ARJO HUNTLEIGH Maxi 500 Operating instructions

1
5001-00553-EN rev 5 • 1/2018
Maxi 500
Maintenance and Repair Manual

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Design Policy and Copyright
® and ™ are trademarks belonging to the ArjoHuntleigh 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.

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001-00553-EN rev. 5
Safety Instructions..................................................................................................................... 4
General Information.................................................................................................................................. 4
Product and Technical Description.......................................................................................... 5
Introduction............................................................................................................................................... 5
Features................................................................................................................................................... 5
Risk Assessment Checklist for Service Technician.................................................................................. 6
Suggested Tools ...................................................................................................................................... 7
Recommended Spares............................................................................................................................. 7
Threadlocker Application.......................................................................................................................... 8
Torque, Lubrication and Threadlocker Data............................................................................................. 9
Preventive Maintenance Schedule.......................................................................................... 11
Technician Inspections........................................................................................................................... 12
Troubleshooting....................................................................................................................... 14
Service Procedures.................................................................................................................. 15
Service Procedure 1 - Check for Updates.............................................................................................. 16
Service Procedure 2 - Checking the Battery and Charger..................................................................... 16
Checking the Battery........................................................................................................................... 16
Battery Test......................................................................................................................................... 17
Check the battery charger (NDA8200).................................................................................................18
Service Procedure 3 - Checking for Corrosion and Damage................................................................. 19
To Verify:............................................................................................................................................. 19
Floor Lift Paint ..................................................................................................................................... 19
Service Procedure 4 - Full Feature Test ................................................................................................ 20
Service Procedure 5 - Verifying the Anti-Crush System......................................................................... 20
Service Procedure 6 - Replacing the Front Wheel................................................................................. 21
Service Procedure 7 - Replacing the Back Wheels................................................................................ 21
Service Procedure 8 - Replacing the Leg Actuator................................................................................ 22
Service Procedure 9 - Replacing the Legs............................................................................................. 24
Service Procedure 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
Service Procedure 16 - Replacing the Boom Actuator........................................................................... 33
Service Procedure 17 - Replacing the Boom......................................................................................... 33
Service Procedure 18 - Replacing the Scale.......................................................................................... 35
Removing the scale............................................................................................................................. 35
Installing the scale............................................................................................................................... 36
Service Procedure 19 - Calibrating the Digital Scale ............................................................................. 36
Error Messages................................................................................................................................... 40
Service Procedure 20 - Replacing the DPS/Spreader Bar from a Load Cell ......................................... 41
Service Procedure 21 - Replacing the Hand Control ............................................................................. 42
Service Procedure 22 - Safe Working Load Test (Local Requirement) ................................................. 43
Service Procedure 23 - Verifying the Slings........................................................................................... 44
Service Procedure 24 - Replacing the DPS or spreader bar.................................................................. . 45
Service Procedure 25 - Anti-sway Adjustment....................................................................................... 46
Technical Specifications.......................................................................................................... 47
Electromagnetic Compatibility................................................................................................ 49
Electromagnetic Compliance.................................................................................................................. 49
Electromagnetic Emissions.................................................................................................................... 49
Electromagnetic Immunity...................................................................................................................... 50
Table of Contents

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001-00553-EN rev. 5
Safety Instructions
General Information
A. ArjoHuntleigh strongly advises that only ArjoHuntleigh designated parts, which are designed for the
purpose, should be used on equipment and other ArjoHuntleigh supplied appliances to avoid injuries
attributable to the use of inadequate parts. ArjoHuntleigh’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 ArjoHuntleigh equipment may affect its safety and are in breach of
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 the local authorities for health and safety requirements.
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.

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001-00553-EN rev. 5
Product and Technical Description
Introduction
The Maxi 500 is a mobile patient lifter and is used for transferring patients from the bed, chair or the toilet.
The floor lift has a maximum safe working load (SWL) of 227kg (500lb).
Each Maxi 500 is supplied with two 24VDC rechargeable batteries and a charging unit.
Features
The features of the Maxi 500 floor lift include:
• 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 and a single-ended actuator (legs
open simultaneously).
NOTE: The SWL will depend on the lift’s configuration and attachments. Always refer to the
maximum SWL of the lowest rated attachment.

