Schaerer 7300 Service And Parts Manual

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Page 1

Schaerer Mayfield USA, Inc.

7300

Modular Surgery

Table

Service and

Parts Manual

SMI

7300

SF-1586 Part No. 504-0023-00 Rev. E (5/04)

CA802000

FOR USE BY SMI TRAINED TECHNICIANS ONLY

Page 2

Page 3

TABLE OF CONTENTS

Section/Paragraph Page Section/Paragraph Page

IMPORTANT INSTRUCTIONS

General Safety Instructions........................................ iv

Warnings.................................................................... iv

Warranty Instructions ................................................. iv

SECTION I GENERAL INFORMATION

1.1 Scope of Manual ......................................... 1-1

1.2 How to Use Manual ..................................... 1-1

1.3 Description of 7300 Modular Surgery

Table ....................................................... 1-1

1.4 Specifications ............................................. 1-7

1.5 Parts Replacement Ordering ....................... 1-8

1.6 Special Tools .............................................. 1-9

SECTION II TESTING AND TROUBLESHOOTING

2.1 Operational Test.......................................... 2-1

2.2 Troubleshooting Procedures ........................ 2-6

SECTION III SCHEDULED MAINTENANCE

3.1 Scheduled Maintenance .............................. 3-1

SECTION IV MAINTENANCE/SERVICE INSTRUCTIONS

4.1 Introduction ................................................. 4-1

4.2 Checking Oil Level / Adding Oil To

Reservoir .................................................. 4- 1

4.3 Calibration Of Return To Level / Neutral

Position .................................................... 4- 2

4.4 Hand Control Button Board

Removal / Installation ............................... 4-4

4.5 Hand Control Board

Removal / Installation ............................... 4-4

4.6 Seat Cylinders Synchronization

Procedure ................................................. 4- 5

4.7 Column Cylinder Slave Line Volume

Adjustment ............................................... 4- 7

4.8 Trendelenburg Cylinder

Removal / Installation ............................... 4-9

4.9 Trendelenburg Pilot Operated Check Valve

Removal / Installation ............................. 4-11

4.10 Trendelenburg Cylinder Orifice(s)

Removal / Installation ............................. 4-13

4.11 Trendelenburg Position Sensor

Removal / Installation ............................. 4-14

4.12 Lateral Tilt Cylinder

Removal / Installation ............................. 4-15

4.13 Lateral Tilt Orifice(s)

Removal / Installation ............................. 4-16

4.14 Lateral Tilt Pilot Operated Check Valve

Removal / Installation ............................. 4-18

4.15 Lateral Tilt Position Sensor

Removal / Installation ............................. 4-20

4.16 Seat Cylinder

Removal / Installation ............................. 4-21

4.17 Seat Cylinder Orifice(s)

Removal / Installation ............................. 4-26

4.18 Seat Cylinder Pilot Operated Check Valve

Removal / Installation ............................. 4-27

4.19 Seat Position Sensor

Removal / Installation ............................. 4-28

4.20 Column Cylinder

Removal / Installation ............................. 4-31

4.21 Column Pilot Operated Check Valve

Removal / Installation ............................. 4-34

4.22 Typical L.H. and R.H. Control Valve Solenoids

Removal / Installation ............................. 4-35

4.23 Typical Base Mounted Control Valve Solenoids

Removal / Installation ............................. 4-37

4.24 Discharge Filter Replacement .................... 4-39

4.25 Main Floor Lock or Outrigger

Floor Lock Cylinder

Removal / Installation ............................. 4-41

4.26 Motor Or Motor Pump

Removal / Installation ............................. 4-42

4.27 Pump Unit

Removal / Installation ............................. 4-44

4.28 Motor Pump Output Check Valve

Removal / Installation ............................. 4-47

4.29 Motor Pump Pressure Relief Valve

Removal / Installation ............................. 4-48

4.30 Outrigger Pressure Relief Valve

Removal / Installation ............................. 4-50

4.31 Main Controller Board

Removal / Installation ............................. 4-53

4.32 Charging / Power Driver Board

Removal / Installation ............................. 4-55

4.33 Emergency Override Panel

Removal / Installation ............................. 4-57

4.34 Distribution Board

Removal / Installation ............................. 4-58

4.35 RFI Filter

Removal / Installation ............................. 4-59

(*) Indicates that there has been a serial number break for the illustration

and that there are additional point page(s) following the original page.

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TABLE OF CONTENTS - CONTINUED

Section/Paragraph Page Section/Paragraph Page

4.36 Transformer

Removal / Installation ............................. 4-61

4.37 Line Power Pilot Lamp

Removal / Installation ............................. 4-63

4.38 Plug Receptacle

Removal / Installation ............................. 4-63

4.39 Batteries

Removal / Installation ............................. 4-64

4.40 Primary Thermostat

Removal / Installation ............................. 4-65

4.41 Secondary Thermostat

Removal / Installation ............................. 4-66

4.42 Floor Lock Status Switch

Removal / Installation ............................. 4-66

4.43 Head Section Gas Spring

Removal / Installation / Adjustment ........ 4-68

4.44 Foot Control Interface Board

Removal / Installation ............................. 4-69

4.45 Typical Latch Mechanism

Removal / Installation ............................. 4-70

4.46 Typical Floor Lock Check Valve

Removal / Installation ............................. 4-71

4.47 Articulating Leg Transfer Board

Adjustments............................................ 4-73

4.48 Bell Footpiece Traction Crank Assembly

Disassembly / Assembly ........................ 4-75

SECTION V SCHEMATICS AND DIAGRAMS

5.1 Electrical Schematics / Wiring Diagrams..... 5-1

5.2 Hydraulic Flow Diagram................................ 5-4

5.3 Hand Control Messages ............................... 5- 5

5.4 Error Code Chart .......................................... 5- 6

SECTION VI PARTS LIST

6.1 Introduction ................................................. 6-1

6.2 Description of Columns ............................... 6-1

6.3 Torque Specifications And Important

Assembly Notes ....................................... 6-1

Pictorial Index ............................................. 6-2

Accessories ................................................. 6- 3

Labels And Decals ....................................... 6-4

Cushions and Table Tops............................. 6- 5

Covers and Shields ...................................... 6-6

Head Section Assembly............................... 6-7

Bridge Components...................................... 6-8

Lateral Tilt Cylinder Assembly...................... 6- 9

Upper Hose Connections............................ 6-10

L.H. Side Components ............................... 6-11

L.H. Control Valve Assembly ..................... 6-12

L.H. Seat Cylinder Assembly ..................... 6-13

R.H. Side Components............................... 6-14

Emergency Override Panel Assembly ........ 6-15

R.H. Control Valve Assembly..................... 6-16

R.H. Seat Cylinder Assembly..................... 6-17

Column Assembly Components ................. 6-18

Column Assembly ...................................... 6-19

Trendelenburg Cylinder Assembly ............. 6-20

Column Cylinder Assembly ........................ 6-21

Hand Control Assembly.............................. 6-22

Base Cover Components ........................... 6-23

Base Hydraulic / Electrical

Components............................................ 6-24

Electrical Control Box Components ............ 6-25

Base Hydraulic Plumbing ........................... 6-26

Base Control Valve Assembly.................... 6-27

Hydraulic Pump / Motor Components ......... 6-28

Hydraulic Motor Components ..................... 6-29

Hydraulic Pump Components ..................... 6-30

Floor Lock Components ............................. 6-31

Main Floor Lock Cylinder Components ....... 6-32

Outrigger Floor Lock Cylinder

Components............................................ 6-33

Caster Components ................................... 6-34

Power Driver Board Components................ 6-35

Battery Components .................................. 6-36

10210 Perineal Post Assembly .................. 6-37

10322 Cross Arm Support Assembly ......... 6-38

10360 Safety Strap .................................... 6-39

10395 Lottes Anklet ................................... 6-40

10508 Well Leg Support Assembly............. 6-41

10509 Equipment Cart................................ 6-42

10620 Drape Stand Assembly .................... 6-43

10821 Removable Siderail.......................... 6-44

10823 Leg Transfer Board .......................... 6-45

10824 Horizontal Perneal Post ................... 6-46

10825 Tibia Extender ................................. 6-47

10830 Well Leg Support (Siderail Mount).... 6-48

10836 Offset Adapter Mount ...................... 6-49

13100 / 13200 Montreal Lateral

Position Device....................................... 6-50

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and that there are additional point page(s) following the original page.

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TABLE OF CONTENTS - CONTINUED

Section/Paragraph PageSection/Paragraph Page

22111 Pin and Wire Holder ......................... 6-51

22119 Traction Bow Assembly ................... 6-52

22314 Traction Cuff Assembly ................... 6-53

70542 Bierhoff Leg Holder .......................... 6-54

70556 Siderail Extension Set ..................... 6-55

71070 Siderail Socket ................................ 6-56

71071 I.V. Arm Board Assembly ................ 6-57

71073 Siderail Clamp ................................. 6-58

71074 Conventional Ether Screen .............. 6-59

71075 Foot Rest......................................... 6-60

71077 Siderail Extender Set ....................... 6-61

71078 A/P Cassette Holder ........................ 6-62

71079 Lithotomy Leg Holder ....................... 6-63

71080 Universal Ether Screen .................... 6-64

71082 Lateral Cassette Holder ................... 6-65

71083 Cross Arm Support .......................... 6-66

71084 / 71085 / 71093 I.V. Arm Board

Cushion .................................................. 6-67

71088 Neuro Headrest Adapter................... 6-68

71090 Lateral Support Set.......................... 6-69

71092 Infant Arm & Hand Table ................. 6-70

71094 Table Side Extenders ...................... 6-71

71097 Tri Clamp 2 ...................................... 6-72

71098 Flexguard Stirrup Set ....................... 6-73

71099 Guardian Stirrup Set ........................ 6-74

71100 Leg Prep Stand................................ 6-75

71101 Snaplock Arm Board........................ 6-76

71102 / 71103 Snaplock Arm

Board Cushion ........................................ 6-77

71104 Shoulder Brace Set.......................... 6-78

71105 Universal Patient Brace /

71113 Circular Head Cushion ..................... 6-79

71106 / 71107 Uro Catch Bags................... 6-80

71108 Winged Anesthesia Screen.............. 6-81

71110 Footswitch ....................................... 6-82

71111 Split Leg Set - 71118 / 71119 Split

Leg Pad Set............................................ 6-83

71112 Foot Extension Assembly /

71114 Foot Extension Cushion................... 6-84

71116 Conductive Safety Strap /

20715 Nonconductive Safety Strap ............ 6-85

71120 Side Extender Shelf......................... 6-86

71125 Image Amplification Extension ....... 6-87

71129 X-Ray Arm Board............................. 6-88

71130 I.A. Board (36-inch).......................... 6-89

73001 Pelvic Base w/ Cushion ................... 6-90

73002 Leg Transfer Board w/ Cushion ........ 6-91

73003 Drain Pan......................................... 6-92

73004 I.A. Extention w/ Cushion (55-inch).. 6-93

73005 X-Ray Top Set................................. 6-94

73006 Back Section ................................... 6-95

73007 Ortho Pelvic Base /

73023 / 73024 Board w/ Cushion............ 6-96

73008 Abductor Bar ................................... 6-97

73009 Abductor Bar Clamp ........................ 6-98

73010 Traction Unit .................................... 6-99

73011 Traction Unit Extention .................. 6-100

73012 Popliteal Support ........................... 6-101

73013 Lateral Well Leg Holder .................. 6-102

73014 Shoulder Arthroscopic Attachment. 6-103 Shoulder Arthroscopic Lumbar

Support Assembly ................................ 6-104

Shoulder Arthroscopic Head Rest............. 6-105

73015 Articulating Bracket ....................... 6-106

73016 Drapery Kit .................................... 6-107

73019 Back Section X-Ray Top ............... 6-108

73020 Leg Transfer Frame ....................... 6-109

73021 Yellofin Leg Holder System.... Not Shown

73022 Clear Vision Drapes ............... Not Shown

10531 Bell Footpiece Traction Assy......... 6-110

73025 Orthopedic Cart ............................. 6-111

73026 General Surgery Cart ..................... 6-112

COMMENTS ............................................................ 7-1

(*) Indicates that there has been a serial number break for the illustration

and that there are additional point page(s) following the original page.

