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elite series surgical tables model elite 6500

1. TTE il 745 Wiring Diagram Model 6500N Page 72 IP 147 el Du 1 154 RC RL 22 ed ACIISV o CNIS o LJ Ho LOT Qa 0 5 O 0 58 LIST ous swe To Toom HOT 3 7 art o Es LL 9 O oos e CR 21 Ert Hol oe 227 9 5 ep oa o 0000090090 f 9 e PENDANT CONTROL 4 1 0 0 o GoGoeQ FOOT CONTROL AUX SWITCHES DOD 3 PDODODOQIOVOSOOOO 4 DOME gl 2 5 Oe t t 5 OO DOGO m AAO FH Og J 111 20069 Hn Q
2. 0 m oc avia ES pOg C Os O p rQ 1 m aa Lie NN C C ou me 0 0 1 I 1 1 6 I 1 E 1 2 9 Wiring Diagram Model 6500B Page 73 16 em res Q 9 9 Qi Keo oa Pota 0 10 4 4 r i gat m 2 1 t o9 4 7 1 4 T a mers 2 672 gJ pant 194 4 9 1 L m i84 9 en Le an E im E EC NNNM D i io CEDE 3 ILI 5 1 14 2 3 09 11 1 et s 77 15 p 9 E 5 ed berg Le 19 TS 9 Jem 9 54 coe 51 09 ecl 187 1 9 8 9 16 s e 2 rs 9 75 22 zp 77 e 01 09 5 8 18 2 Ca Qa 1 e Qo Di G 1 7 4 o 1 9 0 oso 0 d 9 3 8 9 7 9 9 mt 169 e m 78 er 83 c e n e Qi a z 9 181 169 ie 15 mt
3. e PP mY a y NK Y FAG di A A HN ACL N ELITE SERIES SURGICAL TABLES MAINTENANCE MANUAL MODEL ELITE 6500 INCLUDING BATTERY MODELS Table of Contents SECTION HYDRAULIC SYSTEM 1 1 1 1 1 2 Component Operation esos Soest 3 a Moior Pump ss rua baud RHOD S M D Eq Lp eS 3 p Press re Relist Valve ERE A DD SS 3 MDC PEE 4 d Mini valve in Neutral Position 4 MiniValve Right Activated 5 f Mi i Valve Left Port GUN 5 g Hydraulic Cylinders Slave 2 4 6 h Elevation Cylinder Return Circuit Recta inci diesel 8 l Brake System 8 j Emergency Brake Release 9 Flex Reflex S
4. ALY TERMINAL A MINI VALVES AJ zb KH PRESSURE he ut y ELEV TILT FLEX BACK LEG BRAKE OIL RESERVOIR MOTOR PUMP ASSEMBLY Figure 1 2 Hydraulic Block Diagram Later Models Page 2 1 2 Component Operation a Motor Pump Operation motor pump assembly is a gear type pump that provides the oil pressure and volume for the entire hydraulic system The pump has an inlet side and an outlet side The inlet side is connected to the reservoir which provides the oil supply The reser voir has a very fine mesh screen strainer which prevents foreign material from entering the oil system The output line of the pump is connected to the main oil galley which is internal and common to all the hydraulic mini valves and pressure relief valve Also common to the hydraulic mini valves and pressure relief valve is an oil galley that internally connects to the oil reservoir to provide a return path for the hydraulic oil See figure 1 3 MAIN RETURN OIL GALLEY INTERNAL MOTOR PUMP ASSEMBLY PRESSURE RELIEF VALVE PUMP INLET Figure 1 3 b Pressure Relief Valve This device provides an alternate oil path when the hydraulic cylinders reach the end of their stroke and the pump continues to run Ifthis path were not provided the pump motor would stall because the oil cannot be compressed The pressure relief va
5. NOTE If you do notreceive the proper continu ity results at connector CN2 it does not necessarily mean the micro switch is defective There could be a problem with the riser cord between connectors CN2 and CN10 orin the wiring from the switch to connector CN10 Further tests will have to be made to determine the exact problem IMPORTANT Wire colors may vary however con nection from indicated pins on CN10 to pins on CN2 remain the same Az 49 KIDNEY 16 4 RED WHITE 8 BLACK 9 5 8 42 3N_ GREY LEG 7 DOWN NS 7 43 WHITE BLACK D Y 10 WHITE BROWN T BACK UP 6 NS 6 42 PURPLE 5 9 42 8 BLUE BACK 5 DOWN NS 5 0 1 TILT RIGHT GREEN NS 4 O 3 YELLOW 5 LEFT NS 3 4 BROWN REVERSE 3 TREND WHITE 2 TREND E 1 1 NS 1 9 ORANGE Rg 2 CN10 RISER CORD Figure 5 13 Return Micro Switch Test Page 35 WHITE RED N SERIES LS 1 KIDNEY LIFT CYLINDER LS 1 Back Up Inhibit Test at pins 11 amp 12 eee Soe eee ee ORANGE CN2 Old Style Base N Series Base Switch Meter Switch Meter Position Reading Position Reading Closed 0 Infinity Open Infinity Closed 0 When K Lift is UP Back Section Not
6. Page 16 3 5 LATERAL TILT DIAGNOSIS CHART Problem Reason Lateral tilt function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control Lateral tilt function chatters or loses position Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil REAR PIVOT BLOCK CYLINDER HOUSING PISTON O RING CYLINDER CAP LEFT TILT FLEXIBLE HOSES PLUMBING COPPER LINE TERMINAL 22 right TILT WE LAM INTERNAL OIL P FROM PUMP MINI VALVE INTERNAL OIL RETURN TO RESERVOIR Figure 3 3 Lateral Tilt Circuit Page 17 3 6 FLEX SYSTEM DIAGNOSIS CHART Problem Back Section or Trendelenburg function moves improperly IMPORTANT If Flex System does not function prop erly check the back section and tren delenburg functions before adjusting the flex system Back Sectionor Trendelenburg function chatters or loses position TREND CIRCUIT TO TRENDELENBURG MINI VALVE CHECK VALVE SPEED CONTROL MINI VALVE INTERNAL OIL FROM PUMP PLUMBING TERMINAL Reason Incorrect Speed Adjustment Trendelenburg Back section or Flex check with gauge Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini Valve Pre
7. Figure 1 23 FOOT UP KIDNEY DOWN Any control function should move in either direc tion atthe same rate Ifthe rate of a certain function is too slow open the speed control slightly and recheck Use the second hand on a watch and time a particular function Match that time in the oppo site direction by opening or closing the speed control Approximate operating times are as fol lows Lateral Tilt 7 seconds Back Up 25 seconds Back Down 15 seconds Kidney Lift 7 seconds A pressure gauge should be used to set the speed of the back section trendelenburg and flex control functions To adjust 1 Attach the pressure gauge onto the main oil galley as shown in figure 1 22 2 Thegauge should read the following values when operating the various control functions in either direction Turn the speed controls until desired values are obtained Back Section Up 65KG CM 925PSI Dn 65KG CM 925PSI Trendelenburg Up 65KG CM 925PSI Dn 65KG CM 925PSI Flex 70KG CM 995PSI Reflex 70KG CM 995PSI NOTE When adjusting Flex Reflex speed con trols set Reflex last Elevation There is not a speed adjustment for raising the table The speed control will only affect the rate of descent and it should equal the rate of elevation Page 11 MECHANICAL TABLE ADJUSTMENTS 2 1 Back Section Gear tre The gear mesh is adjusted by the use of tric cam This cam moves the gear teeth closer together to
8. POWER SWITCH FUSE PLATE 7 RECHARGING N13 LAMP POWER CORD Figure 6 1 Electrical Circuit Block Diagram Model 6500B Page 41 6500B 6 3 Main Switch The main power supply 120 VAC 60 HZ comes inthrough the power cord and through the main switch The main switch opens both lines when in the OFF position An 8 amp fuse is used to protect the complete electrical system and is located next to the main switch See figure 6 2 a Main Switch Test The following test will determine if line voltage is applied to connector CN12 which in turn would supply 120VAC power to the table 1 Plug the power cord into the 120VAC supply wall receptacle and turn the main switch ON 2 Disconnect connector CN12 See figure 6 1 Leave all other connectors connected CAUTION Line voltage 120 VAC will be mea sured in this test Do not touch uninsu lated connector pins or metertestleads 3 Use an AC voltmeter capable of measuring 120 VAC and measure the voltage between pins 1 and 2 black and white wires located in connector CN12 See figure 6 3 You should receive line voltage 120 VAC Connector CN12 Color Code Pin 1 Black Pin 4 Black Pin 2 White Pin 5 Red Pin 3 Yellow Pin 6 Blue Figure 6 3 Connector CN12 Test b Test Results If the correct voltage is obtained everything is good up to this point and the problem would have to be in another area Page 42 If you do not receive the correct mea
9. tae pentes 20 3 9 stk sc dnt utut 21 2 10 BRAKE CIRCUIT DIAGNOSIS CHART sierras 22 3 11 Flexible Hose Identification and Placement 23 SECTION IV ELECTRICAL SYSTEM dS 24 4 1 General rs 24 4 2 COMPONEN Cm 24 4 3 Battery Model Components 04 444400 00 0 24 Although current at time of publication SKYTRON s policy of continuous development makes this manual subject to change without notice REV 9 01 Table of Contents continued SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING 26 od Troubleshooting MOIBS 26 sa 26 53 Fendant ee ee errr or er 27 54 28 S9 METER 30 546 Motor Pump Assembly 32 8 1 6 D ET 34 5 8 Troubleshooting aaa a 34 SECTION 6500B BATTERY MODEL ELECTRICAL TROUBLESH
10. the motor or wiring is defective Page 67 SECTION VIII ELECTRICAL SYSTEM ADJUSTMENTS 8 1 Relay Box Adjustments The Relay Box contains variable resistors for ad justing the operating timers for the BRAKE SET and BRAKE UNLOCK functions The Relay Box for the battery model tables also has variable resistors for setting the Power Off timer and the battery recharge warning circuit These timers are set at the factory and usually never need adjust ment If an adjustment is necessary remove the relay box cover and use the following procedures See figures 8 1 through 8 3 a Brake Release Timer The Brake Release Timer is set for about 7 sec onds and is controlled by the variable resistor VR1 on the relay box circuit board Turn the adjuster clockwise to increase the operating time Counter clockwise to decrease the operating time b Brake Set Timer The Brake Set Timer is setfor about 7 seconds and is controlled by the variable resistor VR2 on the relay boxcircuit board Turnthe adjuster clockwise to increase the operating time Counterclockwise to decrease the operating time c Battery Low Voltage Indicator When the battery voltage drops below 23 5 volts the BATTERY power indicator will begin to Flash indicating low battery power This circuit is con trolled by the variable resistor VR3 and should be set at 23 5 volts Turn the adjuster clockwise to increase the voltage at which the circuit is acti vated countercl
11. 1 8 Mini Valve Left Port Activated 1 Spool Valve Pushed to the right by electric solenoid This opens the internal oil pressure gal ley allowing the fluid to go through the check valve and on to the cylinder Also the spool valve opens the oil return line providing an oil path through the internal oil galley back to the reservoir 2 Pilot Plunger Valve Right pilot plunger valve is pushed up by the incoming oil pressure mechani cally opening the check valve located above it in the return circuit This action allows the oil from the right side of the slave cylinder to go back into the reservoir Theleftpilot plunger valve is not affected in this operation mode 3 Check Valves Both check valves are opened in this operation mode The left valve is pushed open by the oil pressure created by the pump The oil then continues to go through the lines and pushes the slave cylinder piston to the right Atthe same time the right check valve is held open mechanically by the pilot plunger providing a return path for the oil through the mini valve back to the reservoir 4 Speed Adjustment The left speed control output side does not have any effect in this oper ation mode because the oil is routed around the speed adjustment through a by pass valve and then to the output port The right speed adjustment controls the speed of the table function by restrict ing the amount of oil going back to the reservoir Page 5 9 Hydraulic Cyl
12. Pinched Hose Defective Mini Valve Defective Relay Box or Pendant Control Brakes Will Not Stay Locked Emergency Brake Release Valve Open or Defec tive Defective or Dirty Check Valve Oil Leakage in Circuit Leaking O Ring Inside Cylinder Brakes will not retract properly Incorrect Speed Adjustment Bad Check Valve Spool Valve Not Centered Defective Mini Valve Pinched Hose Defective Solenoid or Wiring Defective Relay Box or Pendant Control BRAKE CYLINDER PLUMBING TERMINAL BRAKE FLEXIBLE CYLINDER HOSES HOSE yu RETURN TO i id i RESERVOIR di S EMERGENCY CHECK VALVE BRAKE RELEASE SPEED CONTRO COPPER LINE RELEASE LEVER MINI VALVE INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR CYLINDER Figure 3 8 Brake System Circuit Page 22 3 11 Flexible Hose Identification and Placement The following figures will show the correct place ment of the flexible hydraulic hoses used in the table and their respective number codes Figure 3 9 shows the hose connections to the plumbing terminal Figure 3 9 Main Plumbing Terminal 20 40 60 80100 10 30 50 70 90110 Figure 3 10 shows the placement of the short flexible hoses which connect to the back section cylinders Figure 3 10 Back Section Hoses BACK CYLINDER RAM RIGHT BACK CYLINDER RAM LEFT TOP VIEW FRONT BLOCK BACK CYLINDER PISTON RIGHT BACK CYLINDER PIST
13. When hydraulic fluid is pumped into one cylinder the piston and connecting rod pushes the lateral tilt lever which tilts the table top to one side To tilt the table top in the opposite direction fluid is pumped into the opposite cylinder See figure 1 13 TABLE TOP LATERAL TILT LEVER CONNECTING RODS Figure 1 13 Lateral Tilt Cylinder Assembly PISTON PISTON 4 Elevation Cylinder This single action cylin der does not have hydraulic fluid on both sides of the piston It depends on the weight of the table top assembly to lower it The cylinder is set in the center of the elevation main column The two stage cylinder is elevated by the driven force of the oil pressure When lowering the oil that is accumulated in the cylinder is re turned to the oil reservoir through the mini valve due to the table top weight A slider support assembly is used to support the weight of the upper table section A stainless steel shroud covers the flexible hydraulic hoses and slider See figure 1 14 ELEVATION CYLINDER EXTERIOR EZ SHROUD 7 2 PRIMARY SLIDER lt PISTON SUPPORT ASSEMBLY SECONDARY BK PISTON Figure 1 14 Elevation Cylinder Assembly 5 Kidney Lift The kidney lift cylinder assembly is aunique type of double action cylinder where the piston remains stationary and the outer housing or cylinder has the relative motion The cylinder housing has rack t
