Arjo MAXI MOVE Operating instructions

MAXI MOVE
MAINTENANCE AND REPAIR MANUAL
09.KM.00/3GB
August 2006
For internal use only!
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For technical data, measurements and upgrades not found in this guide, please refer to the
Operating Instructions.
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CONTENTS:
Product and Technical Description..........................................................................................4
General........................................................................................................................................5
Risk Assessment Checklist for Engineers ..............................................................................6
Service Matrix.............................................................................................................................7
Suggested Tools........................................................................................................................8
Standard tool kit. ......................................................................................................................8
Recommended Spares ..............................................................................................................8
New implementations in Sweden .............................................................................................8
Loctite Application.....................................................................................................................9
Torque Data and Consumable Materials................................................................................10
12 Monthly Service Procedure................................................................................................16
Jib and Attachments................................................................................................................19
Four Point DPS (Combi and Dedicated).................................................................................21
Four Point Powered DPS (Combi illustrated) .........................................................................22
Jib with Scale Fitted (Combi illustrated)..................................................................................23
Mast Assembly and Push Handle...........................................................................................24
Chassis Assembly ...................................................................................................................27
Sling Checks ............................................................................................................................28
Load Test (local requirement).................................................................................................29
1. Medium Powered and Non Powered Dynamic Positioning System (DPS)......................29
2. Loop Medium Two Hook and Walking Jacket Two Hook ...............................................29
3. Loop Small Two Hook.....................................................................................................29
4. Loop Large Four Hook ....................................................................................................29
5. Large Powered and Non Powered Dynamic Positioning System (DPS) .........................29
6. Combi Stretcher Frame and Strap Stretcher...................................................................29
PCB:s and Wiring Diagram .....................................................................................................33
24 Monthly Service Procedure................................................................................................36
Lift Band Removal and Replacement.....................................................................................36
Repair Procedures...................................................................................................................43
Mast Actuator Removal and Replacement............................................................................43
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Product and Technical Description
The Maxi Move is a mobile patient lifter and is used for transferring patients from bed or chair to
the toilet or bath. The hoist has a Safe Working Load (SWL) of 228kg (501 lb): refer to NOTE.
NOTE: The SWL will depend on the hoist configuration (attachments) always refer to the
maximum SWL label adhered to the lowest rated fitted attachment.
Each Maxi Move is supplied with two 24V rechargeable batteries and a charging unit.
Features of the hoist comprise:
•Emergency lowering button and limit stop switch.
•Emergency stop/reset switch with thermal cut-out.
•Overload current circuit breaker.
•Overload current limit protection in the PCB.
•Up limit switch.
•Down limit/slack tape switch.
•Additional mast keypad.
•Emergency manual wind down.
•Battery condition and machine hours run display.
•Audible low battery warning.
The raising and lowering mechanism comprises an electro mechanical linear actuator powered
by 24V DC motor.
The leg opening and closing mechanism comprises a 24V DC motor and single-ended actuator
(legs open independently).
The Maxi Move with the ‘Lock & Load’ (combi attachment) has the facility to accommodate:
•A 2 point spreader bar for use with a loop sling to support patients with contracted (restricted
movement) or ‘windswept’ (deformed) limbs and walking slings.
•A 2 point loop small.
•A 2 point loop medium.
•A 4 point loop large.
•A 4 point spreader bar Dynamic Positioning System (DPS) for general lifting (small, medium
and large).
•A 4 point powered spreader bar Dynamic Positioning System (DPS) for general lifting
(medium and large).
•A stretcher system for handling dependent, fragile patients with a minimum of disturbance
(SWL 160kg (350 lb)).
•Patient Weighing Scale.
Alternatively the Maxi Move can be a dedicated lifter that is also available with a 200mm
extended jib. If fitted with the extended jib this hoist then has a reduced SWL of 130kg (286 lb)
with the following options:
•Dynamic Positioning System powered or non-powered (DPS).
•Patient Weighing Scale.
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General
A. ARJO strongly advise that only Company Designated parts, which are designed for the
purpose, should be used on equipment and other appliances supplied by the Company,
to avoid injuries attributable to the use of inadequate parts. The Company’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. Un- authorised modifications on any ARJO equipment may affect its safety and
are in breach of any warranty on it. ARJO will not be held responsible for any
accidents, incidents or lack of performance that occur as a result of un-authorised
modifications to its products.