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001-00553-EN rev. 5
Risk Assessment Checklist for Service Technician
The following assessment MUST be made before carrying out servicing, repair work or installations:
• Make sure the work area of adequate size, 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 ArjoHuntleigh reporting procedure.
• If necessary use hard surface wipes (alcohol impregnated) to decontaminate a machine before
carrying out any work.
• 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.
• 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.
WARNING: Service must be carried out by qualified personnel, using correct tools and with a
knowledge of procedures. Failure to meet these requirements could result in personal injuries
and/or unsafe equipment.
WARNING: IF IN DOUBT, CONTACT YOUR LOCAL ArjoHuntleigh REPRESENTATIVE. DO NOT
TAKE UNNECESSARY RISKS.
NOTE: The above wipes should be of the type that has proven bactericidal action for disinfecting
hard surfaces against MRSA & E.COLI.
DANGER – Electrical Shock can kill.

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001-00553-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

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001-00553-EN rev. 5
Threadlocker Application
Refer to the manufacturer’s instructions found on the container before use, in addition to the following
information:
The procedure for correctly applying Loctite 242 and Loctite 243 (Blue color) threadlocking is as follows:
• Clean both of the joint faces with Loctite 7063 cleaner or a lint-free cloth moistened with acetone or
another suitable solvent.
• Apply Loctite 243 sparingly but sufficiently enough to fill all engaged threads. (This product performs
best in thin bond gaps [0.05 mm]).
• Installthe threaded componentsand,whereknown,torqueto the applicable torque value.Ifthetorque
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 general Loctite specifications and application details, refer to Loctite manufacture’s instructions.
NOTE: Because Loctite 243 is oil-tolerant, it is not necessary to meet the same standard of oil-
free cleanliness as for Loctite 242.
NOTE: The cure time will depend on the materials used, the ambient temperature and the bond
line gap.

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001-00553-EN rev. 5
Torque, Lubrication and Threadlocker Data
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.
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

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001-00553-EN rev. 5
Fig. 3
Loctite 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

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001-00553-EN rev. 5
Preventive Maintenance Schedule
WARNING: Service must be carried out by qualified personnel, using correct tools and with a
knowledge of procedures. Failure to meet these requirements could result in personal injuries and/
or unsafe equipment.
TO BE INSPECTED ANNUALLY BY A QUALIFIED TECHNICIAN Call out reference
(page 12-13)
• Inspect all weld sites for cracking or separation both on lift and spreader bar/DPS. -
• Make sure that the spreader bar/DPS is securely fastened. 8
• Make sure that the spring pin is inserted through the pivot bolt and the load cell. Verify that
the pivot screw cannot be unscrewed (see SP20). 9
• Actuator’s attachments
With shoulder bolts :
Ensure that the shoulder bolts at both ends of the actuator are well
secured by the locknut stovers with Loctite and that the pivot bushings are in place and in good
condition.
With clevis pins : Ensure that the clevis pins at both ends of the actuator are well secured
by the split rings and that the pivot bushings are in place and in good condition.
10-11
• Make sure that all nuts and locknuts of the base open/close mechanism are securely
fastened and the ball joints are in good condition. 12-19
• Check both mast screws to ensure that they are tight. 20-21
• Make sure that the pivot bolts on legs are tight. 22-23
• Check that all casters are securely tightened. 24-27
• If applicable, verify 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 for the clevis pin has not widened. 33
• Verify that the boom is not abnormally loose with relation to the mast. -
• Run both actuators to ensure that the limit stops are functioning. -
• Press the emergency stop button and make sure that all electrical power is cut off and that
the green power light is off. 34
• Check all functions of the hand control - ensure that the hand control touch pad membrane is intact. 35
• Check for the proper function of each auxiliary switch located on the control box. 36
• Verify that the batteries are in good condition and that they are not leaking. 37
• Verify all cables. 38-39
• Verify the actuator’s anti-crush system (see SP5). -
• Ensure that the cotter pin is properly securing the clevis pin. Push back the boom cap to
have access to the cotter and clevis pins. 40
• Check that the spreader bar flange bushings, pivot bolt and welds are in good condition. 41
• Check the condition of the friction discs and bushings of the DPS within the pivot points.
If found worn and/or damaged, parts must be replaced. 42
• Whenthe frictiondiscs andbushingsof theDPS havebeen checked/replaced, resetfriction
assembly to support a 5.4 kg (12 lb) load at the handle. 42

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001-00553-EN rev. 5
Technician Inspections
Fig. 4

