SKYTRON Elite 3100 O/R Table Service Manual
Contents
1. 24 5 1 Troubleshooting 24 5 2 ES rdm 24 5 3 BOX 26 5 4 Pendant COMMON Em 29 5 5 C 30 5 6 Motor Pump Assembly 2 5 aint ce pec See ee 32 5 7 Return to Level Micro Switches 34 WIRING DIAGRAM MODEL 3100 early base 36 SECTION VI 3100N ELECTRICAL SYSTEM 5 38 6 1 Troubleshooting 38 6 2 38 6 3 Pendant LEUTE LN I a 39 64 Relay 40 6 55 lt 6 42 6 6 Motor Pump Assemlbly 5 2 9 0 a ee ee 44 6 7 Return to LevelMicro Switches rennen rsen EEEE 46 WIRING DIAGRAM MODEL 3100N 48 SECTION 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 of2. 5 ces oie a ted reta te Ho see Dru RE artes 15 3 4 Trendelenburg Diagnosis Chart sissisodan nedenarne aaaea aaa aa kaina a iaa aE 16 3 5 Lateral Diagnosis aE gr du nd 17 3 6 Kidney Lift Diagnosis sinn resins 18 3 7 Slide FUNCTION Diagnosis Chat cies eck Ene Poe kk ENTER E a EA 19 3 8 Double Action Brake Circuit Diagnosis enne nne nnne 20 3 9 Single Action Brake Circuit Diagnosis 21 3 10 Flexible Hose Identification and 22 SEGTION IV EEECTRIGAE SYSTEM cnra ato oe ne b aet Ere beendet temer deese non ere 23 4 1 EE 23 4 2 23 4 3 Model Coverage tecta 23 10 01 Although current the time of publication SKYTRON s policy of continuous development makes this manual subject to change without notice TABLE OF CONTENTS CONTINUED SECTION V ELECTRICAL
3. h 4 4 h g 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 notloose or making a bad connec tion with their mate 5 4 Pendant Control The Pendant Control consists of 13 micro switches buttons When any of the circuits are completed by depressing a control button the appropriate relay contacts located in the relay box close and TABLE CONNECTOR 120V potential is applied to the solenoid to operate the hydraulic mini valve The Pendant Control has only 6 3 volts applied to it PIN NO LED TABLE UP PENDANT CONNECTOR FRONT VIEW Figure 5 9 Pendant Control Test Page 29 Pendant Control Test The following test will determine if the micro switches inside the Pendant Control are function ing correctly 1 Unplug the 19 pin connector from the base ofthe table You will be checking the cord side connector 2 Use an ohmmeter x 1 and check the continuity between pins 1 through 16 See figure 5 9 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 LED power on light on the pendant control and cannot be checked with a
4. 9 1 3 Hydraulic Adjustments nte cese rp te ee raa Eno du EE ne eR 9 9 b Bleeding tm rrr ete rna reete du 9 Pressure 10 Speed AdJUStITedts steer ede 10 SECTION II MECHANICAL TABLE 12 2 1 Kidney Lift Cylinder Adjustment coi e tertie nete ke ee is aude en n ree RR read NEP 12 a Side Frame Cover Removal viisisataa aa aaa a 12 e c 12 2 2 Slide Function Bearing rt er e ned sree Fea e E ea 12 2 3 Cassette Tray Chain 12 2 4 Elevation Column Adjustment i npe 13 14 3 1 Procal on Ssss UII 14 3 2 166 lt 14 3 3
5. CN4 Figure 6 2 Main Power Test CAUTION Line voltage 120VAC will be mea sured in this test DO NOT touch uninsulated connector pins or meter test leads 3 Use an AC voltmeter capable of measuring 120VAC and measure the voltage between pins 1 and 2 black and white wires located in connector CN4 See figure 6 3 You should receive line voltage 120VAC Black Red Blue Yellow Figure 6 3 Connector CN4 b Test Results If you do not receive the correct voltage measure ment the problem would have to be in the 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 6 3 Pendant Control The Pendant Control consists of 12 micro switches buttons When any of the circuits are completed by 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 and the pump motor The Pendant Control has only 5 6 volts applied to it a Pendant Control Test The following test will determine ifthe micro switches inside the Pendant Control are functioning cor rectly TABLE CONNECTOR 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 andpins 4through 15 See figure 6 4 3
6. 2 Disconnect the 2 pin connector from the solenoid in question connector D shown for ex ample in Figure 5 11 BLUE BLACK WHITE p TH Figure 5 11 Solenoid Test Page 31 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 button must be pushed during this test The motor will run when this test is performed and the brake locking solenoid will be activated by any func tion other than UNLOCK c Test Results If you do not receive the correct voltage the prob lem could be in the wires leading down to connec tor The problem could also be in the relay box or the Pendant Control refer to that section for troubleshooting If the 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 pin connector in question connector D shown for example in Figure 5 11 Connector must be disconnected Polarity of meter leads is not impor tant 2 The meter should read approximately 80 90 ohms at room temperature 58 ohms for tables S N 1997 4 amp L 3 Measure the resistance between either pin and ground 4 Meter should read infinity e Test Results If the solenoid d
7. ASSEMBLY 3 PIN CONNECTOR Figure 5 12 3 Use a voltmeter capable of measuring 120 VAC and measure the following connector pins in connector C See figure 5 13 3 PIN CONNECTOR Figure 5 13 Back View Connector C CONNECTOR C COLOR CODE 1 Red 2 Blue 3 Yellow TEST TEST METER READINGS LEAD LEAD AC VOLTS 120 ACV 120 ACV c Test Results If you do notreceive 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 either the motor or the starting capacitor d Step 2 If the starting capacitor is shorted or grounded the motor will 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 Connectors C and C shouid be discon nected 3 Use the x 100 scale of the ohmmeter andtouch pins 2 and 3 of connector C See figure 5 13 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 discharged first by shorting pins 2 and 3 together before
8. O Ring Inside Cylinder Brakes will not retract properly Incorrect Speed Adjustment Bad Check Valve Spool Valve Not Centered Defective Mini Valve Defective Solenoid or Wiring Defective Relay Box or Pendant Control REAR BRAKE CYLINDERS SINGLE ACTION PLUMBING amp 77 FLEXIBLE HOSES RETURN TO RESERVOIR SPEED CONTROL M EMERGENCY BRAKE RELEASE VALVE 3 WAY MINI VALVE INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR Figure 3 7 Single Action Brake System Page 21 3 10 Flexible Hose Identification and Place ment The following figures will show the correct place ment of the flexible hydraulic hoses used in the 109 0120 OO CL table and their respective number codes O4 O1008 013 Figure 3 8 Main Plumbing Terminal Figure 3 9 Cylinder and Plumbing Terminals Page 22 SECTION IV ELECTRICAL SYSTEM 4 1 General 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 ofthe table The pump motor and the hy draulic valves are controlled electrically with the pendant control The electrically operated functions are as follows ELEVATION Up and Down TRENDELENBURG Head up and down LATERAL TILT Right and left KIDNEY LIFT Up and down SLIDE FUNCTION RETURN Trendelenburg and lateral tilt UNLOCK Brake release The p