C. If the terms listed below are used in the text their meaning is as follows:
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.
D. Dangerous substances . If using hazardous substances be sure how to handle these
and refer to applicable information. In doubt refer to the local authorities for health and
safety requirements.
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Risk Assessment Checklist for Engineers
WARNING: IF IN DOUBT ASK DO NOT TAKE UNNECESSARY RISKS.
The following assessment MUST be made before carrying out servicing, repair work or
installations.
•Make sure the work area is adequately sized, 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 ARJO reporting procedure.
•If necessary use Hard Surface Wipes (Alcohol Impregnated) to decontaminate a machine
before carrying out any work.
NOTE: The above wipes should be of the type that has proven bactericidal action for
disinfecting hard surfaces against MRSA & E.COLI.
•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.
•DANGER – Electrical Shock can kill.
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.
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Service Matrix
Service 12 Monthly 24 Monthly
MAXI MOVE
Refer to 12 Monthly Service Procedure ,
page 24 
Refer to 24 Monthly Service Procedure,
page 36 
NON-POWERED AND POWERED DYNAMIC POSITIONING SYSTEM (DPS)
2 HOOK SPREADER BAR (VARIOUS MODELS)
4 HOOK LARGE SPREADER BAR
STRETCHER FRAME
Refer to Jib and Attachments., page 19.
SLINGS
Refer to Sling Checks, page 28 
BATTERY CHARGER
Visually check the battery charger for
loose connectors, damage or
deterioration. Recommend replacement
if necessary.

LOAD TEST (LOCAL REQUIREMENT)
Refer to Load Test (local requirement),
page 29 
Refer to Preventive Maintenance Schedule 04.KM.01 for a checklist of action/check
points for both customer and service technician.
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Suggested Tools
Standard tool kit.
Special Tool ST252.
2 x 20kg weights ST219.
Socket Allen Key: (4mm ST82) (5mm ST274) (6mm ST55) (8mm ST87).
Drift ST288.
Ball End Allen Key (4mm) ST292.
Starlock Washer Installation Tool (ST295).
Sling Clip Gauge ST331.
Load Test Equipment: refer to Section 11.0.
Recommended Spares
Refer to PARTS LIST 05.KM.00
New implementations in Sweden
O-ring on actuator guide bush including lubrication of o-ring and inner mast.
See:Technical Bulletin SE57 (noise reduction)
BDI version 3 (from serial number SEE0610423). See:Technical Bulletin SE57
PCB new version 5 (from serial number SEE0618119). See:Technical Bulletin SE57
Spacer of nylon together with new steel spacer for actuator attachment (noise reduction).
Stop screw securing nut on dedicated loop without DPS (Loctite should be applied as screw
has no pre-applied locking) .See page 15.
Stop screw securing nut on dedicated DPS loop, Combi Jibs extended to 8 mm (safety
reasons). See page 13 and 15.
New version of Jackplug (reinforced version)
Covers for scale jib with five screws instead of three screws ( to replace either cover on old
versions will need both new top and bottom cover and two new screws).
The welding of the two steering pins on the detachable combi hanger bar has been
reinforced.
Plastic spacer added for the micro switch mechanism on top of the inner mast in order to
prevent the micro switches from “missing” the top mounting and not being activated.
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
Loctite Application
Refer to the manufacturer instructions on the container before use, in addition to the following
information. (a) Procedure for the correct use of Loctite 242 and Loctite 243 (Colour blue) –
Threadlocking:
- Clean both of the joint faces with Loctite 7063 Cleaner or a lint-free cloth
moistened with Acetone or another suitable volatile solvent.
NOTE: Because Loctite 243 is oil tolerant it is not necessary to
prepare to the same standard of oil free cleanliness as for
Loctite 242.
- Apply Loctite 243 sparingly but sufficient to fill all engaged threads. (This
product performs best in thin bond gaps (0.05 mm)).
- Install the threaded components and where known, torque to the applicable
torque figure. If the torque figure is not known tighten to a firm fixing.
- Clean off any unwanted adhesive.