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

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001-00553-EN rev. 5
Troubleshooting
(*) Some wall outlets are controlled by wall/light switches. Ensure power to wall outlet continues after
wall/light switch is turned off.
(**) Generally with low amperage, the actuator will make a humming noise, indicating insufficient battery
power.
Lift Trouble Resolution
Hand control does not
respond
• Check the red emergency stop button on the control box.
• Check the connector on hand control cable.
• Checkifthe batterypackis installedcorrectlyandfully charged.Test
with a new, fully-charged battery pack.
UP and DOWN buttons on
control box do not respond
• Check the red emergency stop button on the control box.
• Checkifthe batterypackis installedcorrectlyandfully charged.Test
with a new, fully-charged battery pack.
Actuator does not respond
• Check the red emergency stop button on control box.
• Checkifthe batterypackis installedcorrectlyandfully 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 exceeding the lifting capacity.
Charger Trouble Resolution
“Power on” light on charger is
not lit • Check if the charger is plugged into an electrical wall outlet.
Charger is plugged in, but
“Power on” light is not lit • Check there is power to the wall outlet.*
Battery Trouble Resolution
Battery pack is properly
seated but no lights are
visible.
• Call for service (charger may be faulty).
Yellow indicator light does
not go off after several hours
of charging time.
• Internal batteries need replacing. Call ArjoHuntleigh for
replacement.
Battery pack indicates it is
fully charged when in the
charger, but when placed in
the lift, will only do a few lifts.
• Replace internal batteries.**

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001-00553-EN rev. 5
Service Procedures
Fig. 6
SP1 - Checking for Updates
SP2 - Checking the Battery and Charger
SP3 - Checking for Corrosion and Damage
SP4 - Full Feature Test
SP5 - Checking the Anti-Crush System
Replacing Front Wheel - SP6
Replacing 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 - SP19Replacing
DPS/Spreader
Replacing Hand Control - SP21
Bar from a Load
Safe Working Load Test - SP22
Verifying the Sling - SP23
Cell- SP20
Adjusting the Legs - SP10

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001-00553-EN rev. 5
Service Procedure 1 - Check for Updates
Service Procedure 2 - Checking the Battery and Charger
Checking the Battery
ArjoHuntleigh has added a fuse in battery NDA0100-20.
There is no noticible difference between the former and the new battery version other than the labeling
(see following pictures for more details on the former battery labeling and the new battery labeling).
Only battery testers with current less than 20A, such as battery tester part #8662950 (refer to TAN
SEE201204 and see Fig. 9 on next page), can be used for 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 last service was performed.
• 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
engineeringchange note,a safetyincidentreport,achange
to form/fit, etc.
Fig. 7
Fig. 8
Former labeling
(battery without fuse) New labeling
(battery with fuse)

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001-00553-EN rev. 5
condition on a meter.
Battery Test
Battery without fuse - former labeling
With former battery tester.
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, turn 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.
.
Battery with fuse - new labeling
With battery tester (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 battery power tester is kept away from flammable
material during test and for several minutes AFTER the test.
• Beware NOT TO TOUCH the metal casing for several minutes AFTER the test.
Tester (8662950) for battery with fuse
Tester for battery without fuse Fig. 9

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001-00553-EN rev. 5
Check the battery charger (NDA8200)
1) Inspect charger and cable for damage.
2) Test charger for operational condition as follows:
• Measure charger output voltage (directly on output socket prongs).
Charger status indicator LED should be GREEN.
Voltage reading should be between 27.04V and 28.16V.
• 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.
Charger must be replaced if any test result is not within specifications stated above.
Fig. 10
Battery charger

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001-00553-EN rev. 5
Service Procedure 3 - Checking for Corrosion and Damage
This verification will help preserve the safety and performance 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

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001-00553-EN rev. 5
Service Procedure 4 - Full Feature Test
Service Procedure 5 - Verifying the Anti-Crush System
1) Place an object beneath the boom (e.g. place Maxi 500 boom over a table).
2) Press the “down” button on the unit’s control panel.
3) The actuator should stop operating and the downward motion should cease immediately when
the boom makes contact with an object.
4) If the motion does not stop, remove the lift from service until necessary repairs are performed
(see “Service Procedure 16 - Replacing the Boom Actuator).
5) Repeat the procedure using the “down” button on the hand control.
6) When repairs are done, perform anti-crush system test again to make sure it is in proper working
condition.
Function Activation/
Validation Actions Criteria for approval
Lift up/down Buttons Full stroke up and down No abnormal noises; unit reaches up/ down points as per specifications
(see the Instructions for Use)
Legs open/
close Buttons Full opening and 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 lift functions working; no display issues
Control panel Buttons Press each button All functions working normally
Emergency
lowering device Manual Use emergency
lowering device
(see the Instructions for Use)Boom must lower as per user manuala
a. In order to have the emergency lowering device work properly, a load that pushes downwards on the boom
must be applied.
Warning: If the anti-crush device does not work properly, this can cause pinching or crushing
which can lead to death or serious injury. If lift components are disassembled in order to maintain
anti-crush system proper operation, it is essential that all parts are reinstalled correctly. If not,
the consequence may be later disengagement, which can lead to death or serious injury.