14. a table surface or does the table surface lose position Once the problem has been determined concen Page 14 trate on that particular hydraulic circuit or control function Listed below are the hydraulic components that are common with all hydraulic circuits If there is a problem with any of them it could affect all control functions 1 Motor Pump Assembly 2 Reservoir 3 Pressure Relief Valve 4 Certain Oil Lines and Galleys If there was a problem in the following components only one control function would normally be af fected 1 Mini Valve 2 Slave Cylinder 3 Oil Lines NOTE Whenever a hydraulic line or compo nent is replaced bleed the air out of the lines using the pump pressure before making the final connection After all connections are tight cycle the control function back and forth two or three times to purge the remaining air from the system IMPORTANT When installing new O rings use hy draulic oil to thoroughly lubricate the O rings and cylinder Keep every thing clean Each complete oil circuit is shown on the following pages When troubleshooting a particular function refer to the appropriate oil circuit diagram and the list of possible problems Problem Table will not elevate properly Table will not descend properly Table loses elevation COPPER LINE 3 3 ELEVATION DIAGNOSIS CHART Reason Pressure Relief Valve Not Set Properly Low on Oil Spool Valve Not Cente
15. air out of the lines using the pump pressure be fore making the final connection Then operate the function until it stalls in both directions c Pressure Relief Valve The pressure relief valve is adjusted by turning the adjustment nut until the desired pressure is reached To adjust Page 10 1 Remove the blind cap and attach a hydraulic pressure gauge to the main oil galley using a 6mm plumbing bolt See figure 1 22 Figure 1 22 PRESSURE GAUGE PRESSURE SN RELIEF VALVE ATTACH HERE BACK VIEW OF RELIEF VALVE 2 Raise the table top until the piston reaches the end of its stroke and stalls Observe reading on pressure gauge and turn the adjustment nut clockwise to increase oil pressure counterclock wise to decrease until desired reading is obtained Pressure should be 80KG CM 1138 PSI d Speed Controls The speed controls restrict the volume of oil return ing back to the reservoir thereby controlling the speed of each control function All four way mini valves have two speed controls located in the ends of each valve body All three way mini valves have only one speed control One speed control adjusts one direction of a particular function and the opposite speed control adjusts the other direction They are adjustable by using a small straight blade screwdriver and turning the adjustment screw clockwise to de crease the speed and counterclockwise to increase the speed Refer to figure 1 23
16. c CN4 to Charging Box Test 1 Disconnect connectors CN4 11 and Figure 7 23 CN4 CN11 and CN51 CN51 Leave all other connectors connected To RELAY BOX NOTE Later model solenoid valves wire colors are Blue and White Blue Figure 7 24 Solenoid Test Page 65 6500NB 7 11 Solenoids The solenoids are energized by 24 volt potential that is controlled by the relay box The solenoid windings are protected from exces sive heat by an internal thermal fuse that will open after approx 7 minutes of continuous operation The solenoid must be replaced if the internal ther mal fuse has been blown The solenoids are mounted directly on either side of the hydraulic mini valves and push the spool valve in one direction or the other depending upon which solenoid is activated a Solenoid Test The following tests will check the voltage applied to the solenoids and the resistance of the solenoid coil b Test 1 1 Activate either BATTERY or AC120V oper ating mode 2 Disconnect the 2 pin connector from the solenoid in question all other connectors should be connected See figure 7 24 3 Use a DC voltmeter and measure the voltage across the 2 pin connector Pin 1 and pin 2 Meter should read approximately 24 28 volts NOTE appropriate pendant control but ton must be pushed during this test The motor will run when this test is performed and the brake locking sole noid will be activate
17. for continuity between pin 22 and pins 4 through 19 while activating the appropriate switch See figure 6 12 Meter should read 0 ohms b Test Results If proper meter readings are not received test the individual switches as necessary Using an ohm CN9 TABLE UP RED oTe 9 TABLE DOWN WHITE RED ecu 20 YELLOW TREND WHITE YELLOW BACK UP BROWN of BACK DOWN WHITE BROWN TILT RIGHT ORANGE o WHITE ORANGE LEG UP GRE 2 WHITE GREY o lt So COOCOO BRAKE UNLOCK o RETURN oO meter test the operation of an individual switch with the test lead at the center terminal of the switch and the test lead at the terminal opposite the direction of the switch actuation See figure 6 13 Meter should read 0 ohms If the switches check out the problem would have to be in the wiring or connector Figure 6 13 Auxiliary Switch Test 6 22 10 22 8 22 4 22 12 22 14 22 17 22 UT T v v 27 vou co DET UN LOC 7 22 11 22 9 22 5 22 13 22 15 22 18 22 19 22 16 22 Figure 6 12 Auxiliary Switch Connector CN9 Page 46 6500B 6 8 Relay Box The power supply is directly connected to the relay contacts When these contacts are closed 24 volts is supplied to the solenoids which are mounted on the hydraulic mini valves One relay is used to supply power to the pump motor and is always activated
18. function button the appropriate relay contacts located in the relay box close and a24V potential is applied to the solenoid to operate the hydraulic mini valve and to the hydraulic pump motor The 6500NB Pendant Control has 5 volts applied to it a Pendant Control Test The following test will determine if the micro switches inside the Pendant Control are function ing correctly 1 Unplug the 24 pin Pendant Control connec tor from the base of the table You will be checking the cord side connector 2 Use an ohmmeter R x 1 and check the continuity between pin 1 and pins 4 through 19 while pressing the appropriate button Also test between pins 21 and 22 See figure 7 12 3 Ohmmeter must show continuity between the pins that are indicated when the appropriate buttons are pressed NOTE Pins 2 and 3 are connected to the LEDs AC120V and BATTERY indicator lights on the pendant control and cannot be checked with an ohmmeter e e 81 8 88 n 2122 LEO LED S skvrRoN AC POWER LED 7 BATTERY LED Dua TABLE UP TABLE DOWN REV TREND TREND BACK UP BACK DOWN TILT RIGHT TILT LEFT LEG UP 6 7 8 9 LEG DOWN 10 11 12 13 14 15 0 FLEX 16 17 18 19 20 REFLEX 21 22 23 24 UNLOCK KIDNEY UP KIDNEY DOWN 9 RETURN ATTERY ON OFF Figure 7 12 Pendan
19. go above horizontal Back Up Inhibit Switch NS 1 Trendelenburg Test at pins 1 amp 9 Table Switch Position Position Open Open Closed Meter Reading Infinity Infinity 0 When table is in Trendelenburg Position NS 1 brings the top back to level NS 2 Reverse Trendelenburg Test at pins 2 amp 9 Table Switch Meter Position Position Reading Open Infinity Closed 0 Infinity Open When table is in Reverse Trendelenburg Position NS 2 brings the top back to level Figure 5 15 Trendelenburg Return Switches Page 36 NS 3 Lateral Tilt Left Test at pins amp 9 Table Switch Meter Position Position Reading Level Open Infinity Tilt Right Open Infinity Tilt Left Closed 0 When table is inTilt Left Position NS 3 brings the top back to level PURPLE NS 5 Back Section Down Test at pins 5 amp 14 Table Switch Meter Position Position Reading Closed 0 Open Infinity Closed 0 When the Back Section is Down NS 5 brings the Back Section Up to level Figure 5 17 NS 4 Lateral Tilt Right Test at pins 4 amp 9 Table Switch Meter Position Position Reading Level Open Infinity Tilt Right Closed 0 Tilt Left Open Infinity When table is in Tilt Right Position NS 4 brings the top back to level Figure 5 16 Lateral Tilt Return Switches NS 6 Back Section Up Test at pins 6 amp 14 Table Switch Meter Positio
20. in parallel to the brake cylinders and the oil reservoir See figure 1 19 When the valve is opened turned counter clockwise a return circuit for the brake hydraulic fluid is opened The return springs force the pistons up pushing the hydraulic oil back into the reservoir and retracting the brake pads EMERGENCY BRAKE RELEASE LEVER Figure 1 19 IMPORTANT The emergency brake release valve must be tightened securely when notin use elf the emergency brake release valve has been operated the UNLOCK but ton on the pendant control may have to be pressed before brakes will lock again If the emergency brake release valve is open or loose two conditions could occur 1 The brakes will release slowly depending how loose the valve is this could take anywhere from a few minutes to several hours 2 None of the table functions will operate properly if the valve is wide open All of the hydraulic fluid from the pump is simply pumped through the brake bypass circuit because thatis the easiest path for the oil to follow k Flex Reflex System The Flex Reflex system on the early model tables consists of two hydraulic systems trendelenburg and back section operating simultaneously When the system is activated by the pendant control both the trendelenburg and back section mini valves are activated and the hydraulic cylinders operate in parallel The Flex Reflex system used on the present tables incorporates an add
21. inlet pressure opens the check valve allowing the oil to enter the cylinder In the return position inlet pressure pushes the pilot plunger up and opens the return check valve See figure 1 17 The open check valve allows a path for the oil in the elevation cylinder to return to the reservoir When the pilot plunger valve is opened the continuing pump pressure opens the pressure relief valve which provides a return oil path to the reservoir The mini valve used in the elevation circuit con tains only one check valve all four way mini valves use two check valves The check valve is used to trap the oil in the elevation cylinder thereby sup porting the table top When the top is being lowered the check valve is mechanically held open by the pilot plunger through pump pressure ELEVATION CYLINDER CHECK SPEED VALVE CONTROL PLUNGER SPOOL VALVE PRESSURE RELIEF VALVE RESERVOIR Figure 1 17 Elevation Return Circuit i Brake System The brake system consists of the following compo nents figure 1 18 1 Single action slave cylinders 4 each 2 3 way single check valve type mini valve Page 8 3 Manually controlled emergency brake re lease 4 Plumbing terminal flexible hoses copper lines and O rings 5 Portions of the electrical system BRAKE SYSTEM m EMERGENCY BRAKE RELEASE PLUMBING TERMINAL PUMP MOTOR ASSEMBLY RESERVOIR Figure 1 18 Bra
22. is also activated when any control function other than BRAKE UNLOCK is initially selected Also inside the 6500NB relay box is a step down transformer and full wave rectifier which decreases the voltage to 5 6 volts This low voltage potential controls the relays by the use of the hand held pendant control buttons Basically the relays en able a 5 6 volt potential to control the 24 volt circuit The following tests will determine if the relay box is functioning correctly a Checking Relay Box Input Power 1 Plugthe power cord into the 120VAC supply wall receptacle Disconnect connector CN4 leave all other connectors connected 2 Using a DC voltmeter test input power for both the BATTERY and AC120V operating modes See figure 7 18 Meter should read approximately 24 28 volts BATTERY mode AC120V mode 1 pin 5 pin2 pin 6 Connector CN4 Color Code Pin 1 Red Pin 5 White Pin 2 Blue Pin 6 Black Pin 3 Yellow Pin 7 Yellow Pin 4 Blue Figure 7 18 Relay Box Input Page 62 b Test Results If you do not receive the correct meter readings the problem is in the input wiring connectors or components If the correct readings are obtained proceed to the next step c Checking Output to Pump 1 Disconnect pump connector CN12 connect all other connectors and activate the AC120V operating mode 2 Test CN12 at pin 1 4 and pin 2 with a DC voltmeter Meter should read approximately 24 28 volts
23. m EE 888881 m 21 24 E aaa 2 H Ll im Wiring Diagram Model 6500NB Page 74 2 gt T Y Feit di 8 A AANI N 5000 36th Street S E Grand Rapids MI 49512 1 800 SKYTRON or 1 616 957 0500 FAX 1 616 957 5053
24. method it doesn t matter what size cylinder and piston is used because the speed canbe controlled by restricting the return oil If the pump puts out more volume to a certain slave cylinder than the speed control is allowing to go back to the reservoir the pressure relief valve provides an alternate path for the pump oil d Mini Valve in Neutral Position No fluid flow See figure 1 6 1 Spool Valve Centered This closes off both oil pressure and oil return galleys 2 Pilot Plungers Both Closed The pilot plung ers control the opening of the check valves If they are closed the check valves must be closed 3 Check Valves Both check valves are closed trapping the oil in the cylinder and oil lines 4 Speed Adjustment When the mini valve is in the neutral position the speed adjustment does not affect anything because there is not any oil flow OIL GALLERY OILRETURN SPOOL SOLENOID PRESSURE RETURN VALVE PISTON Figure 1 6 Mini Valve in Neutral Position e Mini Valve Right Port Activated See figure 1 7 Slave Cylinder Piston Moves to Left Right Mini Valve Port is Supply Line Left Mini Valve Port is Return Line f Mini Valve Left Port Activated See figure 1 8 Slave Cylinder Piston Moves to Right Left Mini Valve Port is Supply Line Right Mini Valve Port is Return Line Figure 1 7 Min
25. pendant control buttons 1 Activate the AC120V operating mode 2 Disconnect the pendant control from the table base connector All other connectors should be connected 3 Use a DC voltmeter and measure the following pins located in the 24 pin table base connector See figure 6 10 15 14 13 12 11 10 0 20 19 18 17 16 0 24 23 22 21 Figure 6 10 Table Connector e Test Results If you do not receive the correct voltage reading the wiring or connector pins may be faulty Discon nect connector CN1 from the Relay Box and using an ohmmeter test the continuity between the cor responding pins in connectors CN1 and CN14 See figure 6 11 If the correct readings are ob tained this part of the circuit is okay and the problem may be in the relay box Red White White Black 14 Red 15 White Red 16 Yellow 17 Purple CN 14 CN 1 CN 14 CN 1 PIN NO WIRE COLOR PIN NO WIRE COLOR 12 13 White Grey White Yellow Purple White Black White Brown 18 White Brown 19 Blue White 20 Not Used Orange 21 Blue Red White Orange 22 Brown White White Purple Blue Yellow 0 m Figure 6 11 Base Connector Continuity Test Page 45 6500B 6 7 Auxiliary Switches The following tests will determine if the auxiliary switches are functioning properly a Switch Test Disconnect connector 9 at the Relay Box and using an ohmmeter check
