trigger and
remove the trigger, there is a sleeve inside
2. Pull out the plastic stop (b)
c
b
a
d
e
f
g
a
b

Service Procedures MRM Malibu/Sovereign
20
3. Replace old valve (c) and spring (d) with
new ones.
4. Unscrew the hose connection 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