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Page 6

IMPORTANT INSTRUCTIONS

General Safety Instructions

Safety First: The primary concern of Schaerer Mayfield USA is that this surgery table is

maintained with the safety of the patient and staff in mind. Toassure that services and repairs are completed safely and correctly, proceed as follows:

(1 ) Read this entire manual before performing any

services or repairs on this surgery table.

(2 ) Be sure you understand the instructions con-

tained in this manual before attempting to service or repair this surgery table.

Warnings

Throughout this manual are Note, Caution, and Danger paragraphs that call attention to particular procedures. These items are used as follows:

NOTE

A note is used to amplify an operating procedure, practice or condition.

Warranty Instructions

Refer to the SMI “Limited Warranty” printed on the back cover of the Installation and Operation Manual for warranty information. Failure to follow the guidelines listed below will void the warranty and / or render the 7300 Modular Surgery Table unsafe for operation.

• In the event of a malfunction, do not attempt to operate the surgery table until necessary repairs have been made.

• Do not attempt to disassemble surgery table, replace malfunctioning or damaged components, or perform adjustments unless you are one of SMI’s authorized service technicians.

• Do not substitute parts of another manufacturer when replacing inoperative or damaged components. Use only SMI replacement parts.

CAUTION

A CAUTION is used for an operating

procedure, practice, or condition which, if not correctly followed, could result in equipment damage.

DANGER

A DANGER is used for an operating

procedure, practice, or condition which, if not correctly followed, could result in loss of life or serious personal injury.

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SECTION I

GENERAL INFORMATION

SECTION I

GENERAL INFORMATION

1.1 Scope of Manual

This manual contains detailed troubleshooting, scheduled maintenance, maintenance, and service instructions for 7300 Modular Surgery Table. This manual is intended to be used by SMI’s authorized service technicians.

1.2 How to Use Manual

A. Manual Use When Performing Scheduled Mainte-

nance. (1) Perform inspections and services listed in

Scheduled Maintenance Chart (Refer to para 3.1).

(2) If a component is discovered to be faulty or out

of adjustment, replace or adjust component in accordance with maintenance/service instructions (Refer to para 4.1).

B. Manual Use When Unit Is Malfunctioning And

Cause Is Unknown. (1) Perform an operational test on unit (Refer to

para 2.1).

(2) Perform troubleshooting procedures listed in

Troubleshooting Guide (Refer to para 2.2).

(3) If a component is discovered to be faulty or out

of adjustment, replace or adjust component in accordance with maintenance/service instructions (Refer to para 4.1).

C. Manual Use When Damaged Component Is Known.

(1) Replace or adjust component in accordance

with maintenance/service instructions (Refer to para 4.1).

1.3 Description Of 7300 Modular Surgery Table

A. General Description (See Figure 1-1, Sheets 1

and 2).

The 7300 Modular Surgery Table is designed for use as a general surgery table on which virtually any surgical procedure can be accomplished. 7300 was designed for maximum C-arm access and X-ray visibility.

Major serviceable components of the surgery table are:

1. Motor pump which includes two motors, two pump

units, two motor pump pressure relief valves, two primary thermostats, two secondary thermostats, and a motor pump output check valve, and a discharge filter,

2. Trendelenburg (UP and DOWN) solenoid valves,

Trendelenburg cylinder pilot operated check valves, and Trendelenburg cylinder, trendelenburg position sensor.

3. Seat (UP and DOWN) solenoid valves, seat cylinder

pilot operated check valves, seat cylinders and, seat position sensor.

4. Lateral tilt (LEFT and RIGHT) solenoid valves,

lateral tilt cylinder pilot operated check valves, lateral tilt cylinder, and lateral tilt position sensor.

5. Column (UP and DOWN) solenoid valves, column

cylinder pilot operated check valve, column cylinder, and column assembly which includes slides.

6. Main and Outrigger Floor Lock solenoid valves,

three main floor lock cylinders, two outrigger floor lock cylinders, outrigger pressure relief valve, main and outrigger floor lock status switches.

7. Head section with two gas cylinders.

8. Main Controller Board which includes a 10 amp

fuse.

9. Charging / Power Driver Board which includes a 40

amp fuse.

10. RFI filter.

11. Transformer.

12. Four batteries.

13. Hand control which includes button board and

hand control board.

14. Foot control which includes foot switch pad and

foot control interface board.

15. Emergency override board.

16. Distribution board.

17. Plug Receptacle which includes two 5 amp fuses,

and line power pilot lamp.

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Page 8

SECTION I GENERAL INFORMATION

Figure 1-1. Major Components (Sheet 1 of 2)

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SECTION I

GENERAL INFORMATION

Figure 1-1. Major Components (Sheet 2 of 2)

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SECTION I GENERAL INFORMATION

B. Theory of Operation. See Figures 5-1, Sheets 1

and 2, and Figure 5-2 for electrical schematic / wiring diagram. See Figure 5-3 for hydraulic schematic.

Electrical Theory Of Operation

When power cord is plugged into power cord receptacle, line voltage (approximately 115 VAC) is supplied to table. Line voltage is applied across an RFI filter. RFI filter reduces line conducted RFI / EMI that is present on incoming power line. Across RFI filter output is a line power pilot lamp which illuminates to indicate power is present at output of RFI filter. Transformer primary lines are also connected across RFI filter output. Transformer steps line voltage down to 32.5 VAC ± 2 VAC. The 32.5 VAC from output of transformer is applied to charging / power driver board. Charging / power driver board uses a DC rectifying circuit to convert 32.5 VAC to approximately 27.8 VDC. Charging / power driver board regulates charging rate of four batteries by regulating rate at which 27.8 VDC is applied to batteries. Charging / power driver board also supplies 27.5 VDC to main controller board to power it. Transformer has thermal fuses connected in each primary winding and they are embedded between the primary and secondary windings. If transformer overheats, normally closed (N.C.) thermal fuses open, disconnecting power to transformer. Transformer is primarily used to supply power to charging / power driver board, so board can charge batteries and supply power to rest of table. Charging / power driver board regulates charge rate of batteries when batteries are being charged. This means that a full load is not continuously being placed on transformer, which is important because transformer is not sized to draw a full current load continuously. If batteries are low and a function is selected, power to drive motor pump(s) is drawn from batteries first and then from transformer as necessary. If batteries are too low or a function is selected for too long, continuous current draw thru transformer will overheat transformer very quickly, causing thermal fuses to blow.

CAUTION

It is important that a table with a low battery charge be operated only in case of

emergency and for a very short time period (less

than a minute).

Logic Theory Of Operation

When ENABLE button is pressed, a 5 VDC signal is sent to main controller board, activating it. Main controller board performs a self diagnostic check on itself. If self diagnostic check fails, error code E11 (Internal RAM / Register Failure) is displayed on hand control. Main controller board and charging / power driver board uses status circuits to check functionality of following electrical components: motors, charging / power driver board, valve spool solenoids, main controller board, position sensors, foot control switch pad, and hand control button board. A status circuit, on charging / power driver board, monitors amount of current draw thru motor pump windings, when a function has been selected. If current draw exceeds a predetermined value, main controller board stops all functions and displays error code E02 (Overcurrent - Motor Pump #1) or E03 (Overcurrent Motor Pump #2), which indicates a failure of a motor pump. If current draw falls below a predetermined value, main controller board stops all functions and displays error code E04, which indicates failure of charging / power driver board. A status circuit, on main controller board, monitors enable circuitry for each valve spool solenoid and detects if a valve spool solenoid or enable circuitry of main controller board is functioning correctly. If not, main controller board stops all functions and displays error code E05 (Valve Drive Failure), which indicates failure of either a valve spool solenoid or main controller board. Another status circuit, on main controller board, monitors voltage input from position sensors. If voltage value exceeds or falls below a predetermined range, main controller board stops all functions and displays appropriate error code: E07 (Trendelenburg Position Sensor Failure), E08 (Tilt Position Sensor Failure), E09 (Seat Position Sensor Failure). An error code indicates failure of either a position sensor, main controller board, or wiring. Main controller board also monitors main floor lock status switch, outrigger floor lock status switch, motor pump #1 primary thermostat, and motor pump # 2 primary thermostat. When hand control is ENABLED, main controller board checks if normally open (N.C.) main floor lock status switch and outrigger floor lock status switch is untripped. If main controller does not detect that energizes main floor lock valve spool and motor pump, causing main floor locks to extend. After eight seconds, main controller de-energizes main floor lock valve spool

both

status switches are untripped, it

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SECTION I

GENERAL INFORMATION

and motor pump, and then energizes outrigger floor lock valve spool and motor pump, causing outrigger floor locks to extend. After six seconds, main controller de-energizes outrigger floor lock valve spool and motor pump. At this time main controller checks status of status switches again. If main controller does not detect that all functions and displays E01 (Floor Lock Status Switch Is Not Responding). Also, when hand control is ENABLED, main controller board checks if normally closed (N.C.) motor pump primary thermostats are closed. If main controller board detects an open circuit, it stops all functions and displays error code E13 (Overheat - Motor Pump #1) or E14 (Overheat - Motor Pump #2), which indicates that motor pump has overheated, opening its primary thermostat. Also, when hand control is ENABLED, main controller board checks status of each set of switches in hand control; there are two normally open (N.O.) switches for each function, one for solenoid valve and one for motor. If only one of the set of two switches is detected as being pressed, main controller board detects this and displays error code E15 (Hand Control Switch Failure). This indicates that one switch is stuck in closed position. Also, if a function button is pressed and then error code E15 displays, this indicates that only one of two switches is working properly. This safety feature prevents unintended table movement due to a switch malfunction. Also, when a function is selected using foot control, main controller board checks status of each set of switches in the foot control pad; there are two normally open (N.O.) switches for each function. If there is a set of switches for which only one of two switches is detected as being pressed, the main controller board detects this and displays error code E06 (Foot Switch Failure) on hand control. This indicates that one of two switches is stuck in closed position or not working properly. This safety feature prevents unintended table movement due to a switch malfunction. Motor pumps also have secondary thermostats which provide backup protection if primary thermostats fail. If a motor pump overheats and its primary thermostat does not shut off motor pump, normally open (N.O.) secondary thermostat closes, directly shorting current past motor windings to ground, causing 40 amp fuse on charging / power driver board to blow, which stops motor pump.

both

status switches are untripped, it stops

Hydraulic System Theory Of Operation

When a function is selected using hand control or foot control, motor pump(s) begins to run and selected function's valve spool shifts. Hydraulic oil flows thru a strainer in reservoir and into pump chamber. Pump pumps oil thru an internal check valve, and a discharge filter. Oil is now in supply line, ready to power selected function's cylinder(s). Motor pump internal check valve allows oil to flow thru to the supply line, but closes when motor pump stops running, preventing oil from back flowing into motor pump, which prevents gravity drain out of supply line and back into motor pump. Discharge filter removes any contaminants from oil before oil reaches any hydraulic components. This prevents reduced life expectancy of hydraulic components such as seals and o-rings and prevents clogging of valves and check valves. There is a 250 BAR (3625 PSI) pressure relief valve on each motor pump. If pressure reaches or exceeds this pressure, valve opens dumping oil back into reservoir.