26. the output can be adjusted at the variable resistor VR R59 on the circuit board inside the Charging Box See figure 6 7 Turn the adjuster clockwise to decrease the voltage Counterclockwise to increase the voltage NOTE The battery connector CN16 must be disconnected to adjust the battery charger output VR R 59 Figure 6 7 Page 43 6 6 Pendant Control The Pendant Control consists of 17 micro switches buttons When any ofthe circuits are completed by depressing a function button the appropriate relay contacts located in the relay box close and a 24V potential is applied to the solenoid to operate the hydraulic mini valve The 6500B Pendant Control has 24 volts applied to it a Pendant Control Test The following test will determine if the micro switches inside the Pendant Control are function ing correctly 1 Unplug the 24 pin Pendant Control connec tor from the base ofthe table You will be checking 6500B the cord side connector 2 Use an ohmmeter R x 1 and check the continuity between pin 1 and 4 through 19 while pressing the appropriate button Also test between pins 21 and 22 See figure 6 8 3 Ohmmeter must show continuity between the pins that are indicated when the appropriate buttons are pressed NOTE Pins 2 and 3 are connected to the LEDs AC120V and BATTERY indicator lights on the pendant control and cannot be checked with an ohmmeter 9 9 BIBI
27. when any function button is activated If no voltage is present use an ohmmeter to test the continuity from CN12 to CN4 yellow and blue wires Refer to figure 7 18 for pin locations d Checking Output to Pendant Control NOTE The Relay Box connectors CN1 Pen dant Control and CN8 Auxiliary Base Connector are interchangeable 1 Disconnect the Pendant Control connector from the base connector connect the power cord and all other connectors Use a DC voltmeter to measure the following sockets located in the table base connector CN13 See figure 7 19 NOTE A fine wire or a paper clip may be needed to accurately test the small sockets in the connector The connec toris low voltage andthere is no danger of electrical shock To make sure all operating modes are OFF use a DC voltmeter to test the base connector CN13 Turn AC120V power OFF at the main switch wait approximately 5 10 seconds before test ing to allow BATTERY operating mode to activate 6500NB 2 Test the base connector CN13 at pin 1 and pins 2 amp 3 With meter test leads at pin 1 and pin 2 if meter reads approx 5 5 volts the table is in the BATTERY mode With meter test leads at pin 1 and pin 3 if meter reads approx 5 5 volts the table is in the AC120V mode With meter test leads at pin 1 and pins 2 amp 3 if meter reads approx 0 volts the table is in the OFF mode 3 With the AC120V and BATTERY o
28. 10 minutes This protector will take about 10 minutes to automatically reset The oil pump unit is attached to the bottom of the motor and is a gear type displacement pump with a pumping capacity of 4 liter per min The Motor Pump Assembly is mounted on an insulated motor plate inthe base ofthe table The starting capacitor is mounted along side the motor pump assembly a Motor Pump Test The following tests will check the voltage applied to the motor and the resistance of the motor field windings CAUTION Line voltage will be measured in this test Do nottouch uninsulated connec tor pins or meter test leads b Step 1 1 Plug the power cord into 120 VAC power supply wall receptacle Turn main switch ON Page 32 2 Disconnect the 3 pin connector CN15 at the motor Leave all other connectors connected See figure 5 9 PUMP MOTOR ASSEMBLY 1 i 15 Figure 5 9 Use a voltmeter capable of measuring 120 VAC and measure the following connector pins in connector CN15 See figure 5 10 AC VOLTS 120 c Test Results If you do not receive the correct meter readings the problem could be in the wires connectors relay box or main switch referto appropriate section for troubleshooting Ifthe correct voltage is obtained everything is good up to that point and the problem could be either the motor or the starting capacitor d Step 2 If the star
29. 5 Pendant CLP E 59 7 8 6 Eo Ee pd necu exusta 61 183 Relay owe 62 7 10 Main Wire Harness Continuity Tests 64 I 0 DER 66 7412 Motor Pump Assembly qoe shes icc Peto Stats RE SU Fu rd FUR RN BO NUN RIEN RM RUE 66 SECTION Vill ELECTRICAL SYSTEM ADJUSTMENTS caisse sunu einn 68 8 1 Relay Box id m MPa E DUM 68 Wining Model TT 71 Wiring Diagram Model 6500 1 struc Pint n pra nth ak rende ks ne re imi 72 Diagram isst 73 Wirtrig Diagram 2 74 SECTION I HYDRAULIC SYSTEM 1 1 General Electro Hydraulic System The hydraulic system with the exception of the hydraulic cylinders and hoses is contained within the base of the table The hydraulic valves and pump are electrically controlled by the use of a hand held push button pendant control The power requirements for the table are 120 VAC 5 amp 60 Hz The table contains the following components Re fer to the block diagrams figures 1 1 amp 1 2 for relationship NOTE Continuing developmen
30. B AC POWER LED BATTERY LED Mua TABLE UP TABLE DOWN S o BEV TREND 6 TREND TREND BACK 10 11 1415 BACK a vs o TU RIGHT O RIGHT 21 220 TILT LEFT didi gt LEG UP UP umm DOWN un UP emm DOWN le 2 mer ics 08 o FO o FO 99 BATTERY ON OFF 2 e3 63 Figure 6 8 Pendant Control Test Page 44 6500B b Test Results If you do not receive continuity between any of the pins either the micro switch in the Pendant Con trolis defective or awire is broken Either of these problems can be repaired easily If you receive correct readings with the meter there is nothing wrong with the Pendant Control c LED Test The BATTERY and AC120V power ON indicators can be checked with an LED tester Test BAT TERY indicator at pin 1 and pin 2 of 24 pin Pendant Control connector Test AC120V indica tor at pin 1 and pin 3 See figure 6 6 If no LED tester is available the LEDs can be tested by applying voltage to the appropriate pins To avoid damage to the LED a 1 5K ohm resistor must be placed between the power source and the connector pins See figure 6 9 R 1 5K OHM 24 VDC Figure 6 9 LED Test d Wiring Harness Test The following test checks the wires leading from the relay box connector to the 24 pin connector table socket These wires apply voltage to the
31. ECTION MICRO SWITCH JAM NUTS Figure 5 20 Leg Section Micro Switch Adjustment Page 39 6500B SECTION VI 6500B BATTERY MODEL ELECTRICAL TROUBLESHOOTING 6 1 General The battery table components operate on 24VDC The internal charging system also incorporates the components to transform the 120VAC input to 24VDC output to the components The Model designation 6500B is for all battery tables with a Serial Number of 6500B 1991 6 078 amp Prior The designation 6500NB is for all battery models with the Serial Number of 6500NB 1991 6 079 amp Later The two models can be easily identified by the position of the Main Power switch The power switch is on the top of the base on the 6500B models See figure 6 2 NOTE This section covers the electrical troubleshooting for the 6500B model ONLY Electrical Troubleshooting for the 6500NB is covered in section 7 SWITCH S N 6500 NB 1991 6 079 amp LATER MAIN POWER SWITCH S N 6500 B 1991 6 078 amp PRIOR Figure 6 2 Model Identification Page 40 6 2 Troubleshooting Notes The basic operation of each component will be defined along with a drawing and explanation on how to check it out Certain defective components could cause the entire table to stop functioning or only one control function to stop It would depend on what part of the component failed Other defective components would only cause one contro
32. ENDANT CONNECTOR fe KIDNEY UP FRONT VIEW KIDNEY DOWN RETURN 19 Figure 5 3 Pendant Control Test Page 27 If you do not receive continuity between any of the pins either the micro switch in the Pendant Control is defective or a wire is broken Either of these problems can be repaired easily If you receive correct readings with the meter the Pendant Control is okay c Wiring Harness Test The following test checks the wires leading from the relay box connector 8 to the 19 pin connec tor table socket These wires apply low voltage to the pendant control buttons 1 The power cord should be plugged into the wall socket and the main switch turned ON 2 Disconnect the pendant control from the base connector All other connectors should be connected 3 Use a DC voltmeter 10V scale and measure the following pins located in the 19 pin table base connector See figure 5 4 NOTE Pin 19 in table base connector will have no voltage potential unless 1 of the return to level micro switches are acti vated i e trendelenburg or tilt Figure 5 4 Table Base Connector d Test Results Page 28 If you do not receive the correct voltage reading the wiring or connector pins may be faulty Discon nect connector CN8 from the relay box and using an ohmmeter test the continuity between the cor responding pins in connectors CN8 and the table base connector See figure 5 5 If the correct readings are obta
33. GER BOX c 15 THERMAL RELAY pa 7 7 7 INTERNALPUMPTHERMALRELAY 1 SWITCH OVER MAIN RELAY FUSE POWER 10AMP SWITCH 1 51516 alle 1 POWER CHARGE CORD 1 1 1 FUSE 15AMP CHARGER Figure 7 1 Electrical Circuit Block Diagram Model 6500NB 6500NB 7 3 Main Switch The main power supply 120 VAC 60 HZ comes inthrough the power cord and through the main switch The main switch opens both lines when inthe OFF position Two 10 amp fuses are used to protect the complete electrical system and are located next to the main switch See figure 7 2 a Main Switch Test The following test will determine if line voltage is applied to connector CN15 which in turn would supply 120VAC power to the table 1 Plug the power cord into the 120VAC supply wall receptacle and turn the main switch ON 2 Disconnect connector CN15 See figure 7 1 Leave all other connectors connected CAUTION Line voltage 120 VAC will be mea sured in this test Do not touch uninsu lated connector pins or metertestleads 3 Use an AC voltmeter capable of measuring 120 VAC and measure the voltage between pins 1 and 2 black and white wires located in connector CN15 See figure 7 3 You s
34. LUE YELLOW PURPLE BLUE BLUE 111 YELLOW 7 BLACK WHITE LAT BACK LEG BRAKE 8 LJ BLUE WHITE BLACK 1 J YELLOW WHITE PURPLE BLUE BLUE YELLOW GREY BLUE BLUE alm YELLOW BLUE WHITE BLUE BLUE YELLOW WHITE ORANGE BLUE ct BLUE YELLOW YELLOW BLUE BLUE YELLOW WHITE RED Figure 6 20 Solenoid Test Page 50 6500B c Test Results If you do not receive the correct voltage the prob lem could be in the wires leading down to the connector The problem could also be in the relay box or the Pendant Control refer to appropriate section for troubleshooting Ifthe correct voltage is obtained everything is good up to that point andthe problem is more than likely the solenoid d Test 2 The solenoid can be checked out using an ohm meter R x 1 scale 1 Measure the resistance between the two pin connector in question as shown in figure 6 20 Connector must be disconnected Polarity of meter leads is not important 2 The meter should read approximately 16 ohms at room temperature 3 Measure the resistance between either pin and ground 4 Meter should read infinity e Test Results If the solenoid does not check out with the meter it is more than likely defective and must be replaced NOTE Whenever there are several compo nents of the same type a defective unit can also be detected by substi tuting a kn
35. ON LEFT Figure 3 11 shows the placement of the short flexible hoses which connect to the leg section cylinders and the kidney lift cylinder Figure 3 11 Leg Section Kidney lift Hoses KIDNEY CYLINDER INNER END CAP KIDNEY CYLINDER OUTER END CAP LEG CYLINDER PISTON LEFT LEG CYLINDER PISTON TOP VIEW FRONT PIVOT BLOCK LEG CYLINDER RAM RIGHT LEG CYLINDER RAM LEFT Figure 3 12 shows the placement and number code for the long flexible hoses which connect from the plumbing terminal to the front and rear pivot blocks NOTE The number codes will be on a label or stamped into the elevation clamp ring and the plumbing terminal 3 TREND 4 LAT TILT LEFT Figure 3 12 Pivot Block Hoses TOP VIEW 2 PIVOT FRONT CK PIVOT BLOCK 2 REV TREND 5 LAT TILT RIGHT Figure 3 13 shows the placement and number code for the long flexible hoses that connect from the elevation clamp ring to the plumbing terminal Figure 3 13 Elevation Clamp Ring Hoses 6 BACK SECTION 10 KIDNEY UP DOWN 11 KIDNEY DOWN 8 LEG UP TOP VIEW FRONT 9 LEG DOWN PIVOT BLOCK 7 BACK SECTION UP 4 1 General Page 23 SECTION IV ELECTRICAL SYSTEM The complete electrical system with the excep tion of the hand held pendant control and the return circuit micro switches is contained within the base of the table The pump motor and the hydraulic valves are controlled electrically with the pendant contro
36. OOTING 40 General ee eee ere eet 40 2 16113 40 6 3 Main 7 42 854 Batteries P 42 0255 Battery Gharging EAE ERAAI 43 6 6 49 11 3 2 44 6 7 Juliane 46 6 8 Gy ee ee roe 47 6 9 Main Wire Harness Continuity Tests 49 M 50 8511 Motor Pump ASSEN 51 SECTION VII 6500NB BATTERY MODEL ELECTRICAL TROUBLESHOOT ING 54 MEET CUN EUN 54 7 2 Troubleshooting c 54 EOM o 56 7 4 rug cce EET 56 7 5 Battery Charging Box AC120V TransfornttBr uoa eroe e 57 746 Switch Over Relay 58 451
37. SECTION CYLINDER ASSEMBLY FLEXIBLE DOWN CIRCUIT J 7 CHECK VALVE 2 t pd 227 NOTE ONE SIDE 2227 SHOWN FOR CLARITY INTERNAL OIL INTERNAL OIL RETURN FROM PUMP TO RESERVOIR Figure 3 6 Leg Section Circuit Page 20 3 9 KIDNEY LIFT DIAGNOSIS CHART Problem Reason Kidney Lift moves improperly Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valve Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control Kidney Lift chatters or loses position Defective or Dirty Check Valve Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil Lift Rods Binding KIDNEY LIFT CYLINDER ASSEMBLY mn MES paar 7 SAN UP CIRCUIT FLEXIBLE B c HOSES PLUMBING TERMINAL COPPER LINES CHECK VALVE SPEED CONTROL MINI VALVE lt lt INTERNAL OIL INTERNAL OIL RETURN FROM PUMP TO RESERVOIR Figure 3 7 Kidney Lift Circuit Page 21 3 10 BRAKE CIRCUIT DIAGNOSIS CHART Problem Brakes will not set properly Reason Emergency Brake Release Valve Open or Defec tive NOTE Spool Valve Not Centered If brakes have been released with the Bad Check Valve Emergency Brake Release Valve Low on Oil brakes will not reset until BRAKE UN Pressure Relief Valve Not Set Properly LOCK Circuit has been activated