9. O 5 Q O op I 1 43 5 IIT Oo O 2 13 Q 014 2 PENDANT TRANSFORMER FUSE 8A RELAY Ct CONTACTS 5 2 es 4 SOLENOIDS 63 Q 1 Mug 2 d O O Oo 2 01 x 2 4 Q L1 ame oo 2 y iol OQ ll 9 ed 5 9 O lt Q O O O Q 9 16 Q7 9 18 NE 10 4 dE bu di 4 a RLII i RELAYBOX _ S HYDRAULIC PUMP MOTOR REY BRIDGE Wiring Diagram Model 3100 early base design 2 PIN SOLENOIDS CONNECTOR PENDANT CONTROL o 00000000 o 00000000 AES AUXILIARY BASE RISER TO RETURN CIRCUIT 11 MICRO SWITCHES A CONNECTOR CN2 CN6 A CN15 MOTOR PUMP ASSEMBLY DPST MAIN POWER SWITCH FUSES Figure 6 1 3100N Electrical Circuit Block Diagram Page 37 3100 SECTION ELECTRICAL SYSTEM TROUBLESHOOTING 6 1 Troubleshooting Notes The basic operation of each component will be defined along with a drawing and explanation on how to check it out NOTE This section covers the electrical sys temforthe N series base de
10. 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 LED power on light on the pendant control and cannot be checked with an ohm meter PIN NO Y LED 2 4 DOWN 5 DOWN 7 TILT RIGHT 8 8 LEFT SLIDE IN 9 OUT 1 K LIFT UP DOWN 5 UNLOCK e a RETURN gt Not Applicable for Model 3100 A PENDANT CONNECTOR FRONT VIEW Figure 6 4 Pendant Control Test Page 39 3100 b Test Results 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 6 5 NOTE Pin 15intable base connector will have no voltage potential unless 1 o
11. by restricting the amount of oil going back into the reservoir 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 8 Mini Valve Left Port Activated 1 Spool Valve Pushed to the right by electric solenoid This opens the internal oil pressure galley allowing the fluid to go through the check valve and ontothe cylinder Also thespoolvalveopens 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 mechanically opening the check valve located above it inthe return circuit This action allows the oil from the right side of the slave cylinder to go back into the reservoir The left pilot plunger valve is not affected in this operation mode 3 Check Valves Both check valves are openedin 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 At the 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 arou
12. rings use hy draulic oil to thoroughly lubricate the rings and cylinder Keep every thing clean Each complete oil circuitis shown on the following pages When troubleshooting a particular func tion 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 CHECK VALVE ELEVATION MINI VALVE 3 3 ELEVATION DIAGNOSIS CHART Reason Pressure Relief Valve Not Set Properly Low on Oil Spool Valve Not Centered 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 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 PISTON O RING PLUMBING TERMINAL CYLINDER BASE O RING FLEXIBLE BASE HOSE CONTROL INTERNAL OIL FROM PUMP INTERNAL OIL RETURN 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 or Adjusted Properly 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 Pen
13. 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 120VAC will be measured 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 from the back while at tached to the relay box 3 Activate each ofthe Pendant Control buttons and using and AC voltmeter capable of measuring 120VAC measure the voltage between the appro priate connector pins located in connector CN6 or CN7 See figure 6 8 Polarity of meter test leads is not important Meter should read 120VAC Page 41 3100 Table Slide Head Down Trend Kidney Down Brake Set Brake Unlock Slide Foot Tilt Right Tilt Lett Figure 6 8 Relay Box Output Connectors CN6 and CN7 f Test Results If you notreceive the correct meter readings the relay box or wiring is defective and should be replaced NOTE Before deciding the relay box is defec tive check the wires and pins in th
14. 59 3 A 4 o one m n 84 6 9 MI 8 He A TI He E Hoon E 1 RL 8 ER p 9 T aus i 1 5 RL 2 RL 2 ab e esce 5 3 p RL 4 To o wa 9 E E i4 p RL 22 9 8 1 Wiring Diagram Model 3100N Page 49 T Y F HUS JINI A A A ARANI CN 5000 36th Street S E Grand Rapids MI 49512 1 800 SKYTRON or 1 616 957 0500 FAX 1 616 957 5053
15. Check Valves Low on Oil Pressure Relief Valve Not Set Properly Pinched Hose Defective Mini Valve Defective Relay Box or Pendant Control Brakes will not stay locked Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil Brakes will not retract properly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pressure Relief Valve Not Set Properly Pinched Hose Defective Mini Valve Defective Relay Box or Pendant Control REAR BRAKE P edi CYLINDERS N DOUBLE ACTION 5 PLUMBING TERMINAL 27 2 COPPER LINES FRONT BRAKE CYLINDERS DOUBLE ACTION INTERNAL OIL FROM PUMP INTERNAL OIL RETURN CHECK VALVE TO RESERVOIR SPEED CONTROL 4 WAY MINI VALVE Figure 3 6 Double Action Brake Circuit Page 20 3 9 SINGLE ACTION BRAKE CIRCUIT DIAGNOSIS CHART Problem Reason Brakes will not set properly Emergency Brake Release Valve Open or Defec tive Spool Valve Not Centered or Adjusted Properly NOTE Bad Check Valve If brakes have been released with the Low on Emergency Brake Release Valve Pressure Relief Valve Not Set Properly brakes will not reset until MOVE Circuit Pinched Hose has been activated 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
16. Wheneverahydraulicline or com ponent is replaced bleedthe air outofthe lines using the pump pressure before making the final connection Then operate the function until it stalls in both directions Page 9 c Pressure Relief Valve The pressure relief valve is adjusted by turning the adjustment nut until the desired pressure is reached To adjust 1 Remove the blind cap and attach a hydraulic pressure gauge to the main oil galley using a 6mm plumbing bolt See figure 1 20 PRESSURE 1 20 2 Raise the table top unit until it reaches the end of its stroke and stalls Observe reading on pressure gauge Turn adjustment nut clockwise to increase oil pressure counterclockwise to decrease until desired reading is obtained Pressure should be 80KG CMT 1138 PSI d Speed Adjustments The speed adjustments control the volume of oil returning back to the reservoir thereby controlling the speed of each control function All four way mini valves have two speed adjustments located in the ends of each valve body All three way mini valves have only one speed adjustment One speed adjustment controls one direction of a particular function and the opposite speed adjustment controls the other direction They are adjustable by using a small straight blade Page 10 screwdriver and turning the adjustment screw clockwise to decrease the speed counterclockwise to increase the speed Refer to figure 1