Oil is now in supply line, ready to power selected function's cylinder(s).

Trendelenburg and Lateral Tilt

Trendelenburg

control was selected (in normal table orientation), motor pump is energized and valve spool for that function moves to an up function position (oil will now flow in new oil flow path that has been created; this path is shown by straight flow symbols on hydraulic schematic) and oil flows thru a check valve (A) and into the base of cylinder, extending cylinder. Check valve (A) prevents oil from escaping from cylinder after valve spool is deenergized, keeping cylinder from drifting. Oil also flows thru a pilot line (represented by a dashed line on hydraulic schematic) and extends a pilot piston. Pilot piston forces open check valve (B) on retracting side of cylinder, allowing oil to escape from top side of cylinder, thru valve spool and into the oil return line. If

Reverse Trendelenburg

hand control was selected (in normal table orientation), motor pump is energized and valve spool for that function moves to a down function position (oil will now flow in new oil flow path that has been created; this path is shown by crossed flow symbols on the hydraulic schematic) and oil flows thru a check valve (B) and into top of cylinder, retracting cylinder. Check valve (B) prevents oil from escaping from cylinder after valve spool is de-energized, keeping cylinder from drifting. Oil also flows thru a pilot line (represented by a dashed line on hydraulic schematic) and extends a pilot piston.

Lateral Tilt Left

button on hand

Lateral Tilt Right

button on

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SECTION I GENERAL INFORMATION

Pilot piston forces open check valve (A) on base of cylinder, allowing oil to flow from base of cylinder, thru valve spool, and into oil return line.

Seat Functions

SEAT UP

normal table orientation), motor pump is energized and valve spool for that function moves to an up function position (oil will now flow in new oil flow path that has been created; this path is shown by straight flow symbols on hydraulic schematic) and oil flows thru a check valve (A) and into base of left cylinder (master cylinder), extending cylinder. Check valve (A) prevents oil from escaping from cylinder after valve spool is deenergized, keeping cylinder from drifting. Oil also flows thru two pilot lines (represented by dashed lines on hydraulic schematic) and extends two pilot pistons (B and D). One pilot piston forces open a check valve (B) which allows oil to flow out of top side of left cylinder thru another check valve (C) and into base of right cylinder (slave cylinder), extending cylinder. Other pilot piston forces open check valve (D) on top side of right cylinder (slave cylinder), allowing oil to flow from top side of cylinder, flow thru valve spool and into oil return line. If

SEAT DOWN

normal table orientation), motor pump is energized and valve spool for that function moves to a down function position (oil will now flow in new oil flow path that has been created; this path is shown by crossed flow symbols on hydraulic schematic) and oil flows thru a check valve (D) and into top of right cylinder (slave cylinder), retracting cylinder. Check valve (D) prevents oil from escaping from right cylinder after valve spool is de-energized, keeping cylinder from drifting. Oil also flows thru two pilot lines (represented by dashed lines on hydraulic schematic) and extends two pilot pistons. One pilot piston forces open a check valve (C) which allows oil to flow out of base of right cylinder thru another check valve (B) and into top side of left cylinder (master cylinder), retracting cylinder. Other pilot piston forces open check valve (A) on base of left cylinder (master cylinder), allowing oil to flow out of base of cylinder, thru valve spool, and into oil return line.

Column Functions

TABLE UP

pump energizes and valve spool for that function moves to an up function position (oil will now flow in new oil flow path that has been created; this path is shown by straight flow symbols on hydraulic schematic) and oil flows thru a check valve (A) and into base of column

button on hand control is selected (in

button on hand control is selected, motor

cylinder, extending cylinder. Check valve (A) prevents oil from escaping from column cylinder after valve spool is de-energized, keeping cylinder from drifting. Oil flows out of top side of column cylinder as necessary, thru valve spool, and into return line. If

TABLE DOWN

motor pump energizes and valve spool for that function moves to a down function position (oil will now flow in new oil flow path that has been created; this path is shown by crossed flow symbols on hydraulic schematic) and oil flows to top side of base cylinder, retracting cylinder. Oil also flows thru a pilot line (represented by a dashed line on hydraulic schematic) and extends a pilot piston. Pilot piston forces open check valve (A) on base of cylinder, allowing oil to flow out of base of cylinder, thru valve spool, and into oil return line.

Floor Lock Functions

ENABLE / LOCK

motor pump energizes and valve spool for main floor lock cylinders moves to an up function position (oil will now flow in new oil flow path that has been created; this path is shown by straight flow symbols on hydraulic schematic) and oil flows thru a check valve (A) and into base of three main floor lock cylinders, extending cylinders. Check valve (A) prevents oil from escaping from three main floor lock cylinders after valve spool is de-energized, keeping cylinders from drifting. After approximately 10 seconds, main controller board de-energizes motor pump and main floor lock spool and then reenergizes motor pump and energizes outrigger floor lock valve spool to an up function position (oil will now flow in new oil flow path that has been created; this path is shown by straight flow symbols on hydraulic schematic) and oil flows thru two check valves (B and C) and into the base of two outrigger floor lock cylinders, extending cylinders. As soon as pressure in outrigger floor lock cylinders reaches 10 BARS (145 PSI), outrigger pressure relief valve opens, dumping oil back to return line. Outrigger cylinders were designed to add stability to table on an uneven floor. Three main floor lock cylinders lift table off of casters; then the two outrigger floor lock cylinders extend with enough power to stabilize table further. Check valves (B and C) prevent oil from escaping from two outrigger floor lock cylinders after valve spool is deenergized, keeping cylinders from drifting. If

UNLOCK & ENABLE

selected for three seconds, motor pump energizes and main floor lock valve spool moves to a down function position (oil will now flow in new oil flow path that has been created; this path is shown by crossed flow

button on hand control is selected,

without lifting

buttons on hand control is

table

Page 1-6Printed in U.S.A.© Schaerer Mayfield USA, Inc. 2004

Page 13

SECTION I

GENERAL INFORMATION

symbols on hydraulic schematic). Oil flows thru three pilot lines (represented by dashed lines on hydraulic schematic) and extends three pilot pistons, which forces open three check valves; check valves A, B, and C. With all three check valves open, oil flows out of base of three main floor lock cylinders and two outrigger floor lock cylinders, causing them to retract. There is a strong spring in each floor lock cylinder which helps retract cylinder.

Seat Slave Line Valve

On the seat functions, there is a manually operated two way-valve (slave line valve) which is used to add or remove oil from closed loop (slave line) to synchronize stroke of left (master) and right (slave) cylinders.

Column Slave Line Valve

There is a manually operated two-way valve (slave line valve) on column function, which is used to add or remove oil from middle stage of column cylinder (if there is too much oil in second stage, column cylinder will "jump" downward and make a noise when column down function is selected. If there is not enough oil in second stage, full height potential of column cylinder will not be reached).

Orifices

Orifices are internal to Trendelenburg, Lateral Tilt, and Seat, cylinders to meter flow of oil into cylinders, thereby regulating speed of cylinders.

1.4 SPECIFICATIONS

Factual data for the 7300 Modular Surgery Table is provided in Table 1-1.

Table 1-1. Specifications

Description Data

Weight

Normal (w/ head & pelvic sections & upholstery) ...........

........................................................... 660 lb. (299 kg)

With Shipping Carton.......................... 764 lb. (347 kg)

Shipping Carton........ 58 in. "L" x 30 in. "W" x 40 in. "H"

(147 cm x 76 cm x 102 cm)

Dimensions: (w/ Head, Back, Pelvic & Leg Transfer Board.)

Table Top Length ............................. 75.6 in. (192 cm)

Table Top Width ...................................... 20.5 (52 cm)

Overall Width......................................... 24 in. (61 cm)

Overall Length..................................... 78 in. (198 cm)

Table Positioning:

Table Top Height (Adjustable) .......... 27.7 (± 0.2) in. to

43.9 (± 0.2) in.

(70 to 112 cm)

Trendelenburg ......................................0° to 28° (±1°)

Reverse Trendelenburg....................... 0° to -28° (±1°)

Lateral Tilt................ 0° to -18° (±1°) in either direction

Seat Section .......... + 75° (±1°) to -40° (±1°) in relation

to back section

Coordinating Flex (Normal Position):

Trendelenburg ................+20° (±5°) above horizontal

Seat Section ......-40° (±5°) in relation to back section

Coordinating Reflex (Normal Position):

Trendelenburg ................. -28° (±5°) below horizontal

Seat Section ..... +60° (±5°) in relation to back section

Head Section:

Mounted on Head End...........+30° (±3°) to -30° (±3°)

Mounted on Foot End ............+30° (±3°) to -75° (±5°)

Page 1-7Printed in U.S.A.© Schaerer Mayfield USA, Inc. 2004

Page 14

SECTION I

MODEL

NUMBER

SERIAL

NUMBER

SMI

7100-001

115 VAC

2 AMP 60 HZ TDWXXXXX

MODEL

INPUT

RATING

SERIAL NO.

GENERAL INFORMATION

Table Speed (Table in normal orientation, full battery

charge, ambient oil temp.):

Extend Column Fully .................. 16.0 to 21.0 seconds

Retract Column Fully.................. 16.0 to 21.0 seconds

Reverse Trend. to Trend. ........... 20.5 to 24.5 seconds

Trend. to Reverse Trend. ........... 16.0 to 20.0 seconds

Lat. Tilt R to Lat. Tilt L .................. 9.5 to 12.5 seconds

Lat. Tilt L to Lat. Tilt R ................ 10.0 to 13.0 seconds

Seat Down to Seat Up ................ 18.0 to 21.0 seconds

Seat Up to Seat Down ................ 18.5 to 21.5 seconds

Weight Capacity (maximum):

Normal Table Orientation ..................500 lbs. (227 kg)

Reverse Table Orientation..............400 lbs. (181.4 kg)

Head Section.........................................40 lbs. (18 kg)

Overweight Operation ................ Patient Positioning is

restricted. To learn of limita-

tions, contact the Surgical

Table Product Manager at

1-800-643-6275

Hydraulic System Oil ................ ISO Viscosity Grade 32

Premium Hydraulic Fluid

Reservoir Capacity ..................... 2.1 Quarts (2.0 Liters)

(2) Refer to the Parts List to determine the item

numbers of the parts, part numbers of the parts, descriptions of the parts, and quantities of parts needed and record this data (Refer to para 6.1).