38. ake sure that the reset button is held IN with the small metal plate See figure 6 23 Figure 6 23 4 The Thermal Relay should activate after 1 1 2 to 2 minutes of continuous pump operation If necessary adjust the thermal cut out time by turn ing the adjustment screw clockwise to increase the time counterclockwise to decrease the time Refer Page 52 to figure 6 22 c Test Results If you do not receive the correct meter readings the problem could be in the wires connectors relay box or main switch refer to that section for trouble shooting If the correct voltage is obtained everything is good up to that point and the problem could be the motor d Motor Resistance Test The motor can be statically checked for resistance using an ohmmeter This testis not 100 accurate because you are checking the motor with very low voltage from the meter and without any load 1 Using an ohmmeter Rx 1 scale measure the resistance between the two pins of CN11 See figure 6 24 2 The meter should read 1 to 2 ohms atroom temperature 3 Measure the resistance between either pin and ground 4 Meter should read infinity Figure 6 24 Motor Connector CN11 e Test Results If you do notreceive the correct meter readings the motor or wiring is defective Page 53 6500NB SECTION VII 6500NB BATTERY MODEL ELECTRICAL TROUBLESHOOTING 7 1 General The battery table components operate on 24VDC The inter
39. asured in this test Do not touch uninsulated connector pins or meter test leads 1 The power cord should be plugged into the wall receptacle and main switch turned ON 2 Disconnect the motor connector CN15 All other connectors should be connected Test con nectors CN6 and CN7 the back while attached to the relay box 3 Activate each of the Pendant Control but tons and using an AC voltmeter capable of measur ing 120VAC measure the voltage between the appropriate connector pins located in connector CN6 or CN7 See figure 5 7 Polarity of meter test leads is notimportant Meter should read 120VAC Page 29 Table Up Leg Up Table Down Leg Down Rev Trend Kidney Up Trend Kidney Down Back Up Back Down Brake Unlock Tilt Right Flex Tilt Left Reflex Figure5 7 Relay BoxOutputConnectors CN6andCN7 f Test Results If you do notreceive the correct meter readings the relay box or wiring is defective and should be replaced NOTE Before deciding the relay box is de fective check the wires and pins in the connector blocks to make sure they are not loose or making a bad connection with their mate 5 5 Solenoids The solenoids are energized by 120 volt potential that is controlled by the relays located inside the relay box The solenoid windings are protected from exces sive heat with an internal thermal fuse that will open after approximately seven 7 minutes of continu ous opera
40. ay supplies the 24 volt input power from either the BATTERY or AC120V oper ating modes to the relay box for table operation In the normal OFF position BATTERY power is sup plied to the relay box See figure 7 9 RELAY BOX BATTERY Figure 7 9 Relay in OFF Position Page 58 b Switch Over Relay in Activated Position When the AC120V mode is activated by the main switch a signal from the relay box activates the Switch Over Relay The relay then supplies the AC operating mode output power to the relay box and also activates the battery charging circuit See figure 7 10 NOTE The battery charging circuit is only op erational when the table is inthe AC120V operating mode AC120V operating mode RELAY BOX SIGNAL OUT RELAY BOX S O RELAY CHARGING BOX Figure 7 10 Relay in Activated Position c Switch Over Relay Test Using aDC voltmeter test the operation of the relay in both the OFF AC120V OFF and Activated AC120V ON positions See figure 7 11 NOTE The Switch Over Relay mounting block may have to be removed from the base for test access OFF AC120V OFF term 7 and term 1 24 to 28VDC term 7 and term 6 OVDC Activated AC120V ON term 7 and term 6 26 541 VDC 6500NB Figure 7 11 Switch Over Relay 7 7 Pendant Control The Pendant Control consists of 17 micro switches buttons When any ofthe circuits are completed depressing a
41. ctive Test appropriate wires and connectors as necessary If the correct readings are obtained this part of the relay box is okay Proceed to the next step f Checking Output to Solenoids This test checks the voltage that is used to energize the solenoids 1 Activate either BATTERY or AC120V oper ating mode NOTE The Brake Lock function is activated by pressing any function button except BRAKE UNLOCK Atimerinthe Relay Box allows continuous output for about 7 seconds If the brakes are already locked no output is provided The BRAKE UNLOCK button activates another timer in the relay box which allows continuous output for the brake release function for approximately 7 seconds f the brakes are already released using the BRAKE UNLOCK button no output is provided Page 63 6500NB 2 Testconnectors CN6 and CN7 from the back while attached to the relay box All connectors should be connected 3 Activate each of the pendant control buttons and measure the output voltage for the corre sponding connector pins with a DC voltmeter See figure 7 20 OPERATION BUTTONS VOLTS Table Up Table Down Rev Trend Trend Back Up Back Down Tilt Right Tilt Left Leg Down Kidney Up Kidney Down Brake Set Brake Unlock Flex Reflex Figure 7 20 Connector CN6 or CN7 9 Test Results If you do not receive the correct meter readings the relay box is defective and should be replaced NOTE Before dec
42. d by any function other than MOVE elf a solenoid does not function when the pendant control button is pushed the problem could be the pendant con trol the relay box or the solenoid c Test Results If you do not receive the correct voltage the prob lem could be in the wires leading down to the connector The problem could also be in the relay box or the Pendant Control refer to appropriate section for troubleshooting Page 66 Ifthe correct voltage is obtained everything is good up to that point andthe problem is more than likely the solenoid d Test 2 The solenoid can be checked out using an ohm meter R x 1 scale 1 Measure the resistance between the two pin connector in question as shown in figure 7 24 Connector must be disconnected Polarity of meter leads is not important 2 The meter should read approximately 16 ohms at room temperature 3 Measure the resistance between either pin and ground 4 Meter should read infinity e Test Results If the solenoid does not check out with the meter it is more than likely defective and must be replaced NOTE Whenever there are several compo nents of the same type a defective unit can also be detected by substi tuting a known good unit or wire con nector In some cases this may be faster than using a multi meter 7 12 Motor Pump Assembly The hydraulic pump motor is a 24 volt DC electric motor The oil pump unit is attached to the bottom
43. eeth cut into the top which meshes with a pinion gear This gear meshes with other gears to supply the up or down drive for the kidney lift bars depending on which direction the oil is pumped into the cylinder See figure 1 15 A cross shaft transmits the rotary motion of the cylin der pinion gear to a gear set on the other side of the table This enables the kidney lift bars to move up and down together without binding PINION GEARS TN KIDNEY N LIFT BAR Y oS lt pmo E J NS 22272222222772222 OIL FLOW CYLINDER HOUSING PISTON Figure 1 15 Kidney Lift Cylinder Assembly 6 Brake Cylinders The brake cylinders are single action type similar to the elevation cylinder The movable piston s ram is connected to a brake pad See figure 1 16 Oil pumped into the top of the cylinder pushes the piston down raising the table base off its casters An internal return spring on the bottom of the piston pushes the piston up to return the oil through the mini valve to the reservoir PISTON RETURN SPRING RAM Figure 1 16 Single Action Brake Cylinder Page 7 h Elevation Cylinder Return Circuit A three way single check valve type mini valve controls both the elevation and return circuits The elevation circuit operation within the mini valve is identical to the operation of the four way valves previously described
44. eliminate gear lash This adjustment arrangement compensates for any wear between the gears that might occur To adjust Loosen the cam locking nut and allen set screw Use a spanner wrench to rotate the eccentric cam Use firm pressure on the spanner wrench See figure 2 1 Tighten the locking nut and set screw when adjustment is complete ECCENTRIC CAM Figure 2 1 Eccentric Cam Adjustment 2 2 Hydraulic Cylinder Adjustment Back amp Foot Leg Sections The hydraulic cylinder rams that control both the back and foot leg sections must move together so that these sections are not twisted when operated This is accomplished by the use of eccentric cams that move the cylinder bodies fore and aft to adjust their effective stroke NOTE Adjust gear mesh before adjusting ec centric cams for the back section a Back Section Position the back section all the way up until it stalls Both sides of the back section should stop moving at the same time and should not show any Page 12 signs of twisting Any twisting or flexing of the back section as it approaches the stalled position indicates that one of the cylinders is not reaching its fully extended position at the same time as the other This condition would require an adjustment To adjust Loosen the cam locking nuts located inside the table side frames Use a spanner wrench to turn the cylinder eccentric cams as required to shift either cylinder fore or aft as
45. els the major table functions lateral tilt tren delenburg back section and leg section The kidney lift has a back section up inhibit switch to prevent the table back section from damaging the kidney lift when the lift is raised The back section still has the capability to be lowered but will not raise above horizontal until the kidney lift is completely down If the back section is raised above horizontal the system will not allow the kidney lift to be raised The return to level kidney inhibit system consists of 9 micro switches 2 electrical connectors and the related wiring The micro switches are mounted on or adjacent to the function they control and are wired for normally open or normally closed opera tion The micro switches are either cam or lever NS 6 NS 3 TOP VIEW 6500 NS 2 NS 4 Ls 1 SS gt NS 5 CN2 RELAY BOX em LtEE mH actuated and can be adjusted at the individual switch mounting brackets See figure 5 12 The micro switches operate on low voltage and control the function circuits pump motor and ap propriate solenoid valves when activated by the pendant control RETURN button The micro switches are wired to the relay box through a riser cord and to the 15 pin connector CN2 See figure 5 12 for switch location and identification 5 8 Troubleshooting If a problem is suspected in the return circuits disconnect the connector CN2 from the Relay Box to eliminate the c
46. endelenburg end caps or the lateral tilt housing are removed refer to figure 2 4 for the proper torque specifications when installing the bolts ALLEN BOLT M10 x 30 TORQUE TO 58 FT LBS ALLEN BOLT M6 x 20 TORQUE TO 156 IN LBS lt lt LATERAL TILT HOUSING TRENDELENBURG TAIL CAP Figure 2 4 Torque Specifications Page 13 SECTION HYDRAULIC TROUBLESHOOTING 3 1 Precautions Before attempting to troubleshoot any hydraulic problem on the table please read through the pre cautions and notes below CAUTION When disconnecting any of the hydrau lic lines fittings joints hoses etc for the following control functions be sure these table surfaces are in their down position or completely supported Elevation Back Section Leg Section Kidney Lift When working on the trendelenburg or lateral tilt hydraulic circuits be sure to support the table top When working on the brake system make sure the brakes are completely retracted CAUTION Failure to follow these precautions may result in an uncontrolled oil spray and damage to the table or personal injury 3 2 Troubleshooting Notes When troubleshooting a table malfunction first determine the following 1 Does the problem affect all control func tions 2 Does the problem affect only one control function 3 Ifthe problem affects one control function is it in both directions 4 15 the problem intermittent 5 Is the problem no movement of
47. estleads 2 Use an AC voltmeter capable of measuring 120 volts and measure the voltage between pins 1 white and 2 black of connector CN4 for input voltage See figure 5 6 Meter should read line voltage 120 VAC 3 Activate any table function with the Pendant Control and using an AC voltmeter test the voltage at pins 3 and 4 of CN4 for output to the pump Meter should read 120 VAC Yellow Figure 5 6 Connector CN4 b Test Results If you do not receive the correct meter readings the relay box or wiring is defective If the correct readings are obtained this part of the relay box is okay Proceed to the next step c Relay Box Output Connector CN8 This test checks the low voltage applied to the pen dant control buttons 1 The power cord should be plugged into the wall receptacle and main switch turned ON 2 Disconnect Pendant Control connector All other connectors should be connected 3 Using a DC voltmeter measure the voltage between pin 1 and pins 4 through 19 of the table base connector See figure 5 4 Meter should read 5 6 volts d Test Results If you do notreceive the correct meter readings the relay box or wiring is defective If the correct readings are obtained this part of the relay box is okay Proceed to the next step e Relay Box Output Connectors CN6 amp CN7 This test checks the high voltage 120V that is used to energize the solenoids CAUTION 120 VAC will be me