17. or Pendant Control Kidney Lift chatters or loses position Defective or Dirty Check Valve Oil Leakage in Circuit P Air Inside Cylinder Pinched Hose A P 7 P KIDNEY LIFT 5 CYLINDER ui 29 f 27 t et e ibis 7 FLEXIBLE HOSES MAIN PLUMBING TERMINAL SPEED CONTROL NOTE ONLY ONE SIDE IS MINI VALVE CL INTERNAL OIL RETURN TO RESERVOIR SHOWN FOR CLARITY Figure 3 4 Kidney Lift Circuit Model 3100 only Page 18 3 7 SLIDE FUNCTION DIAGNOSIS CHART Problem Reason Slide function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valve Low on Pressure Relief Valve Not Set Properly Pinched Hose Defective Mini Valve Bad Solenoid Defective Relay Box or Pendant Control Slide function chatters Defective or Dirty Check Valve Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil Lue PISTON 0 RING SLIDE FUNCTION 2972 2 P MAIN PLUMBING N TERMINAL COPPER LINES CHECK VALVE SPEED CONTROL FLEXIBLE HOSES INTERNAL OIL FROM PUMP MINI VALVE INTERNAL OIL a TO RESERVOIR Figure 3 5 Slide Function Circuit Page 19 3 8 DOUBLE ACTION BRAKE CIRCUIT DIAGNOSIS CHART Problem Reason Brakes will not set properly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad
18. readings the problem could be in the wires connectors relay box or main switch refer to 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 starting 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 6 11 e Test Results The meter needle should move up scale and than 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 6 12 Approx 5 ohms Approx 4 ohms Approx 8 ohms Figure 6 12 P
19. 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 Connectors C and C should be discon nected 3 Use the R x 1 scale of the ohmmeter and measure the resistance between the pins located in 3 pin connector C shown on the chart See figure 5 14 Page 33 9 Test Results o If you do notreceive the correct meter readings the S FIN pR motor or wiring is defective CONNECTOR 5 7 Return to Level Micro Switches The return to level feature is activated by a single Figure 5 14 Back View Connector C button on the pendant control and automatically relevels the table top from the lateral tilt and CONNECTOR C COLOR CODE trendelenburg positions 1 Red 2 White The micro switches are cam operated They oper 3 Yellow ate on 6 3 VDC and control the function circuits pump motor and appropriate solenoid valves ex actly like the pendant control TEST TEST APPROX 5 OHMS The micro switches are wired to the relay box APPROX 4 5 through the 36 pin connector and to the pendant APPROX 8 OHMS control 19 pin connector See figure 5 15 LATERAL TILT RETURN SWITCH TRENDELENBURG RETURN SWITCH RETURN TO LEVEL M S OPERATION SWITCH POSITION SWITCH owo CONNECTOR 36 CONNECTOR Figure 5 15 Return t
20. 00 300 OHMS 0 OHMS 00 INFINITY c 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 d Step 2 Checking Low Voltage Connector E This test checks the low voltage applied to the pendant control buttons 1 The power cord should be plugged into the wall receptacle and main switch turned ON 2 Disconnect connector E and E See figure 4 1 All other connectors should be connected 3 Use a DC voltage meter 10V scale or equivalent and measure the following connector pins located in connector E See figure 5 6 16 9 5 9 8 12 14 16 e Figure 5 6 Back View Connector CONNECTOR E COLOR CODE 1 Red White 2 White 3 Black 4 Red 5 White Red 6 Yellow 7 Brown 8 White Brown 9 White Blue 10 Orange 11 White Orange 12 White Yellow 13 Violet White 14 Black White 15 16 TEST TEST METER READINGS LEAD LEAD DC VOLTS e 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 f Step 3 Checking High Voltage Connector This test checks the high voltage 120V that is used to energize the solenoids CAUTION 120 VAC will be measured in t
21. 21 HEAD UP 7 RIGHT TILT SLIDE FOOT KIDNEY LIFT UP AN HEAD DOWN LEFT TILT SLIDE HEAD KIDNEY LIFT DOWN Figure 1 21 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 On the electric tables use the second hand on awatch and time that particular function Match that time in the opposite direction by opening or closing the speed control A pressure gauge can be used to set the speed of each control function NOTE Kidney Lift not applicable for Model 3100 A To adjust 1 Attach the pressure gauge onto the main oil galley pictured in figure 1 19 2 The gauge should read the following values when operating the various control func tions in either direction Turn the speed controls until desired values are obtained Lateral Tilt 75 1065 PSI Kidney Lift Up 50KG CM 710PSI Dn 65KG CM 925PSI Trendelenburg Hd Dn 30KG CM 425PSI Hd Up 60KG CM 850PSI Slide 55KG CM 780PSI Brakes Set 10 30KG CM 142 425PSI Pressure Relief Valve 1138PSI 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 NOTE These pressure values should be used as a guideline If the speed ofa control function moves faster in one directio
22. 92 8 441 amp LATER 4 1 Model Identification Page 23 SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING 5 1 Troubleshooting Notes The basic operation of each component will be defined along with a drawing and explanation on how to check it out NOTE This section covers the electrical sys tem for the early base design tables with serial number 3100 1992 8 440 amp prior See section VI for the N series base design serial number 3100N 1992 8 441 amp later Certain defective components could cause the entire table to stop functioning or only one control function to stop depending upon what part of the component failed Other defective components would only cause one control function to stop These defective components could affect all con trol functions a Motor Pump Assembly starting capacitor b Main Switch Circuit and Wiring These defective components could affect all con trol functions or only one control function a Relay Box b Pendant Control A defective Solenoid would only affect one control function 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 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 in one line to protect the complete electrical system and it is located next to the main switch
23. ELITE SERIES SURGICAL TABLES MAINTENANCE MANUAL MODEL 3100 5 SECTION THYDRAULIG SYSTEM oet etes oto als doce den 1 rd ELM 1 Electro Hydraulie System E E 1 1 2 t irent uve ERR Ra duce tu ane teehee 3 Operatloh tec ches RE SERE 3 b Pressure Ftelief Valve teet tec rte tg tegebant end ea uu aeu pee rupe E nV e E Eu 3 emn cc ERE 4 d Neutral rrt te e e ve e un EP eua Du a Gare 4 e Right Port 5 t Mini Valve Lert Port AIV d ccce tete regie tun eue uua tcu t 5 g Hydraulic Cylinders Slave 6 h Elevation Cylinder Return eee hh pex ee easet Yun a duce Er eu SA Ra anu RR 8 Brake MERE 8 Emergency Brake Relea86 rettet ee ane E Cua vtae s exse x uu E Cu