- Allow the Loctite 243 to cure before subjecting to load.
NOTE: The cure time will depend on the materials used, the ambient
temperature and the bond line gap.
-Where the cure speed is unacceptably long, or large gaps are present,
applying Loctite Activator ‘N’ or ‘T’ to the surface will improve the cure
speed.
For general Loctite specifications and application details: refer to Loctite manufactures
instructions.
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Torque Data and Consumable Materials
NOTE: It is acceptable to use alternative equivalents to the product items listed. The
alternative equivalents must be authorised by the Technical Support department
as suitable for use
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, castors are excepted.
25Nm (18 lbf ft)
Pre-treated
locking
alt. Loctite 243
25Nm (18 lbf ft)
Pre-treated
locking
alt. Loctite 243
Pre-treated
locking
Engrease
L21M 47Nm (35 lbf ft)
Pre-treated
locking
42Nm (31 lbf ft)
Pre-treated
locking
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Engrease
L21M/Lenson/Castrol
Loctite 638
8,7Nm (6,4 lbf ft)
Loctite 243
Lenson White
Grease
Lenson White
Grease
Statoil Uniway
Lix 62
Shell Cassida
8,7Nm (6,4 lbf ft)
Loctite 243
Engrease
L21M/Castrol
20Nm (14,8 lbf ft)
Loctite 243
Shell Cassida
Inside mast
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Lenson White
Grease
Silicone
Loctite Superflex
595
Loctite 454
Loctite 415
5 Nm (3,7 lbf ft)
Loctite 243
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Locking bolt
60Nm (44 lbf ft)
Loctite 243
25Nm (18 lbf ft)
Engrease
L21M/Castrol/vaselin
Engrease
L21M/Castrol/
vaselin
Loctite 243
Loctite 243
Sapphire
Precision Lube
Scale
72Nm (52 lbf ft)
Loctite 243
60Nm (44 lbf ft)
Pre-treated
locking
Tufloc screw
Replaced by
extended
version
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Attachment see page
19
Nyloc and Loctite 243
25Nm (18 lbf ft)
Nyloc
Loctite 415
Bostik 1782
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Attachment see
page 19
Nyloc/ Loctite 243
25Nm (18 lbf ft)
Nyloc
Bostik 1782
Loctite 415
60Nm (44 lbf ft)
Pre-treated
locking
60Nm (44 lbf ft)
Pre-treated
locking
Tufloc screw
replaced. Now use
Loctite 243
Tufloc screw
Replaced by
extended version
Sapphire
Precision Lube
Sapphire
Precision Lube
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12 Monthly Service Procedure
WARNING: OBEY ALL RELEVANT SAFETY PRECAUTIONS.
-Visually check the general condition of all external parts.
-Check that the latest updates have been implemented:
- Check if there are any Field Correction Bulletins, Safety
Notices or Technical Bulletins that have been published
since the last service. (These replaces the previously
used Technical Advice Notices (TAN) with status A
(Safety issue, requiring some form of recall) or B (Non
safety issue).
The check 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
engineering change note, a safety incident report or a
change to form/fit etc.
-Check the serial number of the hoist this is located on the mast console behind the 24V
battery: refer to bar-code label.
-Check that all labels are legible replace as necessary.
-Check that the operating controls on the handset function correctly. If necessary
recommend replacement.
-Check that the operating controls on the keypad mounted on the console function correctly
at all limits.
-Operate the emergency lowering switch, the hoist must lower.
-Push in the ‘STOP’ button. When pressed in, all power functions should be inoperative.
Press the ‘ON’ button to reset.
-With the hoist jib positioned at approximately its mid lifting height:
-Using the handset, lower the hoist jib.
-Keeping the handset button depressed use your other hand to restrain the weight
of the jib.
-The motor will stop while the jib remains restrained by your hand, release the
button on the handset.
-Remove your restraint of the jib.
-The jib must remain in its previously restrained position.
-Repeat using the mast keypad.
NOTE: The lift actuator has a recommended number of 40,000 lift cycles or 440 hours of
use before replacement. One lifting cycle equals raising then lowering the patient.
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-Operate the raise/lower function of the hoist through its full operating range and listen for
any abnormal noise from the actuator. If the actuator is noisy recommend replacement of
the actuator.