48. hould receive line voltage 120 VAC Figure 7 3 Connector CN15 Test b Test Results If the correct voltage is obtained everything is good up to this point and the problem would have to be in another area If you do not receive the correct measurements the problem would have to be in the wires main switch fuses or power cord Check the continuity from the power cord connec tor ICN1 through the fuses switch and wiring to Page 56 connector CN15 Remove the power cord discon nect CN15 black and white wires and test as shown in figure 7 4 TO GROUND Figure 7 4 CN15 to ICN1 Continuity Test 7 4 Batteries The BATTERY operating mode is powered by two 12 volt batteries connected in series to provide the 24 volt operating power The battery system voltage should be 24VDC ata range of 22VDC to 26VDC If the battery charge level falls below 23 5 volts the BAT TERY operation indicator on the pendant control will blink indicating that the batteries require recharging The built in charging system automatically keeps the batteries at the proper charge level when the 120 oper ating mode is ON The charging system will oper ate while the table is being operated in the AC120V mode a Battery System Test 1 Disconnect the main power cord and using a DC voltmeter test each individual battery at its terminals Meter should read 12VDC 1V 2 accurately test the batteries they must be
49. i Valve Right Port Activated 1 Spool Valve Pushed to the left by electric solenoid This opens the internal oil pressure gal ley allowing the fluid to go through the check valve and on to the cylinder Also the spool valve opens the oil return line providing an oil path through the internal oil galley back to the reservoir 2 Pilot Plunger Valve Left pilot plunger valve is pushed up by the incoming oil pressure mechani cally opening the check valve located above it in the return circuit This action allows the oil from the left side of the slave cylinder to go back into the reservoir The right pilot plunger valve is not affected in this operation mode 3 Check Valves Both check valves are opened in this operation mode The right check valve is pushed open by the oil pressure created by the pump The oil then continues to go through the lines and pushes the slave cylinder piston to the left At the same time the left check valve is held open mechanically by the pilot plunger providing a return path for the oil through the mini valve back to the reservoir 4 Speed Adjustment The right speed control output side does not have any effect in this operation mode because the oil is routed around the speed adjustment through a by pass valve and then to the output port The left speed adjustment controls the speed of the table function by restrict ing the amount of oil going back into the reservoir Figure
50. i valve to the function The spool valve also opens an oil return circuit which allows the oil to return to the oil reservoir The main components of the mini valve and their functions are listed below 1 Spool Valve Opens the main oil galley pump pressure to either mini valve outlet de pending on which direction the spool valve is pushed Also it provides a return path for the oil returning back into the reservoir 2 Pilot Plunger There are two plungers ina four way mini valve one in a 3 way mini valve One under each check valve The purpose of the pilot plungers is to mechanically open the return check valve allowing the oil to return back into the reservoir 3 Check Valve Two are provided in each four way mini valve to seal the oil in the cylinders and oil lines and prevent any movement of the table One check valve is provided in a 3 way mini valve 4 Speed Adjustments There are two speed adjustments in each mini valve They are needle valve type controls which restrict the volume of oil returning back into the reservoir thereby control ling the speed of the table surface movement 3 way mini valve has only one speed adjustment The speed controls are always located in the return oil circuit This prevents uncontrolled movement of the piston in the slave cylinder due to one side of the piston being loaded with hydraulic pressure and the other side having no load Page 4 Also by using this control
51. iding the relay box is de fective check the wires and pins in the connector blocks to make sure they are notloose or making a bad connec tion with their mate If the battery power is ON and no table functions have been activated for 3 hours the power off circuit will interrupt the battery power Page 64 7 10 Main Wire Harness Continuity Tests If correct meter readings are not received in tests between components before replacing the com ponents test the Main Wire Harness to be sure all connectors and wires are making a good connec tion a CN4 to Batteries Test 1 Disconnect connectors CN4 and the and connectors from the batteries Leave all other connectors connected 2 Using an ohmmeter test for continuity between pin 1 of CN4 and battery connector Also test between pin 2 of CN4 and battery connector See figure 7 21 NOTE The 15 amp battery protection fuse is in the line between CN4 pin 1 and the battery connector Test the continuity of the fuse if correct meter reading is not received Figure 7 21 b CN4 to CN12 Test 1 Disconnect connectors CN4 and CN12 Leave all other connectors connected 2 Using an ohmmeter test for continuity between pins 3 and 4 of CN4 and pins 1 and 2 of CN12 See figure 7 22 6500NB 2 Using an ohmmeter test for continuity between pins 4 5 and 6 of CN4 pins 1 and 2 of CN11 and pin 4 of CN51 See figure 7 23 Figure 7 22
52. inders Slave Cylinders There are several different types of hydraulic cylin ders used in the table that activate the control functions With the exception of the elevation and brake cylinders all operate basically the same way The control functions are listed below See figure 1 9 Back Section 2 double action cylinders Leg Section 2 double action cylinders Trendelenburg 1 double action cylinder Lateral Tilt 1 double action cylinder Elevation 1 single action cylinder Kidney Lift 1 double action cylinder Brakes 4 single action cylinders TRENDELENBURG BACK SECTION CYLINDER CYLINDER E Z dx LP 2 este ores 22 A T 05 KIDNEY LEG SECTION CYLINDER 4 2 CYLINDER WS Ot 48 Wa UN 72 Q NS ELEVATION CYLINDER LATERAL TILT CYLINDER Figure 1 9 Cylinder Placement 1 Back Section and Leg Section Cylinders The double action cylinders are closed at one end and have a movable piston with hydraulic fluid on both sides Connected to this piston is a ram or shaft that exits out of the other end of the cylinder Through the use of either a gear or clevis and pin arrangement this ram is connected to a movable table surface The movable surface can be moved one way or the other by pumping hydraulic fluid into the cylin der on either side of the piston Obviously if oil is pumped into one side of the cylinder a return path
53. ined this part of the circuit is okay Figure 5 5 Base Connector Continuity Test CN8 Red White White Orange White Grey Black White Grey Red White Yellow White Red Purple White Yellow Black White Brown Purple White Brown White Purple Blue Blue Yellow Orange 1 2 3 4 5 6 8 9 5 4 Relay Box The 120 volt power supply is directly connected to the relay contacts When these contacts are closed 120 volts is supplied to the solenoids which are mounted on the hydraulic mini valves One relay is used to supply 120V to the pump motor and is always activated no matter what control function is selected The brake locking circuit relay is also activated when any control function other than BRAKE UNLOCK is initially selected Also inside the relay box is a step down trans former and full wave rectifier which decreases the line voltage to 5 5 volts This low voltage potential controls the relays by the use of the hand held pendant control buttons Basically the relays en able a 5 5 volt potential to control the 120 volt circuit The following tests will determine if the relay box is functioning correctly a Relay Box Input Connector CN4 1 Plug the power cord into the 120 VAC power supply wall receptacle and turn the main switch ON Leave all connectors connected CAUTION Line voltage 120 VAC will be mea sured in this test Do not touch uninsu lated connector pins or meter t
54. interrupt the battery power 6500B 6 9 Main Wire Harness Continuity Tests If correct meter readings are not received in tests between components before replacing the com ponents test the Main Wire Harness to be sure all connectors and wires are making a good connec tion a CN4 to CN16 Test 1 Disconnect connectors CN4 and 16 Leave all other connectors connected 2 Using an ohmmeter test for continuity between pins 1 and 2 of CN4 and pins 1 and 2 of CN16 See figure 6 17 NOTE The 15 amp battery protection fuse is in the line between CN4 pin 1 and CN16 pin 1 Test the continuity of the fuse if correct meter reading is not received Figure 6 17 b CN4 to CN11 Test 1 Disconnect connectors CN4 and CN11 Leave all other connectors connected 2 Using an ohmmeter test for continuity between pins 3 and 4 of CN4 and pins 1 and 2 of CN11 See figure 6 18 Figure 6 18 c CN4 to CN12 Test 1 Disconnect connectors CN4 and CN12 Leave all other connectors connected 2 Using an ohmmeter test for continuity between pins 5 and 6 of CN4 and pins 3 and 4 of CN12 See figure 6 19 Figure 6 19 Page 49 6500B 6 10 Solenoids The solenoids are energized by 24 volt potential that is controlled by the relays located inside the relay box The solenoid windings are protected from exces sive heat with an internal thermal fuse that will open after approximately seven 7 minutes of continuou
55. ircuits Ensure that all table functions operate properly using the Pendant Con trol If the functions do not work properly using the Pendant Control refer to the appropriate test sec tion and make all needed repairs before working on the return circuits Back Up Inhibit SW Trendelenburg Rev Trendelenburg Lateral Tilt Left Lateral Tilt Right Back Section Back Down Level Back Section Back Up Level Leg Section Leg Down Level Leg Section LegUp Level Figure 5 12 Page 34 NOTE It is normal for the back section to move up if the RETURN button is pushed when connector CN2 is disconnected from the relay box All of the micro switches are connected to the relay box via a wiring harness and the micro switch riser cord using connectors CN2 and CN10 Connector a Switch Test Turn Main Power ON lock the table brakes and place the table top sections in a level position with the Kidney Lift down Disconnect connector CN2 from the relay box and using an ohmmeter test the wiring and switch operation at the appropriate pin numbers for the micro switch in question as shown in figures 5 14 through 5 18 CN10 is located under the slider shroud in the same area as the hydraulic hoses Connector plugs into the relay box and is the most convenient location to make circuit continuity checks See figure 5 13 for connector pin locations NOTE Be sure to isolate the circuit when mak ing continuity checks
56. itches as necessary Using an ohm TABLE UP TABLE DOWN o z BACK DOWN TILT RIGHT d KIDNEY UP KIDNEY DOWN m 13 7 White Orange meter test the operation of an individual switch with the test lead at the center terminal of the switch and the test lead at the terminal opposite the direction of the switch actuation See figure 7 17 Meter should read 0 ohms If the switches check out the problem would have to be in the wires or connector 9 Figure 7 17 Auxiliary Switch Test 1A 3B 1A 5B 1A 4B 1A 2B 1A 6B 1A 9A c 2 o o 1 4 1A 6A 1A 5A 1 7 1A 9B 25 13A 26 13B Red White 14 7B 15 8A 16 8B Red 17 9A Purple White Red 18 9B White Purple Yellow 19 10A White Yellow 20 10B Brown 21 11A White Brown 22 118 Orange 23 12A 24 12B Grey 25 13A White Grey 26 138 White Black Purple White Figure 7 16 Auxiliary Switch Connector CN9 Page 61 6500NB 7 9 Relay Box The power supply is directly connected to the relay contacts When these contacts are closed 24 volts is supplied to the solenoids which are mounted on the hydraulic mini valves One relay is used to supply power to the pump motor and is always activated no matter what control function is se lected The brake locking circuit relay
57. itional mini valve 8 total which connects the trendelenburg and back section hy draulic systems in a series When FLEX is acti vated by the pendant control the Flex Reflex mini valve opens the oil pressure path to the Reverse Trendelenburg piston The return oil path from the trendelenburg piston is routed through the back section cylinder to the mini valve return port See figure 1 20 _ TREND BACK UP REV TREND PLUMBING TERMINAL FLEX REFLEX MINI VALVE Figure 1 20 Flex Reflex System 1 3 Hydraulic Adjustments Page 9 a Fluid Level The fluid level should be approximately 1 2 below the filler hole or gasket surface If additional fluid is needed remove the filler vent cap with a phillips screwdriver and add fluid through this opening using a funnel See figure 1 21 NOTE The elevation cylinder should be com pletely down and all the other control functions in their neutral position when checking oil level Figure 1 21 FILLER VENT RESERVOIR OPENING The type of oil that should be used is Mobil DTE 25 or equivalent This is a very high quality hydraulic oil The table requires approximately two quarts of oil to operate properly b Bleeding The Hydraulic System To purge the air from the hydraulic system operate each function back and forth at least two or three times NOTE Whenever a hydraulic line or com ponent is replaced bleed the
58. ke System Block Diagram Each corner of the cast iron table base has a hydraulic brake cylinder These single action cyl inders are hydraulically connected in parallel to the mini valve and all four are activated together It is normal for one corner of the table to raise before the others due to the weight distribution of the table On early models the brakes are activated when the elevation up button on the pendant control is pushed andheld down The brakes are completely set when the elevation function table top starts to move upward Later models use an electronic timer in the relay box so that when any function on the pendant control is pushed momentarily the pump motor and brake system mini valve is activated and the brake cylinders are completely set The electronic timer runs for approx 8 10 seconds The brakes are released by pushing the BRAKE UNLOCK button momentarily An electronic timer in the relay box activates the brake function hy draulic mini valve and pump motor When activated the return hydraulic circuit oper ates similar to the elevation cylinder return circuit Return springs inside the single action brake cylin ders retract the brake pads and provide the pres sure to return the hydraulic oil back to the reservoir The electronic timer operates the return circuit for approximately 8 10 seconds j Emergency Brake Release The emergency brake release is simply a manually operated bypass valve connected