24. MP ASSEMBLY OIL PUMP RESERVOIR 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 andthe pump continues to run Ifthis path were not provided the pump motor would stall because the oil cannot be compressed The pressure relief valve is directly connected to the mini valve bodies and shares both the common internal main pressure oil galley and the return oil galley that internally 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 clockwise increases the amount of oil pressure re quired to open the valve and turning it coun terclockwise decreases the amount of oil pressure See adjustment section for specifica tion PRESSURE RELIEF ADJUSTMENT NUT PRESSURE SPRING LOADED PLUNGER Figure 1 4 Pressure Relief Valve Not Functioning PRESSURE RELIEF ADJUSTMENT NUT PRESSURE SPRING LOADED PLUNGER Figure 1 5 Pressure Relief Valve Functioning Page3 Mini Valves The operation of the mini valves is identical for 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
25. a Main Switch Test The following test will determine if line voltage is applied to connector B which in turn would power the table Page 24 1 Plugthe power cord into the 120VAC supply wall receptacle and turn ON main switch 2 Disconnect connectors B and B See figure 5 2 Leave all other connectors connected 6 PIN CONNECTOR MAIN SWITCH BOX FUSE 8 AMP DPST MAIN SWITCH GROUND Figure 5 2 Main Switch Box and Fuse CAUTION Line voltage 120 VAC will be mea sured in this test Do not touch uninsulated connector pins or meter test leads 3 Use an AC voltmeter capable of measur ing 120 VAC and measure the voltage between pins 1 and 3 black and white wires located in connector B See figure 5 3 You should receive line voltage 120 VAC Figure 5 3 Back View Connector CONNECTOR B COLOR CODE Pin 1 White Pin 2 Blue Pin 3 Black Pin 4 Red RETURN LEVEL MICRO SWITCHES TRENDELENBURG LATERAL TILT SOLENOIDS 2 PIN CONNECTOR PENDANT CONTROL CONNECTOR RELAY BOX MAIN SWITCH BOX CAPACITOR MOTOR PUMP ASSEMBLY 6 PIN CONNECTOR CONNECTOR Figure 5 1 Electrical Circuit Block Diagram Page 25 b Test Results If you do notreceive the correct voltage measure ment the problem would have to be in the wires main switch fuse or power cord If the correct voltage is obtained everything is good up to this point and the problem would have to be in
26. another area 5 3 Relay Box The 120 volt power supply is directly connected tothe relay contacts When these contacts are closed 120 volts is suppliedtothe 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 UNLOCK is selected Also inside the relay box is a step down trans former and full wave rectifier which decreases the line voltage to 6 3 volts This low voltage potential controls the relays by the use of the hand held pendant control buttons Basically the relays enable a6 3 voltage potential to control the 120 volt circuit a Relay Box Test The following tests will determine if the relay box is functioning correctly b Step 1 Checking Connector B 1 Plug the power cord into the 120 VAC supply wall receptacle Leave the main switch in the OFF position 2 Disconnect and See figure 5 4 Leave all other connectors connected RELAY BOX 6 PIN CONNECTOR Jt Figure 5 4 Page 26 3 Use an ohmmeter R x 1 scale to measure the following connector pins in connector B See figure 5 5 6 PIN CONNECTOR Figure 5 5 Back View Connector B CONNECTOR B COLOR CODE Pin 1 Yellow Pin 2 Blue Pin 3 Blue Pin 4 Red TEST TEST LEAD LEAD METER READING APPROX 200 300 OHMS APPROX 2
27. connector In some cases this may be faster than using a multi meter 6 6 Motor Pump Assembly The electric motor is a capacitor start type with a rating of 120VAC 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 10 minutes This protector will take about 10 minutes to automatically reset The oil pump unitis 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 in the base of the table The starting capacitor is mounted along side the weights 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 NOT touch uninsulated con nector pins or meter test leads b Step 1 1 Plug the power cord into 120VAC power supply wall receptacle Turn main switch ON 2 Disconnect the 3 pin connector CN15 at the motor Leave all other connectors connected See figure 6 10 Page 44 PUMP MOTOR ASSEMBLY CN15 CAPACITOR Figure 6 10 3 Use a voltmeter capable of measuring 120VAC and measure the following connector pins in connector CN15 See figure 6 11 120 E 120 0 Figure 6 11 Connector 15 c Test Results If you do notreceive the correct meter
28. cuits be sure to support the table top 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 Doesthe problem affectall control functions 2 Does the problem affect only one control function 3 If the problem affects one control function is itin both directions 4 Is the problem intermittent 5 15 the problem no movement of a table surface or does the table surface lose position Once the problem has been determined concentrate on that particular hydraulic circuit or control function Page 14 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 compo nents only one control function would normally be affected 1 Mini Valve 2 Slave Oylinder 3 Lines NOTE Whenever a hydraulic line or com ponentis 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
29. d 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 could 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 3100 Ifthe correct voltage is obtained everything is good Connector being tested must be disconnected up to that point and the problem is more than likely Polarity of meter leads is not important the solenoid 2 The meter should read approximately 80 90 d Step 2 ohms at room temperature The solenoid can be checked out using an ohmme 3 Measure the resistance between either pin ter R x 1 scale and ground 1 Measure the resistance between the two 4 Meter should read infinity pins of the connector in question See figure 6 9 Not Applicable for Model 3100 A Figure 6 9 Solenoid Test Page 43 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
30. dant Control Trendelenburg function chatters or loses position Defective or Dirty Check Valve Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil F TRENDELENBURG CYLINDER ASSEMBLY A PLUMBING TERMINAL COPPER FLEXIBLE HOSES SPEED CONTROL INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR Figure 3 2 Trendelenburg Circuit Page 16 3 5 LATERAL DIAGNOSIS CHART Problem Reason Lateral tilt function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly 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 A PISTON ed O RING CYLINDER O RING PLUMBING P iun P LEFT TILT SPEED CONTROL FLEXIBLE HOSES INTERNAL OIL FROM PUMP INTERNAL OIL RETURN TO RESERVOIR Figure 3 3 Lateral Tilt Circuit Page 17 3 6 KIDNEY LIFT DIAGNOSIS CHART Problem Reason Kidney Lift moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valve Low on Oil Pinched Hose Defective Mini Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box