NOTE

Ask the Purchasing Department of the company that owns the unit for this information. Otherwise, this information may be obtained from the dealer that sold the unit.

(3) Determine the installation date of the unit and

record this data.

Serial Number when contacting SMI

(4)Call SMI with recorded information and ask

for Technical Services Department. Use phone number 1-800 643-6275

Please have the Model and

System Capacity ........................ 3.7 Quarts (3.5 Liters)

Battery Charging Time.............................. 8 to 12 hours

Motor Pump Pressure

Relief Valve ...............Opens At 250 BARS (3625 PSI)

Outrigger Pressure

Relief Valve ...................Opens At 10 BARS (145 PSI)

Electrical Requirements:

115 VAC Unit........................... 110 - 120 VAC, 60 HZ,

2 amp, single phase

Battery Power Output............ 24 VDC, 18 amp-hours

1.5 Parts Replacement Ordering

If a part replacement is required, order the part directly from the factory as follows:

(1) Refer to Figure 1-2 to determine the location of

the model number and serial number of the unit and record this data.

SMI

7100

CA7681

Figure 1-2. Model Number / Serial

Number Location

Page 1-8Printed in U.S.A.

Page 15

1.6 Special Tools

Table 1-2 lists all of the special tools needed to repair the unit, how to obtain the special tools, and the purpose of each special tool.

Table 1-2 is on the following page.

Table 1-2. Special Tools List

SECTION I

GENERAL INFORMATION

Description of Special Tool

Multimeter Commercially Available Any Type Used to perform continuity and voltage checks. Pin Extractor (has

interchangable bits - M3x0.5, M4x0.7, M5x0.8, M6x1.0, 1/4-20, 10-24, and 5/16-18)

Spanner Wrench - locking nut Schaerer Mayfield USA

Spanner Wrench - brass pivot puck

Retaining Bolt Schaerer Mayfield USA

Spanner Wrench - retainer cap Schaerer Mayfield USA

Pressure Relief Valve Test Harness

Blanking Plug Kit Schaerer Mayfield USA

Soldering Iron Commercially Available Any Type Used to connect wires to terminals with solder. 60 / 40 Solder Commercially Available Any Type Type of solder which should be used when

Internal retaining ring pliers Commercially Available Any Type Used to remove snap rings which secure bearings

Torque Wrench Commercially Available Any Type Used to tighten hardware to specified torque

Transport Tool Schaerer Mayfield USA

Tipping Tool Schaerer Mayfield USA

Manufacturer's

Name / Address / Phone

Schaerer Mayfield USA 4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

Schaerer Mayfield USA 4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

Schaerer Mayfield USA 4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

4900 Charlemar Drive Cincinnati, Ohio 45227 (800) 755-6381

Manufacturer's

Part Number

M05390 Used to pull pins which secure cylinders, handles,

etc. in place. Can also be used to remove caster fork.

M07235 Used to remove locking nut which secures top of

column cylinder in column.

M07236 Used to remove brass pivot puck which secures

top of column cylinder in column.

M07407 Used to hold rod of column cylinder stationary,

while special tools, M07235 and M07236 are used.

M07161 Used to remove retainer cap which secures

latching mechansim in place.

M07443 Used to adjust crack settings of motor pump

pressure relief valves and outrigger pressure relief valve.

502-0176-00 Used to cap the end of hydraulic lines to allow

pressure checks to be made.

soldering wires on surgery table.

in base of cylinders.

values.

502-0169-00 A dolly type tool which is used to transport Model

7100 or 7300 surgical tables around.

502-0168-00 Used to tip over Model 7100 or 7300 surgical

tables to access base of table for servicing.

Purpose of Special Tool

Page 1-9Printed in U.S.A.

Page 16

SECTION I GENERAL INFORMATION

Page 1-10Printed in U.S.A.

Page 17

TESTING AND TROUBLESHOOTING

SECTION II

TESTING AND TROUBLESHOO TING

SECTION II

2.1 Operational Test

In order to effectively diagnose malfunctions of the 7300 Modular Surgical Table, it may be necessary to perform an operational test as follows:

DANGER

Refer to the Operator Manual for

complete instructions on operating the surgical table. Failure to do so could result in personal injury. Power must be supplied to the unit to measure the voltage at the Test Points. Do not touch any bare wires or terminals while making these voltage checks. Failure to do so may result in electrical shock which could result in serious personal injury or death.

NOTE

The Operational Test, for the most part, only describes what should happen when the surgical table is operated. If the surgical table does something other than described, a problem has been discovered. Refer to the Troubleshooting Guide to determine the cause of the problem and its correction.

(1 ) Plug power cord into table's plug receptacle.

See Figure 2-1, Sheets 1 and 2.

(8 ) Move the surgery table around. (9) Observe. The casters should swivel freely and

the table should roll easily on the casters. The

table should not wobble. (10) Press ENABLE button on hand control. (11) Observe. The motor pump should run and the

main floor lock cylinders should extend. After

eight seconds, the motor pump should stop

running. Then the motor pump should begin

running again and the outrigger floor lock

cylinders should extend. After six seconds, the

motor pump should stop running. The hand

control display should read LOCKING FLOOR

while the floor lock cylinders are extending. (12) Insert pins of Head Section into sockets on

column end of table. Rotate latch handles to

locked position (to move latch handles to locked

position, rotate them away from you) and then

pull and push on head sections. (13) Observe. When the latch handles are rotated to

the locked position, the section being installed

should now be held securely in place. No side-

to-side or in-and-out movement should be

possible.

(2) Observe. The line power pilot lamp should

illuminate. (3 ) Unplug the power cord. (4 ) Press ENABLE button on hand control. (5) Observe. The hand control display should

illuminate and display the current table position

and battery charge level (XX POSITION and

BATT LEVEL XX. After 10 seconds, the hand

control display should extinguish. (6 ) Press and hold UNLOCK & ENABLE buttons on

hand control for three seconds. (7) Observe. The motor pump should run and the

table should lower (floor lock cylinders should

retract) until table is on its casters. The hand

control display should read UNLOCKING

FLOOR and then ON WHEELS.

(14) Press the ENABLE and REVERSE POSITION

buttons on hand control.

(15) Observe. The hand control display should read

REVERSE POSITION.

(16) Press the FLEX button and then REFLEX

button.

(17) Observe. Hand control display should indicate

these positions are "disabled" and cannot be used when table is in REVERSE POSITION.

(18) Press the ENABLE and NORMAL POSITION

buttons on hand control.

(19) Observe. The hand control display should read

NORMAL POSITION.

Page 2-1 Printed in U.S.A.

Page 18

SECTION II TESTING AND TROUBLESHOOTING

LINE POWER

PILOT LAMP

HEAD

SECTION

HAND

CONTROL

LATCH

HANDLE

EMERGENCY

OVERRIDE

PANEL

FOOT

CONTROL

RELEASE

HANDLE

ENABLE LOCK

LEVEL

SMI

7300

SMI

PLUG

DISABLE

UNLOCK

7100

SMI

7300

BACK

SECTION

RECEPTACLE

SEAT SECTION (PELVIC BASE)

POWER

CORD

TRENDEL-

ENBURG

REVERSE

TRENDEL-

ENBURG

TABLE

TABLE DOWN

FLOOR

LOCK

CYLINDERS

LATERAL

TILT

LEFT

LATERAL

TILT

RIGHT

Figure 2-1. Operational Test (Sheet 1 of 2)

LOCKED

POSITION

AUTO CAPTURE POSITION

UNLOCKED

POSITION

LATCH HANDLE

POSITIONS

(TYP. 2 PLACES)

CA819700

Page 2-2Printed in U.S.A.

Page 19

SECTION II

TESTING AND TROUBLESHOOTING

BUTTONS

SMI

DISABLE

LATERAL

TILT LEFT

SYSTEM

OVERRIDE

SYSTEM

OVERRIDE

7300

DISABLE

TABLE DOWN

TABLE

TRENDELENBURG

REVERSE

TRENDELENBURG

UNLOCKLOCK

SEAT

DOWN

HAND

CONTROL

DISPLAY

ENABLE

NORMAL

POSITION

TRENDELENBURG

TABLE

LATERAL

TILT LEFT

SEAT

FLEX

ENABLE

LOCK

DISABLE

NORMAL

REVERSE

POSITION

TREND

POSITION

REV TREND

HEIGHT UP

HEIGHT DOWN

TILT L

TILT R

SEAT UP SEAT DOWN

FLEX

UNLOCKLEVEL

SMI

LEVEL

(RETURN TO)

DISABLE

REVERSE POSITION

REVERSE

TRENDELENBURG

TABLE DOWN

LATERAL

REFLEX

TILT RIGHT

SEAT

DOWN

7300

REFLEX

UNLOCK

LATERAL

TILT RIGHT

LEVEL

UNLOCK

(RETURN TO)

Figure 2-1. Operational Test (Sheet 2 of 2)

(20) Press the ENABLE button and then press the

TABLE UP, TABLE DOWN, TRENDELENBURG, REVERSE TRENDELENBURG, LATERAL TILT LEFT, LATERAL TILT RIGHT, SEAT UP, SEAT DOWN, FLEX, and REFLEX buttons, running each function thru its full range of motion, and checking its speed and range of motion performance.

(21) Observe. The table performance should meet

the following specifications:

Range Of Motion:

Table Top Height (Adjustable) ........... 27.7 (± 0.2) in. to

43.9 (± 0.2) in. (70 to 112 cm)

Trendelenburg ....................................... 0° to 28° (±1°)

Reverse Trendelenburg ......................... 0° to -28° (±1°)

Lateral Tilt................. 0° to -18° (±1°) in either direction

CA819800

Seat Section ........... + 25° (±1°) to -40° (±1°) in relation

to back section

Coordinating Flex (Normal Position):

Trendelenburg .................. +20° (±5°) above horizontal

Coordinating Reflex (Normal Position):

Trendelenburg ................... -12° (±5°) below horizontal

Table Speed (Table in normal orientation, full battery

charge, ambient oil temp.):

Extend Column Fully................... 16.0 to 21.0 seconds

Retract Column Fully .................. 16.0 to 21.0 seconds

Reverse Trend. to Trend. ............ 20.5 to 24.5 seconds

Trend. to Reverse Trend. ............ 16.0 to 20.0 seconds

Lat. Tilt R to Lat. Tilt L .................. 9.5 to 12.5 seconds

Lat. Tilt L to Lat. Tilt R ................ 10.0 to 13.0 seconds

Seat Down to Seat Up ................ 18.0 to 21.0 seconds

Seat Up to Seat Down ................ 18.5 to 21.5 seconds

Page 2-3Printed in U.S.A.

Page 20

SECTION II TESTING AND TROUBLESHOOTING

(22) Press the ENABLE button and then press the

LEVEL button until the table reaches its level position. Using a protractor, check the table top to ensure it is level within ±2°.