59. l The electrically operated functions are as follows ELEVATION Up and Down TRENDELENBURG Head up and down LATERAL TILT Right and left BACK SECTION Up and Down LEG SECTION Up and Down FLEX REFLEX KIDNEY LIFT Up and down RETURN TO LEVEL BRAKE UNLOCK Brake release The power requirements are 120 VAC 60 Hz fuse protected The main power on off switch is an enclosed DPST type and the power cord is a three wire fifteen foot long UL listed cord with a three prong hospital grade plug 4 2 Components Page 24 Refer to figure 4 1 for the relationship of the elec trical components a Wires Connectors Switches Fuse These provide the path for the various electrical circuits b Relay Box Contains the step down trans former full wave rectifier and relay switches The relay switches are activated by the pendant control and in turn energize the solenoid c Hand Held Pendant Control Closes micro switches to activate relay box Operates on 5 VDC d Solenoids These electrically open and close the hydraulic ports of the mini valve to direct the fluid to the correct cylinders They operate on 120 VAC e Motor Pump Assembly 120 VAC 60 HZ 200 Watt capacitor induction motor 4 3 Battery Model Components The functions of the battery model tables are the same as the standard 120 VAC models The electrical components and operation however vary greatly between the two m
60. l function to stop Thefollowing defective components could cause all control functions to be affected a Motor Pump Assembly b Main Switch Circuit and Wiring The following defective components could cause all control functions to be affected or only one control function a Relay Box b Pendant Control The component listed below would only affect one control function Solenoid When troubleshooting an electrical circuit start at the problem and work back to the power source NOTE On the battery model tables trouble shooting should begin by switching the operating mode For example if a function fails when attempting to oper ate the table in the AC120V mode switch to the BATTERY mode If the function now operates the problem is probably located between the power cord and the relay box If the function also fails when in battery operation use the auxiliary switches to operate the function If the function now operates the problem is probably in the pendant control connectors or wiring from the pendant control to the relay box 6500B Oo PENDANT O CONTROL DB EJ GJ 3 SOLENOID e COIL 24VDC MINLVALVES EIE 21 MICRO SWITCHES AUX BASE CONNECTOR CN14 CONTROL BOX CONNECTOR CN10 BATTERY RECHARGING BOX 000000000 AUXILIARY SWITCHES BATTERY POWER BOX THERMAL RELAY
61. ld be in the wires leading to connectors CN6 and CN7 The problem could also be in the relay box or the Pendant Control refer to appropri ate section for troubleshooting Ifthe correct voltage is obtained everything is good up to that point and the problem is more than likely the solenoid d Step 2 The solenoid can be checked out using an ohm meter R x 1 scale 1 Measure the resistance between the two pins of the connector in question See figure 5 8 Connector being tested must be disconnected Polarity of meter leads is not important 2 The meter should read approximately 80 90 ohms at room temperature 58 ohm for tables S N 1997 4 amp L 3 Measure the resistance between either pin and ground 4 Meter should read infinity TO RELAY BOX TO RELAY BOX WHITE PURPLE BLUE Figure 5 8 Solenoid Test Page 31 e Test Results If the solenoid does not check out with the meter it is more than likely defective and must be replaced NOTE Whenever there are several compo nents of the same type a defective unit can also be detected by substituting a known good unit or wire connector In some cases this may be faster than using a multi meter 5 6 Motor Pump Assembly The electric motor is a capacitor start type with a rating of 120 VAC 200 watts The field windings are protected with a thermal protector that will open the winding circuit if the motor is run continuously for approximately
62. lve is directly connected to the mini valve bodies and shares both the common internal main pres sure oil galley and the return oil galley that inter nally connect to the reservoir The main component of the valve is an adjustable spring loaded plunger that is pushed off from its seat by the oil pressure The oil then flows back into the reservoir Turning the adjustment nut clock wise increases the amount of oil pressure required to open the valve and turning it counterclockwise decreases the amount of oil pressure See adjust ment section for specification PRESSURE RELIEF ADJUSTMENT NUT PRESSURE GAUGE SPRING LOADED PLUNGER Figure 1 4 Pressure Relief Valve Not Functioning PRESSURE RELIEF ADJUSTMENT NUT PRESSURE GAUGE SPRING LOADED PLUNGER Figure 1 5 Pressure Relief Valve Functioning Page 3 c Mini Valves The operation of the mini valves is identical for all table functions except the elevation and Single Action Brake circuits These two hydraulic circuits use a 3 way single check valve type mini valve All other functions use a 4 way dual check valve type mini valve Either type mini valve is controlled by two pushing type electrically operated solenoids The sole noids push the spool valve located in the lower portion of the valve one way or the other This motion opens the main supply galley which has pump pressure allowing the oil to flow through the various parts of the min
63. mer is located in the rear of the base under the stainless steel base cover The stainless steel cover will have to be discon nected and lifted from the base for access to the transformer for further testing c Battery Charging Box Test 1 Make sure all connectors are connected and turn AC120V operation ON Using a DC voltmeter test pin 3 and pin 4 of CN51 DO NOT disconnect connector CN51 See figure 7 7 BLACK 4 2 BROWN 1 BROWN Figure 7 7 Connector CN51 2 Meter should read 26 5 1VDC 3 Test pin 5 and pin 6 of CN51 with DC voltmeter to test operation of CHARGING indicator light next to power cord connector 4 Meter should read 26 5 1VDC if charger is operating If batteries are fully charged there will be under 5 volts at pins 5 and 6 d Test Results If you do not receive the correct readings the charger system connectors wires or the trans former may be defective Page 57 6500NB e Charging System Output Adjustment If output reading at pins 4 not 26 5 1VDC the output can be adjusted at the variable resistor VR R59 on the circuit board inside the Charging Box See figure 7 8 Turn the adjuster clockwise to decrease the voltage Counterclockwise to increase the voltage NOTE The battery connectors must be dis connected to adjustthe battery charger output Figure 7 8 7 6 Switch Over Relay a Switch Over Relay in OFF Position The Switch Over Rel
64. must be provided for the oil on the other side See figure 1 10 Page 6 O RING O RING Figure 1 10 Back Section Cylinder 2 Trendelenburg Cylinder Assembly This cylinder piston arrangement has rack teeth cut into the top of each piston These teeth mesh with a pinon gear that is connected directly to the table side frames The pinion gear shaft and table side frames are supported by bearings at either side When hydraulic fluid is pumped into one side of the cylinder the pistons are pushed in one direction moving the pinion gear and table side frames with them Oil pressure can be applied to either side of the piston making the table tilt end for end See figure 1 11 ET t TABLE TOP PINION GEAR PISTONS SIDE VIEW Figure 1 11 Trendelenburg Cylinder Assy In order to remove any looseness or play in the table top the trendelenburg pistons are made in two pieces as shown in figure 1 12 This arrange ment eliminates any gear lash between the piston teeth and the table pinion gear due to oil pressure always being present on both sides of the pistons OIL PRESSURE OIL PRESSURE fi 3 SPLIT PISTONS REMOVE GEAR LASH TOP VIEW Figure 1 12 Trendelenburg Cylinder Pistons 3 Lateral Tilt Assembly The lateral tilt assem bly consists of two cylinders pistons and connect ing rods The connecting rods attach to the lateral tilt lever which connects to the table side frames
65. n If necessary adjust the thermal cut out time by turn ing the adjustment screw clockwise to increase the time counterclockwise to decrease the time Re fer to figure 7 26 d Thermal Relay Test Internal Relay Models Tables with the thermal relay built into the pump have an additional connector on the pump that is connected to two white wires 19 1 Turn OFF both Battery and AC120V operat ing models and disconnet connectors CN19 See Figure 7 27 2 Use an ohmmeter to test for continuity accross the 2 pin connector WHITE WIRES TO PUMP Figure 7 27 d Test Results If you do not receive the correct meter readings the problem could be in the wires connectors relay box or main switch refer to that section for trouble shooting If the correct readings are obtained everything is good up to that point and the problem could be the motor e Motor Resistance Test The motor can be statically checked for resistance using anohmmeter This testis not 100 accurate because you are checking the motor with very low voltage from the meter and without any load 1 Using an ohmmeter Rx 1 scale measure the resistance between the two pins of CN12 See figure 7 28 2 The meter should read 1 to 2 ohms atroom temperature 3 Measure the resistance between either pin and ground 4 Meter should read infinity Figure 7 28 Motor Connector CN12 f Test Results If you do notreceive the correct meter readings
66. n Position Reading Open Infinity Open Infinity Closed 0 When the Back Section is Up NS 6 brings the Back Section Down to level Back Section Return Switches Page 37 NS 7 Leg Section Down Test at pins 7 amp 10 Table Switch Meter Position Position Reading Open Infinity Closed 0 Open Infinity When the Leg Section is Down NS 7 brings the Leg Section Up to level NS 8 Leg Section Up Test at pins 8 amp 10 Table Switch Meter Position Position Reading Open Infinity Open Infinity Closed 0 When the Leg Section is Up NS 8 brings the Leg Section Down to level Figure 5 18 Leg Section Return Switches b Switch Adjustment If proper readings are not obtained during test or if table does not properly return to level use the following procedure to adjust the switches 1 Apply table brakes and using a level level the table top using the TRENDELENBURG and LATERAL TILT function buttons on the pendant control RETAINING SCREWS MICRO SWITCH Figure 5 19 Micro Switch Adjustment Page 38 2 For all switches except the Leg Section switches carefully loosen the switch retaining screws and adjust the switches as needed See figure 5 19 3 To adjust the Leg Section switches remove seat section top loosen the 2 phillips head screws securing bracket adjust the switch tighten the screws and replace seat section top See figure 5 20 LEG S
67. nal charging system also incorporates the components to transform the 120VAC input to 24VDC output to the components The Model designation 6500B is for all battery tables with a Serial Number of 6500B 1991 6 078 amp Prior The designation 6500NB is for all battery models with the Serial Number of 6500NB 1991 6 079 amp Later The two models can be easily identified by the position of the Main Power switch The power switch is on the lower front of the base on the 6500NB models See figure 7 2 NOTE This section covers the electrical troubleshooting for the 6500NB model ONLY Electrical Troubleshooting forthe 6500B is covered in section 6 6500 NB SWITCH S N 6500 NB 1991 6 079 amp LATER MAIN POWER SWITCH 5 6500 B 1991 6 078 8 PRIOR Figure 7 2 Model Identification Page 54 7 2 Troubleshooting Notes The basic operation of each component will be defined along with a drawing and explanation on how to check it out Certain defective components could cause the entire table to stop functioning or only one control function to stop It would depend on what part of the component failed Other defective components would only cause one control function to stop The following defective components could cause all control functions to be affected a Motor Pump Assembly b Main Switch Circuit and Wiring The following defective components could cause all control functions to be affected or onl
68. needed so no twisting or flexing of the back section is observed when itis stalled in the full up position See figure 2 2 BACK SECTION BACK SECTION CYLINDER ECCENTRIC CAM Figure 2 2 Back Section Adjustment b Foot Leg Section Position the leg section all the way up until it is above horizontal Both sides of the leg section should stop moving at the same time and should not show any signs of twisting Any twisting or flexing of the leg section as it approaches the stalled position indicates that one of the cylinders is not reaching its fully extended position at the same time as the other and an adjustment is required NOTE The leg section cylinder eccentric cam is located under the nameplate on the side casting To make an adjustment the nameplate will have to be removed and a new nameplate will have to be installed when the adjustment is com pleted To adjust Loosen the cam locking nuts located inside the table side frames Use a spanner wrench to turn the cylinder eccentric cams as required to shift either cylinder fore or aft as needed so no twisting or flexing of the leg section is observed when it is stalled in the above horizontal position Tighten locking nuts when proper adjustment is achieved 6500 NAMEPLATE la 7 LEG SECTION ni LEG SECTION CYLINDER ECCENTRIC ARM Figure 2 3 Leg Section Adjustment 2 3 Torque Specifications If the bolts for the tr