31. e connector blocks to make sure they are not loose or making a bad connection with their mate 6 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 operation The solenoid mustbe replaced ifthe internal thermal fuse has been opened The sole noids 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 Page 42 a Solenoid Test The following tests check the voltage applied to the solenoids and the resistance of the solenoid coil NOTE 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 Each solenoid is controlled with 120V source coming from the relay box This source can easily be checked by mea suring the voltage at the 2 pin connector in question CAUTION Line voltage will be measured in this test DO NOT touch uninsulated con nector 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 6 9 3 Use a voltmeter capable of measuring 120VAC an
32. e 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 2 Remove micro switch covers refer to figure 6 15 carefully loosen the switch retaining screws and adjust the switches as needed See figure 6 16 TRENDELENBURG LA MICRO SWITCH MICROSWITCH COVER COVER VIEWED FROM HEAD END OF TABLE Figure 6 15 Micro Switch Covers RETAINING RETAINING SCREW SCREW RETAINING SCREWS RETAINING RETAININ SCREW SCREW AXES q gt RETAINING SCREWS Figure 6 16 Micro Switch Adjustment Page 47 17 Care pru 9 gt SS ee D RS 7 Y O A E E E A ou a BID gs axe pr ERES e CUN E a ND B P 6 RS OR 9 8 1 m eser 3 t te 0 111 0 5 9 111111 Em Sl ON DERE ee lt OO 2 2 E CN6 O i Hee te gt sv 2 BIA RL 3 lo o
33. e figure 1 12 HYDRAULIC PRESSURE TOP MOVEMENT m T7 T RAM PISTON RAM Figure 1 12 Slide Function Cylinder 4 Elevation Cylinder Single Action This cyl inder is different than the others because it does not have hydraulic fluid both sides of the piston It depends on the weight of the table top assembly to lower it The oylinder is set in the center of the elevation main column The piston and piston rod are elevated by the driven force of the oil pressure When lowering the oil that is accumulated in the cylinder is returned 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 The stainless steel decorative shrouds cover the flexible hydraulic hoses and slider See figure 1 13 ELEVATION lt lt CYLINDER gt lt ROD EXTERIOR gt DECORATIVE 2 SHROUD ELEVATION CYLINDER TUBE ELEVATION PISTON O RING SLIDER SUPPORT ASSEMBLY CYLINDER TUBE O RING Figure 1 13 Elevation Assembly 5 Double Action Brake Oylinder Early Table Models The brake cylinders are double action cylinders similar to the trendelenburg cylinder The movable piston s ram is connected to a brake pad Oil pumped into the top of the cy linder pushes the piston down and raises the table base off its casters Oil pumped into the bottom of the cylinder pushes the piston up low
34. ecomes accessable Tighten as overtighten the set screws as irrevers described in step 4 above ible damage to the elevation compo nents may result 6 Repeat this process until the elevation col umn is fully extended and all 10 rows of set screws To adjust have been adjusted 1 Lower elevation column 7 Lower elevation column and repeat steps 4 through 6 until there is no horizontal movement to 2 Remove the screws which retain the lower the table top and the elevation column descends shroud to the base See figure 2 5 smoothly without binding 3 Using tape or bungy cord secure the lower shroud piece to the upper shroud piece NOTE This adjustment should be checked afterone week then approximately once 4 Elevate the table top until the first row of a year adjustment set screws becomes accessible Gen SET SCREW oooooooo o lt ADJUSTMENT P SET SCREWS Re BU Figure 2 5 Elevation Column Adjustment Page 13 SECTION Ill 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 hydraulic lines fittings joints hoses etc for the following control functions be sure these table surfaces are in their down position or completely supported Elevation Kidney Lift When working on the trendelen burg or lateral tilt hydraulic cir
35. ering thebase back onto its casters See figure 1 14 PISTON N Figure 1 14 Double Action Brake Cylinder 6 Single Action Brake Cylinder Later Table Models 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 15 Oil pumped into the top of the cylinder pushes the piston down and raises 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 77 222222865 EI LINE N N N PISTON mw RETURN Ng PN SPRING BY 24 Figure 1 15 Single Action Brake Cylinder 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 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 16 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 retu
36. f the return to level micro switches are acti vated i e trendelenburg or tilt Figure 6 5 Table Base Connector Page 40 d Test Results If you do not receive the correct voltage reading the wiring or connector pins may be faulty Discon nect connector from the relay box and using an ohmmeter test the continuity between the cor responding pins in connectors 8 and the table base connector See figure 6 6 If the correct readings are obtained this part of the circuit is okay Orange White Yellow Purple White Black White Gray White Brown White Blue White Orange 1 2 3 4 5 6 7 8 9 10 Figure 6 6 Base Connector Continuity Test 6 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 voltcircuit 3100 The fo
37. hese direct the fluid to the appropriate hydraulic motion cylinders BRAKES TRENDELENBURG FUNCTION LIFT LATERAL TILT E Grm EMERGENCY BRAKE RELEASE PLUMBING TERMINAL PUMP MOTOR ASSEMBLY RELIEF Y BOX L1 ON OFF SWITCH RESERVOIR 120 ELEVATION TREND TILT SLIDE BRAKE 60 HZ Kidney Lift Not Applicable for Model 3100 A Figure 1 2 Hydraulic Block Diagram Later Models Page2 1 2 Component Operation a Motor Pump Operation The 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 anoutletside Theinletside is connected to the reservoir which provides the oil supply The reservoir 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 PRESSURE RELIEF VALVE MAIN PRESSURE OIL GALLEY INTERNAL PUMP OUTLET MAIN RETURN OIL GALLEY INTERNAL MOTOR PU
38. his 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 connectors A and A E and E and the motor connector C and C All other connectors should be connected 3 Ajumper wire must be used to electrically close the relay contacts in order to make this test The jumper wire will be used to connect pins 1 through 16 in the 16 pin connector E See figure 5 7 These pins are low voltage 6 3V and there is no danger of electrical shock 16 PIN CONNECTOR JUMPER WIRE Figure 5 7 Back View Connector E 4 Use AC voltmeter capable of measuring 120 VAC and measure the voltage between the indicated connector pins located in Connector A See figure 5 8 5 6 7 8 Figure 5 8 Back View Connector Page 27 CONNECTOR COLOR CODE 1 Red 2 Blue 3 White Red 4 Blue 5 Yellow 6 Blue 7 Brown 8 Blue 9 White Brown 10 Blue 11 White Blue 12 Blue 13 Orange 14 Blue 15 White Orange 16 Blue 17 White Yellow 18 Blue 19 Violet White 20 Blue 21 White Black 22 Blue 23 Black White 24 Blue 25 Red White 26 Blue White 27 Green White 28 Brown White IMPORTANT Connector A is High Voltage 120 VAC Connector E is Low Voltage 6 3 VDC Page 28 CONNECTORA CONNECTORE TEST TEST JUMPER METER LEAD LEAD WIRE READING 1 3 ah