(23) Observe. The table top should move to a level

position within ±2° as follows: The lateral tilt function should level out first; then a sequence of the Seat, and Trendelenburg functions should move, with each function moving no more than 10° at a time.

(24) Squeeze the release handle on the head section

and move the head section thru its full range of motion.

(25) The head section should move smoothly and

should not take excessive force. The head section should meet the following range of motion specifications:

Head Section:

Mounted on Head End ........... +30° (±3°) to -30° (±3°)

Mounted on Foot End ............ +30° (±3°) to -75° (±5°)

(26) Move head section to level position and then

place approximately 40 lbs. (18 kgs) at Point C (head section). Observe head section for two to

three minutes. (27) Observe. The head section should not drift. (28) Place approximately 400 lbs. (181.4 kg) of

weight on table top as follows: 28 lbs. (12.7 kg)

at Point C (head section), 152 lbs. (69 kg) at

Point B (back section), and 168 lbs. (76.2 kg) at

Point A (seat section).

(33) Observe. Each function should move as

depicted by the illustration on its button.

(34) Press each function button on the foot control.

Then place the table top in REVERSE position. Then press each function button on the foot control again.

(35) Each function should move as depicted when

table top is in NORMAL position. The table should not operate, using the foot control, when the table top is in REVERSE position.

(36) Plug power cord into table's power receptacle.

DANGER

Electrical power must be connected to

perform the following steps. Do not touch any bare wires or terminals. Failure to do so could cause an electrical shock which could result in serious personal injury or death.

(37) See Figure 2-2 for this step. Check for 32.5

VAC ± 2 VAC across Test Points C and D and across Test Points D and E.

(38) Observe. There should be 32.5 VAC ±2 VAC

across

(39) See Figure 2-2 for this step. Check for 27.7

VAC ± 2 VAC across Test Points F and G and across Test Points H and J. Check for 27.8 VAC ±2 VAC across Test Points K and L.

(40) Observe. The proper voltages should be

present across

both

sets of test points.

each

set of test points.

(29) Press ENABLE button and then press TABLE

UP and TABLE DOWN buttons to run column function up and down several times.

(30) Observe. Column function should move up and

down steadily and smoothly. No binding condition should be evident, especially when column is lowering. There should be no exces-

sive side-to-side play in column assembly. (31) Remove weight from table top. (32) Press and hold the SYSTEM OVERRIDE button

while pressing the function buttons, one at a

time, on the emergency override panel.

Page 2-4Printed in U.S.A.

Page 21

SECTION II

TESTING AND TROUBLESHOOTING

POWER CORD RECEPTACLE

5 amp. FUSE

115

VAC

5 amp. FUSE

Note

Wire colors may change without notification

ST5b

7 8

141316

RED

BLACK

BROWN

BLUE

BLACK

WHITE

VIOLET

GREEN

YELLOW

ORANGE

RED

FOOT

CONTROL

PORT

NOTE: FOOT AND HAND CONTROL

PLUGS ARE POSITIONED TO VIEW

TERMINAL (BACK) END.

HAND

CONTROL

PORT

GREEN

= DENOTES "TEST POINTS"

LINE POWER PILOT LAMP

BROWN

RFI

FILTER

BLUE

YELLOW / GREEN

ST6

GREY / PINK

GREY / WHITE

BROWN / GREY

WHITE / GREEN

BROWN / GREEN

YELLOW / WHITE

BROWN / YELLOW

BLUE

GREEN

YELLOW

RED

BROWN

GREY

GREY BLUE

GREEN

WHITE

YELLOW

RED

BROWN

9111413161518172019 10

RED / BLUE

7 8

WHITE

BLUE

YELLOW / GREEN

5 6

GREY

VIOLET

WHITE YELLOW

1 2

BLUE

N.C.

80° c

(176° F)

FUSE

OUTRIGGER

FLOOR LOCK

STATUS SWITCH

BLACK

WHITE

GREY

WHITE

100° c

MOTOR

(212° F)

PUMP

SECONDARY

THERMAL

RED

BROWN

N.O.

N.C.C.

(SWITCHES SHOWN IN UNTRIPPED POSITION)

BROWN

FUSE

MAIN FLOOR

LOCK STATUS

SWITCH

BLACK

WHITE

RED

BROWN

N.C.

80° c

(176° F)

PRIMARY

THERMAL

FUSE

N.O.

N.C.C.

BROWN

ST3

9 11

PINK

WHITE

GREEN

YELLOW

RED / BLUE

GREY / PINK

RED

2 1 3 5

BLUE

GREY

VIOLET

BLACK

ST10

10 12 14

1 3 5

RED

PINK

BLUE

BLACK

BROWN

VIOLET

GREEN

YELLOW

RED / BLUE

GREY / PINK

WHITE / GREEN

BROWN / GREEN

RED

PINK

BLUE

GREY

RED / BLUE

BLACK

GREEN

VIOLET

BROWN

YELLOW

GREY / PINK

911

St23

WHITE

ST3a

ST2a

TRANSFORMER

THERMAL

FUSE

BLACK

RED

THERMAL

FUSE

YELLOW

BLACK

RED

ST1

ST8 (P2)

CHARGING / POWER

ST8

BLACK

RED

BLACK

ST3a

(BATT. -)

C D E

9 10

DRIVER BOARD

9 10

RED

YELLOW

BLUE

BLACK

BROWN

2 1 3 5

7 8

WHITE

VIOLET

ST5a

ST2a

(BATT. +)

5 6

GREY

3 4

VIOLET

WHITE

8 7

ST2b

9111413161518172019

1 3 5

MAIN CONTROLLER BOARD

WHITE

GREEN

BROWN

2 4

1 3

St35

BLACK

GREEN

BROWN

YELLOW

GREEN

BROWN

YELLOW

10 amp.

FUSE

St1

2 2

RED

PINK

BROWN

YELLOW

RED

1 3

BLUE

St37

GREY

RED

1 3

BLUE

St36

WHITE

GREY

SEAT POSITION

YELLOW

SENSOR

16 14 13

12 10 8 6 4 2

RED

ST6

St1

St4

11 9 7

St5b

5 3 1

LATERAL TILT

POSITION SENSOR

GREEN

St33

St32

ST7a

(PUMPS +)

1 2

BLUE

RED

10 9

ST2b

ST9 a & b

ST7 (P1)

BLACK

YELLOW

8 7

WHITE

FUSE

40 amp.

ST4

2 1

BLACK

BROWN

10 9

GREEN

BROWN

- +- +- +-

BATTERY BATTERY BATTERY BATTERY

ST9a

RED

ST9b

RED

2 1

RED

GREY

WHITE

BLACK

BROWN

1 3 5

ST7

1 3 5

ST7

TRENDELENBURG POSITION SENSOR

100° c

MOTOR

(212° F)

PUMP

SECONDARY

THERMAL

N.O.

ST4

FUSE

PRIMARY THERMAL

WHITE

BLACK

GREEN

YELLOW

9 11

1 3 5

ST3

ON ON

10 12 14

1 3 5

ST10

Figure 2-2. Voltage Checks

CA819900

Page 2-5Printed in U.S.A.

Page 22

SECTION II TESTING AND TROUBLESHOOTING

2.2 Troubleshooting Procedures

Table 2-1 is a Troubleshooting Guide which is used to determine the cause of the malfunction.

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Table seems powerless even when plugged into a wall outlet.

Line Power Pilot Lamp does not illuminate (with power cord plugged in).

Line Power Pilot Lamp illuminates, but batteries do not recharge and table is powerless (with power cord plugged in).

Line Power Pilot Lamp illuminates, but table is powerless.

Facility circuit breaker providing power to table is tripped.

One of two 5 amp fuses in the power cord receptacle is blown.

RFI filter is blown. See Figure 5-1 for this

Line power pilot lamp is burned out.

Wires or wire connections between power cord receptacle and transformer are broken, loose or dirty.

Thermal fuse(s) in transformer are blown.

Transformer is blown. See Figure 5-1 for this

Charging / power driver board is malfunctioning.

Wires or wire connections between transformer and charging / power driver board are broken, loose, or dirty.

10 amp fuse on main controller board is blown.

Check to see if facility circuit breaker is tripped.

Remove both 5 amp fuses from power cord receptacle and perform a continuity check on the fuses.

check. Check for 115 VAC ± 5.0 VAC across Test Points A and B.

Replace suspect line power pilot lamp with known working line power pilot lamp.

Perform a continuity check on all suspect wires or connections.

See Figure 5-1 for this check. Check for 32.5 ±

2.0 VAC across Test Points C and D and across Test Points D and E.

check. Check for 32.5 ±

2.0 VAC across Test Points C and D and across Test Points D and E.

See Figure 5-1 for this check. Check for 27.7 +/- 0.3 VDC across Test Points F and G. Check for 27.7 +/- 0.3 VDC across Test Points H and J. Check for 27.8 +/- 0.3 VDC across Test Points K and L.

Perform a continuity check on all suspect wires or connections.

Perform continuity check on 10 amp fuse.

If circuit breaker is tripped, determine what caused the circuit breaker to trip, correct the problem, and then reset / replace circuit breaker.

Replace any blown 5 amp fuses.

If 115 VAC ± 5.0 VAC is not present across Test Points A and B, replace RFI filter. Refer to para 4.35.

Replace line power pilot lamp. Refer to para 4.37.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

If 32.5 VAC ± 2.0 VAC is not present across one or both of the Test Point groups, replace the transformer. Refer to para 4.36.

If proper voltage is not present at Test Points, replace charging / power driver board. Refer to para

4.38.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace 10 amp fuse. See Figure 5-1 for fuse location.

Page 2-6Printed in U.S.A.

Page 23

Problem Symptom Probable Cause Check Correction

Table operates when power cord is plugged in, but will not operate when power cord is unplugged.

Table 2-1. Troubleshooting Guide

When ENABLE button on hand control is pressed, its display does not illuminate (with power cord unplugged).

TESTING AND TROUBLESHOOTING

40 amp fuse on charging / power driver board is blown.

10 amp fuse on main controller board is blown.

Batteries are dead and are not supplying charging / power driver board with enough power to operate.

See Figure 5-1 for this check. Check fuse visually or perform continuity check on fuse (may need to check secondary thermal fuse of motor pump. If blown, thermal fuse will cause 40 amp fuse to blow).

Perform continuity check on 10 amp fuse.

See Figure 5-1 for this check. Check individual batteries by checking for

13.2 +/- 0.4 VDC across terminals of each battery (Test Points M and N).

SECTION II

Replace 40 amp fuse. See Figure 5-1 for fuse location.

Replace 10 amp fuse. See Figure 5-1 for fuse location.

If 13.2 +/- 0.4 VDC is not present across Test Points, replace batteries. Refer to para 4.39.

Batteries do not recharge in 6 to 8 hours from low charge.

Hand control does not work.

Batteries do not recharge very quickly.

When ENABLE button on hand control is pressed, its display does not illuminate.

Charging / power driver board is malfunctioning.

One of thermal fuses in transformer is blown.

Batteries are dead. See Figure 5-1 for this

10 amp fuse on main controller board is blown.

Main controller board or hand control board is malfunctioning.