-If a powered DPS system is fitted check the operation of the system using the handset and
the mast key pad making sure that the operation is smooth and precise.
-Check the emergency lowering facility as follows:
Electrical
-With the jib raised to approximately its mid lifting height:
- Press and hold the emergency lowering switch. The jib must lower.
- Whilst the jib lowers use your hand to restrain the jib. The motor must
stop.
- Release the emergency lowering switch.
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Mechanical
-With the jib raised to approximately its mid lifting height:
- Remove the battery from the hoist.
- Remove the top cover from the mast.
- Using the Wind Down Tool provided loosen the M12 cap screw
approximately four full turns enough to allow the actuator to rotate freely:
refer to Figure below.
-Insert the Wind Down Tool provided into the top of the actuator and turn in
a clockwise motion to wind down the actuator and jib. The jib must lower
freely.
-Align the black line on the actuator with the black line on the outer mast and
using the Wind Down Tool provided tighten the M12 cap screw, this is a
hand tight fit and must not be over tightened.
Location and Use of Wind Down Tool
Step 1 Step 2
Step 3 Step 4
-Raise the lift arm and visually examine the two lifting bands for any signs of wear or damage
making sure that the starlock washers are installed. Replace if necessary.
NOTE: If the starlock washer is not fitted make sure that it has not fallen inside the
mast.
-Install the mast top cover and battery.
-Check the castors for damage, deterioration and freedom of operation. Check the
effectiveness of the braked castors.
-Visually check the battery indicator and make a note of the hours of powered movement on
the service paperwork.
-If a scale unit is installed to the hoist check the accuracy using the 2 x 20kg weights
(ST219). If recalibration is necessary it must be performed and verified by an approved
organisation and signed off in the logbook.
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Jib and Attachments
(Torques and consumable material according to page 10-15).
WARNING: OBEY ALL RELEVANT SAFETY PRECAUTIONS.
Refer to Figure below:
1.Remove the jib top cover and use a 30mm Socket to check the torque on the M20
locknut that retains the lift support/teebar to the jib.
2. Make sure that the M4 screw item 23 is installed to the lift support/teebar.
3.Check that a force of between 2 – 3 kg is required to rotate the spreader bar in either
direction. -Adjust item 11 if required to achieve the correct force use Loctite on the
threads if adjustment is required in accordance with Section 5.5.
-If a powered DPS is installed visually check the condition of the jackplug (item 20), socket
(item 19) and attached cables.
-Visually check the condition of the jib top cover if cracked or damaged recommend
replacement. Install the jib top cover.
-When rotating the spreader bar listen for any abnormal noise such as rubbing this would
indicate that the assembly requires lubrication. If necessary lightly lubricate the spindle area.
NOTE: If fitted with a 2 point spreader bar attach the Load Cell to the lift hook.
T Bar (Combi) and Lift Support (Dedicated) Retention to Jib
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T Bar to Jib
-Refer to Figure above. Check the clearance between the jib and the T bar this should be
between 1 and 2mm and can only be altered by replacing the bushes there is no other
adjustment.
NOTE: The clearance of between 1 and 2mm is also applicable to the dedicated lift
support.
-Visually check the jib for damage and defects to the paintwork and the welded joints. Make
sure that the end plugs are installed: recommend replacement of any defective parts.
-If fitted with a combi system (see picture below) operate the locking clip and
remove the attachment from the T bar.
NOTE: The combi attachments are optional therefore it is possible that not all will be with
each hoist. Make a note on the Service/Repair Paperwork of all attachments
checked.
-Visually check the condition of the following combi attachments paintwork, welds, hooks,
locking clip, steering pins and sling retaining clips: recommend replacement of any damaged
or defective parts.
-Walking Jacket Small (2 Hook)
-Loop Small (2 Hook)
-Loop Medium (2 Hook)
-Loop Large (4 Hook)
-4 Point DPS
-4 Point Powered DPS
-Stretcher: make sure that the operation of the locking bolt is smooth and precise
and when in the locked position you are not able to fold the stretcher: refer to
Page 13.
Check the welding
of the two steering
pins. If loose
replace the hanger
bar!
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