39. htened securely when not in use If 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 Thebrakes will release slowly depending on 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 hydrau lic fluid from the pump is simply pumped through the brake bypass circuit because that is the easiest path for the oil to follow 1 3 Hydraulic Adjustments a Fluid Level The fluidlevel should be approximately 1 2 below the filler hole or gasket surface If additional fluidis needed remove the filler vent cap with a phillips screwdriver and add fluid through this opening using a funnel See figure 1 19 NOTE The elevation cylinder should be com pletely down and all the other control functions in their neutral position when checking oil level FILLER A VENT FILLER Figure 1 19 The type of oil that should be used is Mobil DTE 25 or equivalent Thisis a very high quality hy draulic oil The table requires approximately two quarts of oil to operate properly b Bleeding The Hydraulic System To purge the air from hydraulic system operate each function back and forth at least two or three times NOTE
40. llowing tests will determine if the relay box is functioning correctly a Relay Box Input Connector 4 1 Plug the power cord into the 120VAC power supply wall receptacle and turn the main switch ON Leave all connectors connected CAUTION Line voltage 120VAC will be mea sured in this test DO NOT touch uninsulated connector pins or meter test leads 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 6 7 Meter should read line voltage 120VAC 3 Activate any table function with the Pendant Control and using an AC voltmeter test the voltage atpins 3 and 4 of CN4 for outputto the pump Meter should read 120VAC White Black Red Blue Yellow Figure 6 7 Connector 4 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 pendant 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 15 of the table base connector See figure 6 5 Meter should read
41. lve has only one speed adjustment The speed controls are always located in the return oil circuit This prevents uncontrolled move ment of the piston in the slave cylinder due to one Page4 side ofthe piston being loaded with hydraulic pressure and the other side having no load Also by usingthis control method it doesn t matter whatsize cylinder and piston is used because the speed can be controlled by restricting the return oil Ifthe 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 inthe neutral position the speed adjustment does not affect anything because there is not any oil flow BALL VALVES OIL LINE SPEED CONTROL CHECK VALVE OIL GALLERY PRESSURE OIL RETURN SPOOL RETURN VALVE Figure 1 6 Mini Valve in Neutral Position OIL LINE Mini Valve Right Port Activated See figure 1 7 Slave Oylinder Piston Moves
42. n ohm meter b Test Results If you do notreceive continuity between any of the pins either the micro switch in the Pendant Con trol is defective or a wire 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 Wiring Harness Test The following test checks the wires leading from the relay box connector to the 19 pin connector table socket These wires apply low voltage to the pendant control buttons This test is similar to the test performed on the connectors explained in the relay box test 1 The power cord should be plugged into the wall socket and the main switch turned ON 2 Disconnect the 19 pin pendant control connector All other connectors should be con nected 3 Use a DC voltmeter 10V scale and measure the following pins located in the 19 pin table socket connector See figure 5 10 Page 30 TEST TEST METER READINGS LEAD LEAD DC VOLTS Pin 16in table socket connector will have no vol tage potential unless 1 of the 4 return to level micro switches are activated i e trendelenburg or tilt TABLE CONNECTOR FRONT VIEW ES Figure 5 10 Front View Table Connector d Test Results If you do not receive the correct voltage reading the wiring or connector pins are faulty If the correct readings are obtained this part of the circuit is okay 5 5 Solenoids The solenoids are energi
43. n than the other direction adjust the speed control until they are equal You may find thatthe pressure gauge may record ahigher reading in one direction This is normal Page 11 SECTION MECHANICAL TABLE ADJUSTMENTS 2 1 Kidney Lift Cylinder Adjustment Model 3100 only The kidney lift is operated by two hydraulic cylin ders The table top sections which make up the kidney lift can twist and become damaged if these two cylinders do not move together properly If an adjustment is necessary use the following proce dures a Side Frame Cover Removal Remove the seven phillips head bolts and side rail collars which secure the side rails and remove the side rail See figure 2 1 Remove the five phillips head screws from the bottom of the side panel and remove the side panel PHILLIPS HEAD SCREW SIDE RAIL COLLAR La PHILLIPS HEAD BOLT Figure 2 1 Side Cover Removal b Adjustment Loosen the nut which locks the cylinder rod to the clevis See figure 2 2 Adjust the cylinder travel by turning the cylinder rod until the operating length of both cylinders is equal Tighten the lock nut CYLINDER ROD Figure 2 2 Kidney Lift Cylinder Adjustment Page 12 CAUTION To prevent internal O ring seal damage use extreme care not to damage the working surface of the cylinder rod the portion which goes inside the cylinder when is retracted When proper adjustment is complete replace side cover a
44. nd side rail 2 2 Slide Function Bearing Adjustment The bottom slide function roller bearings are mounted on eccentric shafts To adjust the bear ing fit in the side frame channel loosen the set screw that holds the shaft in place and turn the shaft with a screwdriver until all play is removed from side rail channel See figure 2 3 ROLLER SCREW 9 SHAFT Figure 2 3 Bearing Adjustment 2 3 Cassette Tray Chain Adjustment Each sprocket shaft is mounted in an eccentric bushing See figure 2 4 To adjust the chain tension loosen the set screw securing the bush ing turn the bushing to achieve the desired tension and retighten the set screw To gain access to the bushing and the set screw the side cover must be removed See paragraph 2 1 a SPROCKET SET we SCREW lt gt i NS BUSHING Figure 2 4 Chain Tension Adjustment 2 4 Elevation Column Adjustment tighten the adjustment set screws using a 4mm NOTE allen wrench until slight pressure is exerted against the bearing thrust plate This adjustment is required only if ex cessive horizontal table top movement occurs or after replacement of the el CAUTION evation column bearing components This adjustment should only be per DO NOT OVERTIGHTEN SET formed by a qualified technician SCREWS WARNING 5 Elevate the table until the next row of adjust Extreme care must be taken not to ment set screws b