Wires or wire connections between main controller board, distribution board, and hand control port are broken, loose or dirty.

Motor pump secondary thermostat is closed creating a direct short to ground, causing 40 amp fuse on charging / power driver board to blow.

See Figure 5-1 for this check. Check for 27.7 +/- 0.3 VDC across Test Points F and G.

See Figure 5-1 for this check. Check for 32.5 +/- 2.0 VAC across Test Points C and D, and across Test Points D and E.

check. Check individual batteries by checking for

13.2 +/- 0.4 VDC across terminals of each battery (Test Points M and N).

Perform continuity check on 10 amp fuse.

See Figure 5-1 for this check. Check for 5.0 VDC across Test Points P and Q. If 5 VDC is present, check for 5.0 VDC across Test Points Q and R within 10 seconds of pressing ENABLE button on hand control.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

See Figure 5-1 for this check. Check for a resistance value of 0 ohms between Test Points S and T for motor # 1 or Test Points U and V for motor # 2.

If proper voltage is not present at Test Points, replace charging / power driver board. Refer to para 4.32.

If 32.5 +/- 2.0 VAC is not present across one or both of the Test Point groups, replace the transformer. Refer to para 4.36.

If 13.2 +/- 0.4 VDC is not present across Test Points, replace batteries. Refer to para 4.39.

Replace 10 amp fuse. See Figure 5-1 for fuse location.

If 5.0 VDC is not present across Test Points P and Q, the main controller board is malfunctioning. If 5.0 VDC is not present across Test Points Q and R during check, then main controller board or hand control board is malfunctioning. Refer to para

4.31 or 4.5. Clean any dirty connections.

Tighten any loose connections. Replace any broken connectors or wires.

Replace malfunctioning motor, secondary thermostat, and 40 amp fuse. Refer to para 4.26 and 4.41.

Page 2-7Printed in U.S.A.

Page 24

SECTION II TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Hand control does not work - Continued.

When ENABLE button on hand control is pressed, its display does not illuminate

- Continued.

Display of hand control board is malfunctioning.

Replace suspect hand control board with known working hand control board.

Replace hand control board. Refer to para 4.5.

Foot control does not work.

When a button on hand control is pressed, error code E15 displays.

When a function button on hand control is pressed, the motor pump does not run and no error codes display.

Foot control operates fine sometimes, but not every time.

When foot switch on foot control is pressed, nothing happens (hand control display should illuminate when foot switch is depressed).

Button board is malfunctioning.

Button board is malfunctioning. One of two button switches for a function is stuck in closed position or will not close.

Hand control board is malfunctioning.

Button board is malfunctioning.

Main controller board is malfunctioning.

Wires or wire connections between main controller board, distribution board, and hand control port are broken, loose or dirty.

Table is in reverse orientation.

The hand control or emergency override panel is being used (hand control and / or emergency override panel takes priority over foot control).

One of two foot switches for a function is stuck in closed position or will not close.

Replace suspect button board with known working button board.

Perform a continuity check on both button switches of suspect function (when a button switch is pressed, there should be continuity between its two terminals).

Replace suspect hand control board with known working hand control board.

Replace suspect button board with known working button board.

Replace suspect main controller board with known working main controller board.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Foot control is locked out from being used when table top is in reverse orientation - foot control may only be used when table top is in normal orientation.

Check if problem occurrs only when hand control or emergency override panel is being used.

See Figure 5-1 for this check. Perform a continuity check on both foot switches of suspect function (when foot switch is pressed, there should be continuity between its two terminals).

Replace button board. Refer to para 4.4.

If check fails, replace button board. Refer to para 4.4.

Replace hand control board. Refer to para 4.5.

Replace button board. Refer to para 4.4.

Replace main controller board. Refer to para 4.31.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Use hand control or set up table top in normal orientation. Inform operator that Foot Control cannot be used when table is in reverse orientation.

Do not use foot control simultaneously with hand control or emergency override panel. Inform operator of Emergency Override Panel, Hand Control, and Foot Control priorities.

If check fails, replace foot switch pad.

Page 2-8Printed in U.S.A.

Page 25

Problem Symptom Probable Cause Check Correction

Foot control does not work

-Continued

Error code E01 (Floor Lock Status Switch Is Not Responding) displays on hand control.

Table 2-1. Troubleshooting Guide

When foot switch on foot control is pressed, nothing happens (hand control display should illuminate when foot switch is depressed) -Continued.

Floor lock cylinders do not extend or retract properly and error code E01 appears on hand control.

Floor lock cylinders extend properly, but error code E01 appears on hand control.

TESTING AND TROUBLESHOOTING

Foot control interface board is malfunctioning.

10 amp fuse on main controller board is blown.

Main controller board or foot control interface board is malfunctioning.

Wires or wire connections between main controller board, distribution board, and hand control port are broken, loose or dirty.

Check valve(s) for main floor lock cylinder(s) or outrigger floor lock cylinder(s) are stuck open, allowing floor lock cylinders to retract after extending.

Foreign matter in main floor lock or outrigger floor lock valve spool.

Outrigger pressure relief valve is malfunctioning, preventing outrigger cylinders from extending fully.

Inside surfaces of main floor lock cylinder(s) or outrigger floor lock cylinder(s) are dirty / covered with foreign matter, which prevents the cylinder(s) from extending or retracting fully.

Main floor lock status switch remains tripped after main floor locks have extended (out of adjustment).

Main floor lock status switch is malfunctioning - stuck open.

Replace suspect foot control interface board with known working foot control interface board.

Perform continuity check on 10 amp fuse.

See Figure 5-1 for this check. Check for 5.0 VDC across Test Points P and W. If 5.0 VDC is present, check for 5.0 VDC across Test Points W and X within 10 seconds of pressing a foot button on foot control.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Remove check valve(s) and check for foreign matter.

Remove valve spool(s) and check for foreign matter. Flush out valve spool manifold with oil.

Replace suspect pressure relief valve with known working pressure relief valve.

Check for foreign matter on inside surfaces of floor lock cylinders.

Check if status switch is tripped.

See Figure 5-1 for this check. Perform continuity check on normally closed status switch (switch untripped = continuity).

SECTION II

Replace foot control interface board. Refer to para 4.44.

Replace 10 amp fuse. See Figure 5-1 for fuse location.

If 5.0 VDC is not present across Test Points P and W, the main controller board is malfunctioning. If 5.0 VDC is not present across Test Points W and X during check, then main controller board or foot control interface board is malfunctioning. Refer to para

4.31 or 4.44. Clean any dirty connections.

Tighten any loose connections. Replace any broken connectors or wires.

Remove and clean check valve(s). Replace any damaged pilot pistons or check valves.

Push on manual release pin of valve spool. If still stuck, remove valve spool(s) and check for foreign matter. Flush out valve spool manifold with oil.

Replace outrigger pressure relief valve and spring. Refer to para 4.30.

Disassemble and clean floor lock cylinder(s).

If necessary, adjust main floor lock status switch. Refer to para 4.42.

If malfunctioning, replace main floor lock status switch. Refer to para 4.42.

Page 2-9Printed in U.S.A.

Page 26

SECTION II TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Error code E01 (Floor Lock Status Switch Is Not Responding) displays on hand control - Continued.

Error Code E02 (Overcurrent - Motor #1) displays on hand control.

Error code E03 (Overcurrent - Motor #2) displays on hand control.

Error code E04 (Motor Driver Failure) displays on hand control.

Floor lock cylinders do not extend or retract properly and error code E01 appears on hand control - Continued.

Floor lock cylinders do not retract properly and Error code E01 appears on hand control.

When function is selected, error code E02 appears on hand control.

When function is selected, error code E03 appears on hand control.

When function is selected, error code E04 appears on hand control.

Outrigger floor lock status switch remains tripped after outrigger floor locks have extended (out of adjustment).

Outrigger floor lock status switch is malfunctioning - stuck open.

Wires or wire connections between floor lock status switches and main controller board are broken, loose or dirty.

One of the floor lock status switches is malfunctioning.

Retaining ring which holds ouside floor lock sleeve onto floor lock cylinder piston is missing.

Motor #1 is malfunctioning. Replace suspect motor #1

Charging / power driver board is malfunctioning.

Motor #2 is malfunctioning. Replace suspect motor #2

Charging / power driver board is malfunctioning.

Wires or wire connections between charging / power driver board and pumps are broken, loose, or dirty.

Charging / power driver board is malfunctioning.

Motor is burned out (most likely motor #1).

Check if status switch is tripped.

See Figure 5-1 for this check. Perform continuity check on normally closed status switch (switch untripped = continuity).

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Perform continuity check on N.C. floor lock status switch (switch untripped = continuity).

Check to see if retaining ring is missing.

with known working motor pump.

Replace suspect charging / power driver board with known working board.

with known working motor pump.

Replace suspect charging / power driver board with known working board.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect charging / power driver board with known working board.

Replace suspect motor with known working motor. (If only COLUMN UP function causes error code E04, motor #2 could be malfunctioning - motor #2 only runs for this function during normal operation).

If necessary, adjust outrigger floor lock status switch. Refer to para 4.42.

If malfunctioning, replace outrigger floor lock status switch. Refer to para 4.42.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

If necessary, adjust or replace floor lock status switch. Refer to para 4.42.

Replace retaining ring.

Replace motor #1. Refer to para 4.26.

Replace charging / power driver board. Refer to para

4.32. Replace motor #2. Refer to

para 4.26.

Replace charging / power driver board. Refer to para

4.32. Clean any dirty connections.

Tighten any loose connections. Replace any broken connectors or wires.

Replace charging / power driver board. Refer to para

4.32. Replace motor. Refer to

para 4.26.

Page 2-10Printed in U.S.A.

Page 27

Problem Symptom Probable Cause Check Correction

Error code E05 (Valve Driver Failure) displays on hand control.

Error code E06 (Footswitch Failure) displays on hand control.

Error code E07 (Trendelenburg Position Sensor Failure) displays on hand control.

Table 2-1. Troubleshooting Guide

When ENABLE button is pressed, or a function button is selected, error code E05 appears on hand control.

When a footswitch button is depressed, error code E06 appears on hand control.

When ENABLE button is pressed, or a function button is selected, error code E07 appears on hand control.

TESTING AND TROUBLESHOOTING

A valve spool solenoid is malfunctioning.

Wires or wire connections between valve spool solenoid and main controller board are broken, loose or dirty.

Main controller board is malfunctioning - valve driver circuitry is malfunctioning.

One of two foot switches for a function is stuck in closed position or will not complete circuit when depressed.

Foot control interface board is malfunctioning.

Wires or wire connections between foot switches and foot control interface board are broken, loose or dirty.

Trendelenburg position sensor is malfunctioning.

Wires or wire connections between Trendelenburg position sensor, distribution board, and main controller board are broken, loose, or dirty.

Main controller board is malfunctioning.

Press and hold the SYSTEM OVERRIDE button on the emergency panel, while pressing, one at a time, all the remaining function buttons on the emergency panel (except for DISABLE button). All functions should operate except for function with malfunctioning valve spool solenoid.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect main controller board with known working main controller board.

See Figure 5-1 for this check. Perform a continuity check on both foot switches of suspect function (switch not depressed = open / switch depressed = continuity.