69. no matter what control function is se lected The brake locking circuit relay is also activated when any control function other than BRAKE UNLOCK is initially selected The following tests will determine if the relay box is functioning correctly a Checking Relay Box Input Power 1 Plug the power cord into the 120VAC supply wall receptacle Disconnect connector CN4 leave all other connectors connected 2 Using a DC voltmeter test input power for both the BATTERY and AC120V operating modes See figure 6 14 Meter should read approximately 24 28 volts in BATTERY mode and 26 5 1 volts in AC120V mode BATTERY mode AC120V mode pin12 4 pin 5 pin2 pin 6 Connector CN4 Color Code Pin 1 White Pin 5 Yellow Pin 2 Black Pin 6 Black Pin 3 Red Pin 7 Blue Pin 4 Blue Figure 6 14 Relay Box Input b Test Results If youdo not receive the correct meter readings the problem is in the input wiring connectors or components If the correct readings are obtained proceed to the next step c Checking Output to Pump 1 Connect all connectors and activate either BATTERY or AC120V operating mode 2 Test CN4 at pin 3 and pin 4 with a DC voltmeter DO NOT disconnect connector CN4 Meter should read approximately 24 volts when any function button is activated Refer to figure 6 14 for pin locations d Checking Output to Pendant Control NOTE The Relay Box connectors CN1 Pen dant Control CN8 Auxiliary Ba
70. ns to be affected or only one control function a Relay Box b Pendant Control The component listed below would only affect one control function Solenoid When troubleshooting an electrical circuit start at the problem and work back to the power source 5 2 Main Switch The main power supply 120 VAC 60 HZ comes in through the power cord and through the main switch The main switch opens both lines when in the OFF position An 8 amp or two 10 amp fuses are used to protect the complete electrical system and are located next to the main switch a Main Switch Test The following test will determine if line voltage is applied to connector CN4 which in turn would power the table 1 Plug the power cord into the 120VAC power Page 26 supply wall receptacle and turn ON the main switch 2 Disconnect connector CN4 from the relay box See figure 5 1 Leave all other connectors connected Figure 5 1 i Test RELAY BOX Line voltage 120 VAC will be mea sured in this test Do not touch uninsu lated connector pins or metertestleads 3 Use an AC voltmeter capable of measuring 120 VAC and measure the voltage between pins 1 and 2 black and white wires located in connec tor CN4 See figure 5 2 You should receive line voltage 120 VAC Figure b Test Results b Test Results If you do not receive the correct voltage measure ment the problem would have to be in the
71. ockwise to decrease Figure 8 1 Relay Box Adjustments Model 6500N Page 68 0 I PR Jc Figure 8 3 Relay Box Adjustments Model 6500NB Page 69 Page 70 gt POG te O o t ware 8 0 4 26 OS 634 svi C 414 4447 42 41 oH lport Z O oN 14 I at It 1 Or 3 2 Oj eu H 16 71 4 sv4 Ll oe 2 G 3 X svs AL gt Te T NS 1 TREND LEVEL te To orr NS 2 REV TREND LEVEL ie pe NS 3 TILT LEFT LEVEL Pe am NS 4 TILT RIGHT LEVEL egg D 5 5 BACK DOWN LEVEL NS 6 BACK UP LEVEL 08 iab han NS 7 LEG DOWN LEVEL HHHH baag 15 EET uf sve NS 8 LEG UP LEVEL TOT LS 1 BACK UP KIDNEY INHIBIT TO m S RETO 3 O P er 1 4 To ALIZ zO _ TEs IES HOT 1 TMT gt T S a a m wi 22721 il 1 RL14 5 14 RL 14 a i d od eS Wiring Diagram Model 6500 Page 71 OOGOOOOOOOQDOOOOOO OOO
72. odels To simplify the troubleshooting procedures the battery model tables are covered separately in Section VI for the model 6500B and Section VII forthe model 6500NB 2 PIN SOLENOIDS CONNECTOR io gi PE i mus 5 CONTROL p o 0 MINLVALVES rola ott AUXILIARY BASE TT BASE MICRO SWITCHES a CONNECTOR CN2 CAPACITO en MOTOR PUMP ASSEMBLY DPST MAIN POWER SWITCH POWER F X CORD 2 10 AMP FUSES Figure 4 1 6500N Electrical Circuit Block Diagram Page 25 5 1 V ELECTRICAL SYSTEM TROUBLESHOOTING The basic operation of each component will be defined along with a drawing and explanation on how to check it out NOTE This section does not cover the bat tery table components They are covered separately in Section 6 and 7 Certain defective components could cause the entire table to stop functioning or only one control function to stop It would depend on what part of the component failed Other defective components would only cause one control function to stop The following defective components could cause all control functions to be affected a Motor Pump Assembly starting capacitor b Main Switch Circuit and Wiring The following defective components could cause all control functio
73. of the motor and is a gear type displacement pump with a pumping capacity of 4 liter per min The Motor Pump Assembly is mounted on insula tors in the base of the table a Motor Pump Test 1 Disconnect motor connector CN12 Leave all other connectors connected and activate either BATTERY or AC120V operating mode 6500NB 2 Activate any function and use a DC voltme ter to measure across the two pin connector Pin 1 and pin 2 See figure 7 25 Meter should read 24 28 volts Figure 7 25 Motor Input Voltage NOTE Ifthe pump has been activated continu ously for 1 1 2 to 2 minutes the thermal relay will interrupt the power to the pump b Thermal Relay Test External Relay Models The Thermal Relay is used to interrupt the current flow to the pump motor to protect it from possible damage due to overheating 1 Turn OFF both BATTERY AC120V operating modes 2 Use an ohmmeter to test for continuity between terminals 7 and 8 on the Thermal Relay See figure 7 26 E m DECREASE TE 700 METAL PLATE RESET INCREASE SWITCH Figure 7 26 Thermal Relay 3 The Thermal Relay should reset itself after approximately one minute if it is in the AUTO mode normal factory setting If the relay fails to reset itself check to make sure that the reset button is held IN with the small metal plate See figure 7 26 4 The Thermal Relay should activate after 1 1 2 to 2 minutes of continuous pump operatio
74. onnec tor is low voltage and there is no danger of electrical shock 15 14 13 12 11 10 20 19 18 17 16 24 23 22 21 CN13 Figure 7 14 Table Base Connector e Test Results If youdo not receive the correct voltage reading the wiring or connector pins may be faulty Discon nect connector CN1 from the Relay Box and using an ohmmeter test the continuity between the cor responding pins in connectors CN1 and 13 See figure 7 15 If the correct readings are obtained this part of the circuit is okay and the problem may be the relay box CN 13 CN 1 CN 13 CN 1 PIN NO WIRE COLOR PIN NO WIRE COLOR 1 Red White 2 White White Grey 3 Black White Yellow 4 Red Purple White 5 White Red Black White 6 Yellow Purple 7 Brown White Purple 8 White Brown Blue Yellow 9 Blue White Not Used Orange Blue Red A o White Orange Brown White Figure 7 15 Base Connector Continuity Test 6500NB 7 8 Auxiliary Switches The following tests will determine if the auxiliary switches are functioning properly a Switch Test Disconnect connector 9 at the Relay Box and using an ohmmeter check for continuity at the connector pins pin 1A common while activating the appropriate switch See figure 7 16 Meter should read 0 ohms b Test Results If proper meter readings are not received test the individual sw
75. ontinue to press the TABLE UP button on the pendant control so that the pump motor contin ues to run and using a DC voltmeter check the voltage drop of each battery individually See figure 6 5 5 Meter should read 12VDC 1VDC BATTERY 2 BATTERY 1 Figure 6 5 b Test Results A reading of 11 volts or below indicates the battery needs charging After batteries have been fully charged repeat the fullload test If either battery s voltage drops below 11VDC it should be replaced 6 5 Battery Charging Box The Battery Charging Box contains the battery charging system as well as the transformer and components for the AC120V operation a Battery Charging Box Test 1 Confirm 120 VAC input at CN12 using Main Switch test in 6 3a 2 With AC120V power ON use a DC voltmeter to test pin 3 and pin 4 of CN12 DO NOT disconnect connector CN12 See figure 6 6 3 Meter should read 26 5 1VDC Figure 6 6 Connector CN12 Test 4 Test pin 5 and pin 6 of CN12 with DC voltmeter to test operation of CHARGING indicator light next to power cord connector 5 Meter should read approximately 26 5 VDC 1V if charger is operating If batteries are fully charged there will be under 5 volts at pins 5 and 6 b Test Results If you do not receive the correct readings the charger or the transformer may be defective c Charging System Output Adjustment If output reading at pins 4 is not 26 5 1VDC
76. own good unit or wire con nector In some cases this may be faster than using a multi meter 6 11 Motor Pump Assembly The hydraulic pump motor is a 24 volt DC electric motor The oil pump unit is attached to the bottom of the motor and is a gear type displacement pump with a pumping capacity of 4 liter per min The Motor Pump Assembly is mounted on insula tors in the base of the table a Motor Pump Test 1 Disconnect motor connector CN11 Leave all other connectors connected and activate either BATTERY or AC120V operating mode 2 Activate any function and use a DC voltme ter to measure across the two pin connector Pin 1 and pin 2 See figure 6 21 Meter should read 24 28 volts Figure 6 21 Motor Input Voltage NOTE Ifthe pump has been activated continu ously for 1 1 2to 2 minutes the thermal relay will interrupt the power to the pump b Thermal Relay Test The Thermal Relay is used to interrupt the current flow to the pump motor to protect it from possible damage due to overheating 1 Turn OFF both BATTERY and AC120V Page 51 6500B operating modes 2 Use an ohmmeter to test for continuity between terminals 7 and 8 on the Thermal Relay 0 DECREASE INCREASE See figure 6 22 Figure 6 22 Thermal Relay 3 The Thermal Relay should reset itself after approximately one minute if it is in the AUTO mode this is the normal factory setting If the relay fails to reset itself check to m
77. perating modes in the OFF position test connector CN13 at pin 1 and pins 2 through 18 Meter should read OVDC Test at pin 21 and 22 meter should read 24 28VDC NOTE To insure that the table is in AC120V mode activate the Main Power Switch wait 5 10 seconds and test the base connector as shown above elf the test shows the table to be in the BATTERY mode momentarily place a jumper wire between pins 21 amp 22 to activate the switch over relay Wait 5 10 seconds and test the connector to make sure AC120V mode is activated pin 1 4 amp pin 2 meter should read 0 volts pin 1 amp pin 3 meter should read approx 5 volts 4 With AC120V power ON Main Power Switch activated test connector CN13 at pin 1 and pins 3 through 18 Meter should read 5 6VDC 5 Activate BATTERY operating mode by switching Main Power Switch OFF and momentari ly placing a jumper wire between pin 21 and pin 22 Test pin 1 and pins 2 through 18 Meter should read OVDC for pin 3 5 6VDC for pins 2 and 4 through 18 8 7 15 14 13 6 5 O o 12 11 10 20 19 18 17 16 24 23 22 21 TEST LEAD AC 120V OFF 22 AC 120V ON 3 18 BATTERY MODE 2 3 4 18 Figure 7 19 Table Base Connector CN13 e Test Results If you do not receive the correct meter readings the relay box or wiring is defe
78. red Defective Pump Defective Mini Valve Defective Solenoid or Wiring Defective Relay Box or Pendant Control Incorrect Speed Adjustment Bad Check Valve Spool Valve Not Centered Galled Slider Assembly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Bad Check Valve Leaking Mini Valve Loose Fittings Joints Hoses Leaking O Ring Inside Cylinder PRIMARY PISTON O RING SECONDARY PISTON PLUMBING O RING TERMINAL CHECK VALVE P d SPEED b CONTROL oe INTERNAL OIL FLEXIBLE FROM PUMP HOSE INTERNAL OIL RETURN MINI VALVE TO RESERVOIR Figure 3 1 Elevation Circuit Page 15 3 4 TRENDELENBURG DIAGNOSIS CHART Problem Reason Trendelenburg function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid or Wiring Defective Relay Box or Pendant Control Trendelenburg function chatters or loses position Defective or Dirty Check Valve Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil PINION GEAR REAR PIVOT BLOCK O RING O RING FRONT PIVOT BLOCK TAIL CYLINDER CAP PISTON ASSEMBLY HEAD CYLINDER CAP HEAD DOWN CIRCUIT HEAD UP CIRC PLUMBING 28 TERMINAL COPPER LINES INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR MINI VALVE Figure 3 2 Trendelenburg Circuit
79. s activated by pressing any function button except BRAKE UNLOCK A timer inthe Relay Box allows continuous output for about 7 seconds If the brakes are already locked no output is provided The BRAKE UNLOCK button activates another timer in the relay box which allows continuous output for the brake release function for approximately 7 seconds the brakes are already released using the BRAKE UNLOCK button no output is provided 1 Activate either BATTERY or AC120V oper ating mode 2 Testconnectors CN6 and CN7 from the back while attached to the relay box All connectors should be connected 3 Activate each of the pendant control buttons and measure the output voltage for the corre sponding connector pins with a DC voltmeter See figure 6 16 Page 48 6500B OPERATION BUTTONS Table Up Table Down Trend Rev Trend Back Up Back Down Tilt Right Tilt Left Leg Up Leg Down Kidney Up Kidney Down Brake Set Brake Unlock Flex Reflex Figure 6 16 Connector CN6 or CN7 g Test Results If you do notreceive the correct meter readings the relay box is defective and should be replaced NOTE Before deciding the relay box is de fective check the wires and pins in the connector blocks to make sure they are notloose or making a bad connec tion with their mate NOTE If the battery power is ON and no table functions have been activated for ap proximately 3 minutes the power off circuit will