45. nd the speed adjustment through a by pass valve and thentothe 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 5 9 Hydraulic Cylinders 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 Single Action Brake Cylinders all operate basi cally the same way The control functions are listed below See figure 1 9 Reverse Trendelenburg Trendelenburg Lateral Tilt Elevation Brake Oylinders Kidney Lift Slide Function NOTE Kidney Lift not applicable for Model 3100 A LATERAL TILT SLIDE FUNCTION CYLINDER CYLINDER P4 TRENDELENBURG CYLINDER KIDNEY LIFT CYLINDER H ELEVATION CYLINDER Figure 1 9 Cylinder Placement 1 Kidney Lift and Trendelenberg Cylinders The double action cylinder is closed at one end and has 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 eithera ball and socket or clevis and pin arrangement this ram is con nected to a movable table surface The movable surface can be moved one way orthe other by pumping hydraulic fluid into either side of the piston Obviously if oil is pumped into one side of the cylinder a return path must be provided for
46. ndant control is pushed and held down The brakes 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 UN LOCK 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 sureto return the hydraulic oil backto the reservoir The electronic timer operates the return circuit tor approximately 8 10 seconds j Emergency Brake Release The emergency brake release is simply a manually operated bypass valve connected in parallel to the brake cylinders and the oil reservoir See figure 1 18 When the valve is opened turned counter clockwise a return circuit for the brake hydraulic fluid is opened The return springs force the piston up pushing the hydraulic oil back into the reservoir and retracting the brake pads EMERGENCY BRAKE RELEASE LEVER Figure 1 18 IMPORTANT The emergency brake release valve must be tig
47. o Level Micro Switches Page 34 a Switch Test 1 Disconnect 36 pin connectors A and A and 19 pin pendant control connector 2 Use an ohmmeter to test the resistance between indicated pins located in the pendant control connector and connector A Refer to figure 5 16 Polarity of test leads is not important TRENDELENBURG LATERAL TILT MICRO SWITCH MICRO SWITCH COVER COVER 19 36 PIN CON CON VALUE OF NECTOR NECTOR RESISTANCE oS LEVEL gt 16 29 OQ 16 30 0 OHM A UP DOWN 27 28 0 d LEFT UP 005 Ss UP Figure 5 16 Return to Level Micro Switch Test VIEWED FROM HEAD END OF TABLE WHEN TABLE IS AT Figure 5 17 Micro Switch Covers RETAINING SCREW RETAINING SCREW RETAINING SCREWS b Switch Adjustment RETAINING SCREW RETAINING If proper readings are not obtained during test or if SCREW 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 2 24 control o 2 Remove micro switch covers refer to figure RETAINING SCREWS 5 17 carefully loosen the switch retaining screws and adjust the switches as needed See figure 5 18 Figure 5 18 Micro Switch Adjustment Page 35 36 POWER SWITCH 120 VAC Al Q 43 14 Q 5
48. oes not check out with the meter it is more than likely defective and must be replaced Page 32 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 5 6 Motor Pump Assembly The electric motor is a capacitor start type with a rating of 120 200 watts The field windings are protected with a thermal protector that will open the winding circuit if the motor is run continu ously for approximately 10 minutes This protec tor 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 in the 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 supply wall receptacle Turn main switch ON 2 Disconnect the 3 pin connector C and C at the motor Leave all other connectors connected See figure 5 12 MOTOR PUMP
49. on Position Reading Level Infinity Head Up 0 Head Dn Infinity When table is in Reverse Trendelenburg Position NS 2 brings the top back to level NS 3 Lateral Tilt Left Test at pins 3 amp 9 Table Switch Meter Position Position Reading Level Open Infinity Tilt Right Open Infinity Tilt Left Closed 0 When table is inTiit Left Position NS 3 brings the top back to level 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 6 13 Return to Level Micro Switches Page 46 3100 Switch Test 1 Disconnect connector CN2 from the relay box 2 Use an ohmmeter to test the resistance between indicated pins located in connector CN 2 Refer to figure 6 14 Polarity of test leads is not important CONNECTOR WHEN TABLE IS AT CN2 VALUE OF PIN PIN RESISTANCE 9 3 INFINITY 9 4 INFINITY 9 1 INFINITY LEVEL 9 2 INFINITY UP INFINITY HEAD UP 0 OHM 9 0 OHM INFINITY HEAD DOWN 9 2 Ea 9 3 INFINITY TILT RIGHT 9 4 0 OHM aa 9 3 0 OHM TILT LEFT 9 4 INFINITY Figure 6 14 Return to Level Micro Switch Test b Switch Adjustment If proper readings are not obtained during test or if table does not properly return to level use th
50. ower requirements are 120 VAC 5 amp 60 HZ protected by internal fuses 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 Refer to figures 5 1 amp 6 1 forthe relationship of the electrical 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 Hand Held Pendant Control Closes micro switches to activate relay box Operates 6 3 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 Model Coverage Section V covers the Electrical System Trouble shooting for the Early Model base design and Section VI covers the Electrical System Trouble shooting for the N Series base design The two models can be easily identified by the position of the main power switch The power switch is located on the top of the base on the early models and on the front of the base for the N series models See figure 4 1 MAIN POWER SWITCH POWER SWITCH S N 3100N 19
51. rn 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 supporting 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 SPEED CONTROL PILOT PLUNGER ELEVATION MINI VALVE PRESSURE RELIEF _ VALVE oy RESERVOIR Figure 1 16 Elevation Return Circuit i Brake System The later model brake system consists of the following components figure 1 17 1 Single action slave cylinders 4 each Page 8 2 3 way single check valve type mini valve 3 Manually controlled emergency brake re lease 4 Plumbing terminal flexible hose copper lines and O rings 5 Portions of the electrical system BRAKE SYSTEM EMERGENCY PLUMBING GOSA BRAKE TERMINAL RELEASE MINI VALVE RETURN TO RESERVOIR Figure 1 17 Brake System Block Diagram Each corner of the cast iron table base has a hydraulic brake cylinder These single action cylinders are hydraulically connected in parallel to the mini valve and all four are activated together It is normalfor one corner of the table to raise before the others due to the weight distribution ofthe table On early models the brakes are activated when the elevation up button on the pe