Replace suspect foot control interface board with known working foot control interface board.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect Trendelenburg position sensor with known working position sensor.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect main controller board with known working main controller board.

SECTION II

Replace malfunctioning valve spool solenoid. Refer to para

4.22 or 4.23.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace main controller board. Refer to para 4.31.

If check fails, replace foot switch pad.

Replace foot control interface board. Refer to para 4.44.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace Trendelenburg position sensor. Refer to para

4.11.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace main controller board. Refer to para 4.31.

Page 2-11Printed in U.S.A.

Page 28

SECTION II TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Error code E08 (Tilt Position Sensor Failure) displays on hand control.

Error code E09 (Seat Position Sensor Failure) displays on hand control.

Error code E11 (Internal RAM / Register Failure) displays on hand control.

Error code E12 (Calibrating data Failure) displays on hand control.

When ENABLE button is pressed, or a function button is selected, error code E08 appears on hand control.

When ENABLE button is pressed, or a function button is selected, error code E09 appears on hand control.

When ENABLE button is pressed, error code E11 appears on hand control.

When ENABLE button is pressed, error code E12 appears on hand control.

Tilt position sensor is malfunctioning.

Wires or wire connections between tilt position sensor, distribution board, and main controller board are broken, loose or dirty.

Main controller board is malfunctioning.

Seat position sensor is malfunctioning.

Wires or wire connections between seat position sensor, distribution board, and main controller board are broken, loose or dirty.

Main controller board is malfunctioning.

Battery power level is too low to properly power table.

Main controller board is malfunctioning.

Replace suspect tilt position sensor with known working position sensor.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect main controller board with known working main controller board.

Replace suspect seat position sensor with known working position sensor.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Replace suspect main controller board with known working main controller board.

Plug power cord into table and press ENABLE button on hand control to see if error code E11 displays now.

Replace suspect main controller board with known working main controller board.

Replace tilt position sensor. Refer to para 4.15.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace main controller board. Refer to para 4.31.

Replace seat position sensor. Refer to para 4.19.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Replace main controller board. Refer to para 4.31.

If error code still appears, recharge batteries.

Replace main controller board. Refer to para 4.31.

Error code E13 (Overheat

- Motor #1) displays on hand control.

When ENABLE button is pressed, error code E13 appears on hand control.

Motor #1 is overheated and has tripped its primary thermostat.

Wait 60 to 90 minutes to allow motor to cool down and the primary thermostat to reset.

After table is operational again, check to see if motor #1 overheats continually.

Wait 60 to 90 minutes to allow motor #1 to cool down and the primary thermostat to reset. Replace primary thermostat. Refer to para

4.40. If motor #1 overheats

continually (E13), replace primary thermostat. Refer to para 4.40. If motor #1 still continues to overheat (E13), replace motor. Refer to para

4.26.

Page 2-12Printed in U.S.A.

Page 29

Problem Symptom Probable Cause Check Correction

Error code E13 (Overheat

- Motor #1) displays on hand control - Continued.

Error code E14 (Overheat

- Motor #2) displays on hand control.

Error code E15 (Hand Control Button Switch Failure) displays on hand control.

When ENABLE and UNLOCK buttons on hand control are pressed, floor lock cylinders do not retract.

Table 2-1. Troubleshooting Guide

When ENABLE button is pressed, error code E13 appears on hand control Continued.

When ENABLE button is pressed, error code E14 appears on hand control.

When ENABLE button is pressed, error code E15 appears on hand control.

Main floor lock cylinders do not retract properly.

TESTING AND TROUBLESHOOTING

Wires or wire connections between motor #1 primary thermostat and main controller board are broken, loose, or dirty.

Motor #2 is overheated and has tripped its primary thermostat.

Wires or wire connections between motor #2 primary thermostat and main controller board are broken, loose, or dirty.

One of two button switches for a function is stuck in closed position or will not complete circuit when pressed.

Hand control board is malfunctioning.

Wires or wire connections between hand control board, hand control port, distribution board, and main control board are broken, loose, or dirty.

All floor lock valve spool is clogged.

Inside surfaces of main floor lock cylinder is dirty / covered with foreign matter, which prevents the cylinder from retracting fully.

Pilot operated check valve is malfunctioning - not opening check valve or check valve is clogged.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Wait 60 to 90 minutes to allow motor to cool down and the primary thermostat to reset.

After table is operational again, check to see if motor #2 overheats continually.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

See Figure 5-1 for this check. Perform a continuity check on both button switches of suspect function (button switch not depressed = open / button switch depressed = continuity.

Replace suspect hand control board with known working hand control board.

See Figure 5-1 for this check. Perform a continuity check on all suspect wires or connections.

Check for foreign matter in valve spool.

Check for foreign matter on inside surfaces of main floor lock cylinders.

Check for broken or bent components or foreign matter in pilot operated check valve.

SECTION II

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Wait 60 to 90 minutes to allow motor to cool down and the primary thermostat to reset. Replace primary thermostat. Refer to para 4.40.

If motor #2 overheats continually (E14), replace primary thermostat. Refer to para 4.40. If motor #2 still continues to overheat (E14), replace motor. Refer to para

4.26. Clean any dirty connections.

Tighten any loose connections. Replace any broken connectors or wires.

If check fails, replace button board. Refer to para 4.4.

Replace hand control board. Refer to para 4.5.

Clean any dirty connections. Tighten any loose connections. Replace any broken connectors or wires.

Remove valve spool and clean valve spool ports out. Replace valve spool component if necessary.

Disassemble and clean main floor lock cylinders.

Remove pilot operated check valve components. Clean out any foreign matter. Replace any broken or bent components.

Page 2-13Printed in U.S.A.

Page 30

SECTION II TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

When ENABLE and UNLOCK buttons on hand control are pressed, floor lock cylinders do not retract - Continued.

All functions run too slow. No error codes are

One function is too slow; the rest are operating properly.

One function is too fast; the rest are operating properly.

Outrigger floor lock cylinders do not retract properly.

displayed, but all functions are too slow or do not extend or retract fully.

No error codes are displayed, but function is too slow or does not extend or retract fully.

No error codes are displayed, but column function moves too slowly or does not extend or retract fully.

No error codes are displayed, but function is too fast.

All floor lock valve spool is clogged.

Inside surfaces of outrigger floor lock cylinder is dirty / covered with foreign matter, which prevents the cylinder from retracting fully.

Pilot operated check valve(s) is malfunctioning - not opening check valve or check valve is clogged.

Motor pump is worn or leaking.

Motor pump pressure relief valve is malfunctioning.

Discharge filter is clogged with foreign matter.

Reservoir strainer is clogged with foreign matter.

Valve spool for suspect function is clogged.

One of pilot operated check valves for suspect function is malfunctioning - not opening check valve or check valve is clogged.

One of orifices for suspect function is clogged with foreign matter (does not apply to column cylinder or floor lock cylinders).

Cylinder for suspect function is malfunctioning.

Column plates and wear pads are binding.

One of orifices for suspect function is missing ( NOTE: only applies to early units which have orifices external to cylinders.)

Check for foreign matter in valve spool.

Check for foreign matter on inside surfaces of outrigger floor lock cylinders.

Check for broken or bent components or foreign matter in pilot operated check valve.

Replace suspect motor pump with known working motor pump.

Replace suspect pressure relief valve with known working pressure relief valve.

_ Replace discharge filter.

Visually check reservoir strainer for excessive foreign matter.

Check for foreign matter in valve spool.

Check for broken or bent components or foreign matter in pilot operated check valve.

Remove orifice and check for foreign matter.

Replace suspect cylinder with known working cylinder.

Check for foreign matter, corrosion, nicks, scratches, or other damage to wear surfaces of column plates or wear pads.

Check for missing orifice. Replace orifice.

Remove valve spool and clean valve spool ports out. Replace valve spool component if necessary.

Disassemble and clean outrigger floor lock cylinders.

Remove pilot operated check valve components. Clean out any foreign matter. Replace any broken or bent components.

Replace motor pump. Refer to para 4.26 or 4.27.

Replace pressure relief valve and spring. Refer to para

4.29.

Refer to para 4.24. Replace reservoir strainer.

Refer to para 4.27.

Remove valve spool and clean valve spool ports out. Replace valve spool component if necessary.

Remove pilot operated check valve components. Clean out any foreign matter. Replace any broken or bent components.

Remove orifice and clean.

Replace malfunctioning cylinder.

Replace column plates or wear pads.

Page 2-14Printed in U.S.A.

Page 31

Problem Symptom Probable Cause Check Correction

One function's cylinder(s) is drifting.

One function is jerky when selected; all other functions operate properly.

Seat cylinders are not synchronized.

When COLUMN DOWN function is selected, table jerks downward.

The column function will not reach full height.

Head section does not operate properly.

Latching mechanism is not working correctly.

Table 2-1. Troubleshooting Guide

One function's cylinder drifts over time.

Function starts off with a jerky movement and then moves smoothly.

Seat board cracks during movement of function or noticeable difference in cylinder synchronization is noticed.

Function starts off with a jerky movement and then moves smoothly.

Column cylinder does not extend fully.

When release lever is squeezed, head section cannot be moved.

Head section drifts up or down without release lever being squeezed.

Section is not automatically captured by latching mechanism.

TESTING AND TROUBLESHOOTING

Valve spool for suspect function is malfunctioning stuck open.

One of pilot operated check valves for suspect function is malfunctioning - stuck open.

Hoses or tubes are leaking oil.

Valve spool for suspect function is malfunctioning stuck open allowing oil to drain from valve spool.

One of pilot operated check valves for suspect function is malfunctioning - stuck open, allowing oil to drain out of check valve.

Oil needs to be added or removed from the seat slave line.

Oil needs to be removed from the column slave line.

Oil needs to be added to the column slave line.

Release point of gas cylinder(s) in head section is out of adjustment.

Gas cylinder(s) is malfunctioning.

Release point of gas cylinder(s) in head section is out of adjustment.

Gas cylinder(s) is malfunctioning.

Latch spring pack assembly is malfunctioning.

Foreign matter is causing latch spring pack assembly to bind.

Latch handle is binding. Check for foreign matter

Check for foreign matter in valve spool.

Check for broken or bent components or foreign matter in pilot operated check valve.

Check for leaking oil. Replace hoses or tubes. If

Check for foreign matter in valve spool.

Check for broken or bent components or foreign matter in pilot operated check valve.

_ Adjust the oil volume in the

Check release point of gas cylinder(s).

Replace suspect gas cylinder with known working gas cylinder.

Check release point of gas cylinder(s).

Replace suspect gas cylinder with known working gas cylinder.

Check for broken spring in latch spring pack assembly.

Check for foreign matter build-up.

build-up.

SECTION II

Remove valve spool and clean valve spool ports out. Replace valve spool component if necessary.

Remove pilot operated check valve components. Clean any foreign matter. Replace any broken or bent components.

necessary add oil to slave line of function. Refer to para 4.7, or 4.8.

Remove valve spool and clean valve spool ports out. Replace valve spool component if necessary.