80. s operation The solenoid must placed if the internal thermal fuse has been blown The solenoids are mounted directly on either side of the hydraulic mini valves and push the spool valve direction or the other depending upon which solenoid is activated a Solenoid Test The following tests will check the voltage applied to the solenoids and the resistance of the solenoid coil NOTE Ifa solenoid does not function when the pendant control button is pushed the problem could be the pendant control the relay box or the solenoid YELLOW NOTE Each solenoid operates on a 24V source from the relay box This source can be checked by measuring the voltage at the 2 pin connector in question b Test 1 1 Activate either BATTERY or AC120V oper ating mode 2 Disconnect the 2 pin connector from the solenoid in question all other connectors should be connected See figure 6 20 3 Use a DC voltmeter and measure the voltage across the 2 pin connector Pin 1 and pin 2 Meter should read approximately 24 28 volts NOTE The appropriate pendant control button must be pushed during this test The motor will run when this test is per formed and the brake locking solenoid will be activated by any function other than MOVE 4 BLUE BLUE YELLOW BROWN BLUE BLUE YELLOW ORANGE BLUE co BLUE YELLOW WHITE BROWN BLUE BLUE aie YELLOW WHITE GREY BLUE B
81. se Con nector and CN9 Auxiliary Switches are interchangeable 1 Disconnect the Pendant Control connector from the base connector connect all other connec tors and use a DC voltmeter to measure the follow ing sockets located in the table base connector CN14 See figure 6 15 for pin locations NOTE A fine wire or a paper clip may be needed to accurately test the small sockets in the connector The connec tor is low voltage and there is no danger of electrical shock 2 With both BATTERY and AC120V operat ing modes in the OFF position test connector CN14 at pin 3 and both pins 19 and 23 Meter should read approximately 24 28VDC 3 With BATTERY power ON test connector CN14 at pin 3 and both pins 1 and 21 Meter should read approximately 24 28VDC 4 With AC120V power ON test connector 14 3 and pins 1 19 and 21 4 Also test at pin 22 and pin 1 Meter should read approximately 24 28VDC Page 47 15 14 13 12 11 10 20 19 18 17 16 24 23 22 21 Figure 6 15 Connector CN14 e Test Results If you do not receive the correct meter readings the relay box or wiring is defective If the correct readings are obtained this part of the relay box is okay Proceed to the next step f Checking Output to Solenoids This test checks the voltage that is used to energize the solenoids NOTE Brake Lock function i
82. ssure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil BACK SECTION MINI VALVE INTERNAL OIL RETURN TO RESERVOIR Figure 3 4 Flex System Circuit Page 18 3 7 BACK SECTION DIAGNOSIS CHART Problem Reason Back Section function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control Back Section function chatters or loses position Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil BACK SECTION CYLINDER ASSEMBLY FLEXIBLE HOSES FLEXIBLE HOSES CHECK VALVE a NOTE ONE SIDE SHOWN FOR CLARITY INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR Figure 3 5 Back Section Circuit Page 19 3 8 LEG SECTION DIAGNOSIS CHART Problem Reason Leg function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control Leg function chatters or loses position Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil LEG
83. surements the problem would have to be in the wires main switch fuses or power cord Check the continuity from the power cord connec tor CN13 through the fuses switch and wiring to connector CN12 Remove the power cord discon nect CN12 turn the Main Power Switch ON and test as shown in figure 6 4 CN 12 SWITCH SWITCH ON OFF 0 ohms Infinity 0 ohms Infinity Figure 6 4 CN12 to CN13 Continuity Test 6 4 Batteries The BATTERY operating mode is powered by two 12 volt batteries connected in series to provide the 24 volt operating power The battery system voltage should be 24VDC with a range of 22VDC to 26VDC If the battery charge level falls below 23 5 volts the BATTERY operation indicator on the pendant control will blink indicating that the batteries require recharging The built in charging system automatically keeps the batteries atthe proper charge level when the AC120V oper ating mode is ON The charging system will oper ate while the table is being operated in the AC120V mode a Battery System Test 1 Disconnect the main power cord and using a DC voltmeter test the voltage of each individual battery at its terminals Meter should read 12VDC 1V 6500B 2 To accurately test the batteries they must be tested under a full load Disconnect the main power cord and make sure all other connectors are connected 3 Turn BATTERY power ON and elevate the table to its full up position 4 C
84. t Control Test Page 59 6500NB b Test Results If you do not receive continuity between any of the pins either the micro switch in the Pendant Con trolis defective or awire is broken Either of these problems can be repaired easily If you receive correct readings with the meter there is nothing wrong with the Pendant Control c LED Test The BATTERY and AC120V power ON indicators can be checked with an LED tester Test BAT TERY indicator at pin 1 and pin 2 of 24 pin Pendant Control connector Test AC120V indica tor at pin 1 and pin 3 See figure 7 12 If no LED tester is available the LEDs can be tested by applying 5 voltstothe appropriate pins To avoid damage to the LED a 330 ohm resistor must be placed between the power source and the connec tor pins See figure 7 13 R 330 OHM 5VDC Figure 7 13 LED Test d Wiring Harness Test The following test checks the wires leading from the relay box connector to the 24 pin connector table socket These wires apply low voltage to the pendant control buttons 1 Activate the AC120V operating mode 2 Disconnect the pendant control from the table base connector All other connectors should be connected 3 Use a DC voltmeter and measure the following pins located in the 24 pin table base connector CN13 See figure 7 14 Page 60 NOTE A fine wire or a paper clip may be needed to accurately test the small sockets in the connector The c
85. t of the Model 6500 Table has resulted in several changes However the basic opera tion ofthe internal components remains the same Figure 1 1 depicts the hy draulic system of the early models and figure 1 2 depicts the later models a Oil Reservoir Main oil supply Approximately two quarts b Motor Pump Assembly A positive displace ment gear type pump provides the necessary oil pressure and volume TRENDELENBURG BACK v LATERAL TILT LEG SL KIDNEY LIFT ELEVATION RN cYuNDER L 28 Li lL 77a ie 5 3 ALIAS NNN ESI ELEV TILT BACK Bil ibi BRAKE w a VOIR Tfi EMERGENCY Gin BRAKE RELEASE N PRESSURE IN OIL RESER MOTOR PUMP ASSEMBLY Figure 1 1 Hydraulic Block Diagram Early Models Page 1 c Pressure Relief Valve Provides an alternate oil e Hydraulic Lines Fittings Connections They path when the hydraulic cylinders reach the end of provide a path for the hydraulic oil their stroke f Hydraulic Cylinders They convert the hydraulic d Electro Hydraulic Mini Valve Assemblies These fluid pressure and volume into mechanical motion direct the fluid to the appropriate hydraulic cylin ders TRENDELENBURG SECTION oO LATERAL CEG pida KIDNEY LIFT ELEVATION S Ere a fi EMERGENCY BRAKE RELEASE
86. tested under a full load Disconnect the main power cord and make sure all other connectors are connected 3 Turn BATTERY power ON and elevate the table to its full up position 4 Continue to press the TABLE UP button on the pendant control so that the pump motor contin ues to run and using a DC voltmeter check the voltage drop of each battery individually See figure 7 5 5 Meter should read 12VDC 1VDC 6500NB Figure 7 5 b Test Results A reading of 11 volts or below indicates the battery needs charging After batteries have been fully charged repeat the full load test If either battery s voltage drops below 11VDC it should be replaced 7 5 Battery Charging Box AC120V Transformer The Battery Charging Box contains the battery charging system as well as the components for AC120V operation except the transformer a Transformer Test 1 Confirm 120VAC input at CN15 using Main Switch test in 7 3a 2 Connect CN15 disconnect CN18 brown and red wires and using an AC voltmeter test the transformer output at CN18 See figure 7 6 3 Meter should read 22VAC Figure 7 6 Connector CN18 Test b Test Results If the correct voltage is obtained everything is good up to this point and the problem would have to be in another area If you do not receive the correct measurements the problem may be in the wires connectors or transformer The transfor
87. ting capacitor is shorted or grounded the motor will not run Capacitors very seldom fail and it requires a dielectric tester to accurately test one However an ohmmeter can be used to determine if the capacitor will store a low voltage charge and most of the time this is adequate 1 Turn the main switch OFF 2 Connector CN15 should be disconnected 3 Use the R x 100 scale of the ohmmeter and touch pins 2 and 3 of connector CN15 See figure 5 10 e Test Results The meter needle should move up scale and then back down to infinity This would indicate that the capacitor is storing an electrical charge NOTE The capacitor may have to be dis charged first by shorting pins 2 and 3 together before you will be able to see the ohmmeter needle swing up the scale f Step 3 The motor windings can be statically checked for resistance using an ohmmeter 1 Turn main power switch OFF 2 Connector CN15 should be disconnected 3 Use the R x 1 scale of the ohmmeter and measure the resistance between the pins located in the pump connector CN15 See figure 5 11 OHM METER Approx 5 ohms Approx 4 ohms Approx 8 ohms Figure 5 11 Pump Connector CN15 9 Test Results If you do not receive the correct meter readings the motor or wiring is defective Page 33 5 7 Return to Level Micro Switches The return to level feature is activated by a single button on the pendant control and automatically lev
88. tion The solenoid must be replaced if the internal thermal fuse has been blown The solenoids are mounted directly on either side of the hydraulic mini valves and push the spool valve in one direction or the other depending upon which solenoid is activated a Solenoid Test Page 30 The following tests check the voltage applied to the solenoids and the resistance of the solenoid coil NOTE If a solenoid does not function when the pendant control button is pushed the problem could be the pendant control the relay box or the solenoid NOTE Each solenoid is controlled with 120V source coming from the relay box This source can easily be checked by mea suringthe voltage atthe 2 pin connector in question CAUTION Line voltage will be measured in this test Do not touch uninsulated connec tor pins or meter test leads b Step 1 1 Plug the table cord into the wall receptacle and turn main switch ON 2 Disconnect the 2 pin connector from the solenoid in question See figure 5 8 3 Use a voltmeter capable of measuring 120 VAC and measure the voltage across the 2 pin connector Polarity of meter leads is not important NOTE The appropriate pendant control but ton must be pushed during this test The motor will run when this test is performed and the brake locking sole noid will be activated by any function other than UNLOCK c Test Results If you do not receive the correct voltage the prob lem cou
89. wires main switch fuses or power cord If the correct voltage is obtained everything is good up to this point and the problem would have to be in another area 5 3 Pendant Control The Pendant Control consists of 16 micro switches buttons When any of the circuits are completed depressing a control button the appropriate relay contacts located in the relay box close applying 120V potential to the appropriate solenoid to operate the mini valve andthe pump motor The Pendant Control has only 5 6 volts applied to it 1 Unplug the pendant control from the base of the table You will be checking the cord side connector 2 Use an ohmmeter R x 1 scale and check the continuity between pin 1 and pins 4 through 19 See figure 5 3 3 Ohmmeter must show continuity between the pins that are indicated when the appropriate buttons are pressed NOTE Pins 2 and 8 are connected to the LED power on light on the pendant control and cannot be checked with an ohm meter a Pendant Control Test The following test will determine if the micro switches inside the Pendant Control are function ing correctly COMMON 2 LED 9 3 TABLE UP 4 o TABLE DOWN REV TREND o TREND BACK UP o BACK DOWN 9 Ni TILT RIGHT c o TILT LEFT 22 LEG UP 2 LEG DOWN 13 2220 FLEX SKYTRON REFLEX BRAKE UNLOCK P
90. y one control function a Relay Box b Pendant Control The component listed below would only affect one control function Solenoid When troubleshooting an electrical circuit start at the problem and work back to the power source NOTE On the battery model tables trouble shooting should begin by switching the operating mode For example if a function fails when attempting to oper ate the table in the AC120V mode switch to the BATTERY mode If the function now operates the problem is probably located between the power cord and the relay box If the function also fails when in battery operation use the auxiliary switches to operate the function If the function now operates the problem is probably in the pendant control connectors or wiring from the pendant control to the relay box All connector pins are numbered usu ally with very small numbers 6500NB SOLENOID COIL 24 PENDANT 4 CONTROL IL RETURN AUXILIARY CIRCUIT CN10 CN14 2 uuu CN9 Un y RELAY BOX CN6 J AUXILIARY SWITCHES peie 000000 CAPACITOR BATTERIES SWITCH OVER RELAY 22 VAC FROM TRANSFORMER 120 1 TRANSFORMER CHAR
91. ystem 9 1 3 Hydraulic AdjUS MEN S 10 10 p Bleeding The Aydra lie System 10 c Pressure Relief 1 10 Speed 10 SECTION II MECHANICAL TABLE ADJUSTMENTS bua ue breue ecu 12 2 1 Back Section Gear Mesh Adjustment usine enhn Prio ue xa ri 12 2 2 Hydraulic 12 cM Seno ee EL m 12 D 12 SECTION IN HYDRAULIC TROUBLESHOOTING 14 3 1 Precautions ET 14 Tr ubleshooting m 14 3 3 ELEVATION DIAGNOSIS CHART 15 3 4 TRENDELENBURG DIAGNOSIS CHART 16 3 5 LATERAL TILT DIAGNOSIS 17 3 6 FLEX SYSTEM DIAGNOSIS CHART sens rx Rer 18 3 7 BACK SECTION DIAGNOSIS CHART scsscsccenssccdencsvancereagstedssaceondteantseteevadionctenabddeeeveueredessincenndes 19 48 LEGSECTION DIAGNOSIS CHART

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