52. sign tables with serial number 3100N 1992 8 441 amp later Refer to Section V for early model tables Certain defective components could cause the entire table to stop functioning or only one control function to stop depending upon what part of the component failed Other defective components would only cause one control function to stop These defective components could affect all con trol functions a Motor Pump Assembly starting capacitor b Main Switch Circuit and Wiring These defective components could affect all con trol functions 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 6 2 Main Switch The main power supply 120VAC 60HZ comes in through the power cord and through the main switch The main switch opens both lines when in the OFF position 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 Page 38 1 Plug the power cord into the 120VAC power supply wall receptacle and turn ON the main switch 2 Disconnect connector 4 from the relay box See figure 6 2 Leave all other connectors connected RELAY BOX
53. the oil on the other side See figure 1 10 Page 6 HYDRAULIC Figure 1 10 Kidney Lift Cylinder 2 Lateral Tilt Cylinder Assembly The lateral tilt cylinder assembly consists of a dual cylinder housing with two pistons complete with connecting rods The connecting rods are attached to a stationary pin in the housing on top of the main support column The cylinder housing attaches tothe table top via both side frames and is attached to the supportcolumn with a pivot pin See figure 1 11 The pistons and connecting rods are attached to a non movable surface Therefore when hy draulic fluid is pumped into one side the cylinder housing itself moves around its pivot pin causing the table top to tilt to one side To tilt the table top the opposite direction hydraulic fluid is pumped into the other side of the cylinder assembly PISTON AND X CONNECTING RODS HYDRAULIC 27 V PRESSURE CYLINDER SUPPORT PIVOT HOUSING COLUMN PIN Figure 1 11 Lateral Tilt Cylinder Assembly 3 Slide Function Cylinder This cylinderis also a double action cylinder It differs from the Kidney Liftand Trendelenburg cylinders in thatthe piston is connected fo rams which exit from each end of the cylinder tube The ends of the rams connect to each end of the table top The cylinder tube Is connected to the main side frame When hydraulic fluid is pumped into one side of the cylinder the entire table top assembly will slide longitudinally Se
54. 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 ferto the block diagrams figures 1 1 amp 1 2 for relationship TRENDELENBURG LATERAL TILT ELEVATION CYLINDER PLUMBING TERMINAL PUMP MOTOR ASSEMBLY RESERVOIR ELEVATION TILT SLIDE K LIF SLIDE FUNCTION LIFT NOTE Continuing development of the Model 3100 Table has resulted in several changes However the basic opera tion of the 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 BRAKES KIDNEY CHEL PENDANT CONTROL ON OFF SWITCH 120 VAC BRAKE 60 HZ Figure 1 1 Hydraulic Block Diagram Early Models Page 1 c Pressure Relief Valve Provides an alternate e Hydraulic Lines Fittings Connections They oil path when the hydraulic cylinders reach the provide a path for the hydraulic oil end of their stroke f Hydraulic Cylinders They convert the hy d Electro Hydraulic Mini Valve Assemblies draulic fluid pressure and volume into mechanical T
55. to Left Right Mini Valve Port is Supply Line Left Mini Valve Port is Return Line Figure 1 7 Mini 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 andonto 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 mechanically 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 into the reservoir 4 Speed Adjustment The 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
56. 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 mini 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 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 in a 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 con trolling the speed of the table surface movement A 3 way mini va
57. ump Connector CN15 g Test Results If you do notreceive the correct meter readings the motor or wiring is defective Page 45 6 7 Return to Level Micro Swiches The return to level feature is activated by a single button on the pendant control and automatically relevels the table top from the lateral tilt and trendelenburg positions The micro switches are cam operated They oper ate on 5 to 6 VDC and control the function circuits pump motor and appropriate solenoid valves ex actly like the pendant control The micro switches are wired to the relay box through the 15 pin connector See figure 6 13 TRENDELENBURG LATERAL TILT RETURN SWITCH RETURN SWITCH CONNECTOR CN2 12345678 9101112131415 NS 1 Trendelenburg Test at pins 1 amp 9 Table Switch Meter Position Position Reading Infinity Infinity 0 Level Open Head Up Open Head Dn Closed When table is in Trendelenburg Position NS 1 brings the top back to level NOTE If a problem is suspected in the return circuits disconnect the connector CN2 from the Relay Box to eliminate the circuits Ensure that all table functions operate properly using the Pendant Control If the functions do not work properly using the Pendant Control re fer to the appropriate test section and make all needed repairs before working on the return circuits NS 2 Reverse Trendelenburg Test at pins 2 amp 9 Table Switch Meter Positi
58. zed 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 continuous operation The solenoid must be re placed ifthe internal thermal fuse has been blown The solenoids are mounted directly on either side ofthe hydraulic mini valves and push the spool valve in one direction orthe other depending upon which solenoid is activated a Solenoid Test The following tests will check the voltage applied tothe 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 BLUE WHITE YELLOW BLUE WHITE ORANGE BLUE WHITE BROWN BLUE YELLOW BLUE RED F smaris 7 Ni BLUE YELLOW ALL JA E BLUE WHITERED 7 BLUE BROWN BLUE WHITE BLUE BLUE ORANGE BLUE VIOLET WHITE BLUE WHITE BLACK un SLIDE PESO MINI VALVES NOTE Each solenoid is controlled with 120V source coming from the relay box This source can easily be checked by measuring the voltage at the 2 pin connector in question 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 table cord into the wall receptacle and turn main switch ON
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