Remove pilot operated check valve components. Clean any foreign matter. Replace any broken or bent components.

seat slave line by performing seat cylinder synchronization procedure. Refer to para 4.6.

column slave line. Refer to para 4.7.

Adjust release point of gas cylinder(s). Refer to para

4.43. Replace gas cylinder(s).

Refer to para 4.43.

Adjust release point of gas cylinder(s). Refer to para

4.43. Replace gas cylinder(s).

Refer to para 4.43.

If necessary, replace latch spring pack assembly. Refer to para 4.45.

Remove latch spring pack assembly and clean components in latch spring pack assembly. Refer to para

4.45. Remove latch handle and

clean. Refer to para 4.45.

Page 2-15Printed in U.S.A.

Page 32

SECTION II TESTING AND TROUBLESHOOTING

Table 2-1. Troubleshooting Guide

Problem Symptom Probable Cause Check Correction

Seat section moves improperly during return to level function.

Seat section does not return to proper position when the "Level" button is pressed.

Screws securing seat position sensor are loose.

Check for loose screws. Tighten loose screws (if

necessary coat threads of screws with removable threadlocking adhesive (Loctite 242). Refer to para

4.19.

Page 2-16Printed in U.S.A.

Page 33

SECTION III

SCHEDULED MAINTENANCE

SECTION III

SCHEDULED MAINTENANCE

3.1 Scheduled Maintenance

Table 3-1 is a Scheduled Maintenance Chart which lists the inspections and services that should be performed

Table 3-1. Scheduled Maintenance Chart

Interval Inspection or Service What to Do

Semi-annually Obvious damage Visually check condition of surgical table for obvious damage such as: cracks in components,

missing components, dents in components, or any other visible damage which would cause surgical table to be unsafe to operate or would compromise its performance. Repair surgical table as necessary.

Fasteners / hardware Check surgical table for missing or loose fasteners/hardware. Replace any missing hardware and

tighten any loose hardware as necessary.

periodically on the surgical table. These inspections and services should be performed as often as indicated in the chart.

Warning and instructional decals

Pivot points/ moving parts/ accessories

Hydraulic hoses, tubes, and fittings

Hydraulic components Run all functions and check hydraulic components for proper operation. Check hydraulic

Column assembly Run column assembly all the way up and all the way down. Check if column cylinder "jumps"

Seat cylinders synchronization

Floor lock cylinders Check that floor lock cylinders extend fully and do not bind. If not, disassemble suspect floor lock

Casters Check that casters roll and swivel freely. If not, disassemble casters, clean, lubricate with

Hand control Operate all functions using hand control and check for malfunctions. All functions should move

Foot control Operate all functions possible using foot control. If foot control is not operating properly, replace

Emergency override panel

Latching mechanism Check latching mechansim for proper operation. Make sure a table section is automatically

Cushions Check for rips, tears, or excessive wear. Replace cushions as necessary. Accessories Check that all accessories have all of their components and that they function properly. If

Operational Test Perform an Operational Test to determine if the surgical table is operating within its specifications

Every Six Years Reservoir strainers Replace reservoir strainer for each pump unit. Refer to para 4.27.

Discharge Filter Replace discharge filter. Refer to para 4.24.

Check for missing or illegible decals. Replace decals as necessary.

Lubricate all exposed pivot points, moving parts, and accessories with silicone based lubricant.

Check all hydraulic hoses, tubes and fittings for leaks. Replace any components causing leaks. Replace and hoses or tubes with fraying, kinks, cuts, holes, or other damage.

cylinders for proper speed (Refer to Table 1-1). Clean or replace components as necessary.

downward with a loud noise when lowered from top height (oil volume too high in column cylinder slave line, resulting in overcompressed oil). Check if column cylinder raises table as high as it should - 43.9 in. (11.5 cm). If necessary, adjust oil level in column cylinder slave line. Refer to para 4.7. Check for binding or excessive sideways play in column assembly. Replace column assembly if necessary.

Remove seat section board and run seat function up and down. Use a straightedge to check if seat cylinders are synchronized. If not, synchronize seat cylinders. Refer to para 4.6.

cylinder, clean, lubricate with silicone based lubricant, and reassemble. Refer to para 4.25.

silicone based lubricant, and reassemble.

as depicted on hand control. When LEVEL button is pressed, table should return to level position ± 2°. If not, calibrate level position. Refer to para 4.3.

components as necessary. Operate all functions possible using emergency override panel. If all functions do not work,

replace components as necessary.

captured by latching mechanisms when inserted. If not, remove latching mechanism, clean, lubricate with silicone based luricant, and reassemble. Refer to para 4.45.

necessary, repair or replace the accessory.

(Refer to para 2.1). Replace or adjust any malfunctioning components.

Page 3-1Printed in U.S.A.

Page 34

SECTION III SCHEDULED MAINTENANCE

Page 3-2Printed in U.S.A.

Page 35

MAINTENANCE / SERVICE INSTRUCTIONS

OIL

CHECK

HOLE

1/16"

(1.6 mm)

(2.54cm)

4.1 Introduction DANGER

Refer to Operator Manual for complete instructions on operating

surgery table. Failure to do so could result in personal injury.

NOTE

Perform an operational test on surgery table after repair is completed to confirm repair was properly made and that

The following paragraphs contain removal, installation, repair, and adjustment procedures for surgery table.

all

malfunctions were repaired.

SECTION IV

MAINTENANCE / SERVICE

OIL

SMI

7100

4.2 Checking Oil Level / Adding Oil To

Reservoir

A. Checking / Adding Oil

(1 ) Lower TABLE DOWN function until column

assembly is fully retracted.

NOTE

Pressing LEVEL button on the hand control will accomplish following step.

(2 ) Using hand control or emergency override panel,

move Trendelenburg, seat, and lateral tilt functions until table top is level.

(3 ) Using the hand control or emergency override

panel, unlock the floor locks.

(4 ) Remove hole plug (1, Figure 4-1) from base

weldment (2). (5 ) Unscrew breather cap (3) from oil check hole. (6) Using a flashlight, check oil level. Oil should be

approximately 1 in. (2.54 cm) below top of oil

check hole opening, which is when oil just starts

to cover top of motor pump housing.

CA7617

Figure 4-1. Checking / Adding Oil

CAUTION

ISO Viscosity Grade 32 Premium Hydrau-

lic Fluid is only type of oil which can be used in hydraulic system of this table. Failure to do so could result in damage to hydraulic system.

(7) If oil level is low, insert a funnel into oil check

hole and add ISO Viscosity Grade 32 Premium Hydraulic Fluid until proper oil level, as de-

scribed in step 6, is reached. (8 ) Screw breather cap (3) into oil check hole. (9 ) Install hole plug (1) on base weldment (2).

Page 4-1Printed in U.S.A.

Page 36

SECTION IV MAINTENANCE / SERVICE

4.3 Calibration Of Return To Level / Neutral Position

A. Calibration

(1) Move table to a flat, level surface; then press

ENABLE button on hand control to engage floor locks.

(2 ) Using a protractor, check to make sure base of

table is level (± 1°) from front-to-rear and from side-to-side. See Figure 4-2.

TRENDELENBURG

ENABLE

LOCK

NORMAL

POSITION

TREND REV TREND

DISABLE

REVERSE

POSITION

REVERSE

TRENDELENBURG

(3 ) If installed, remove head section from back

section. (4) If installed, remove cushion from back section. (5 ) Place protractor at Position A; then using hand

control, move LATERAL TILT LEFT and

LATERAL TILT RIGHT functions until back

section is level (± 0.5 °) in side-to-side direction.

PROTRACTOR

POSITION

"A"

BACK

SECTION

LATERAL

TILT LEFT

HEIGHT UP

TILT L TILT R

SEAT UP SEAT DOWN

FLEX

HEIGHT DOWN

SMI

REFLEX

UNLOCKLEVEL

7300

LATERAL

TILT RIGHT

POSITION

"B"

SMI

ENABLE

SMI

LOCK

NORMAL

POSITION

TREND

HEIGHT UP

TILT L

SEAT UP SEAT DOWN

FLEX

DISABLE

REVERSE

POSITION

REV TREND

HEIGHT DOWN

TILT R

REFLEX

UNLOCKLEVEL

POSITION

"C"

TABLE

BASE

7100

0°

(+ / - 1°)

7300

0°

(+ / - 1°)

CA805800

Figure 4-2. Leveling Table Top

Page 4-2Printed in U.S.A.

Page 37

SECTION IV

MAINTENANCE / SERVICE

(6 ) Place protractor at Position B; then using hand

control, move TRENDELENBURG and REVERSE TRENDELENBURG functions until back section is level (± 0.5°) in front-to-rear direction.

(7 ) Place protractor at Position C; then using hand

control, move SEAT UP and SEAT DOWN functions until seat section is level (± 0.5°).

(8 ) Repeat steps 5 thru 7 to ensure all sections of

table top are properly leveled within ± 0.5°.

CAUTION

There are sixteen switch actuator plates

(4) in upper case. Use care when separating upper and lower case to prevent switch actuator plates from falling out and being lost.

(9 ) Remove six screws (1, Figure 4-3) and separate

upper case (2) from lower case (3).

(10) Remove sixteen switch actuator plates (4) from

upper case (2).

(11) Press ENABLE buttons; then within 10 sec-

onds, press the calibration button (display on hand control should read "CALIBRATING NEUTRAL POSITION").

ENABLE

LOCK

LEVEL

SMI

DISABLE

UNLOCK

CALIBRATION

BUTTON

ENABLE

BUTTONS

7100

CA7619

(12) Install sixteen switch actuator plates (4) in

upper case (2).

(13) Install lower case (3) on upper case (2) and

secure with six screws (1). (14) If removed, install cushion on back section. (15) If removed, install head section on back

section. See Figure 4-2.

Figure 4-3. Calibrating Neutral Position

Page 4-3Printed in U.S.A.

Page 38

SECTION IV MAINTENANCE / SERVICE

4.4 Hand Control Button Board Removal / Installation

A. Removal

(1 ) Disconnect hand control coil cord from table. (2 ) Remove six screws (1, Figure 4-4) and separate

upper case (2) from lower case (3).

(3 ) Remove sixteen switch actuator plates (4) from

upper case (2). (4 ) Remove four screws (5) from button board (6). (5 ) Carefully disconnect button board (6) from

connector of hand control board (7).

B. Installation

CAUTION

Use care when connecting button board

to hand control board so that pins of button board connector do not get bent or broken. Broken or bent pins will result in board malfunction.

(1 ) Carefully connect button board (6) to hand

control board (7).

ENABLE

LOCK

LEVEL

SMI

DISABLE

UNLOCK

7100

CA7620

(2 ) Secure button board (6) to hand control board

(7) with four screws (5).

(3) Install sixteen switch actuator plates (4) in

upper case (2).

(4 ) Install lower case (3) on upper case (2) and

secure with six screws (1).

(5 ) Connect hand control coil cord to table.

Figure 4-4. Button Board Removal / Installation

4.5 Hand Control Board Removal / Installation

A. Removal

(1 ) Remove hand control button board (Refer to

para 4.4).

(2 ) Tag and desolder seven wires (1, Figure 4-5)

from top side of hand control board (2).

(3 ) Tag and desolder one wire (3) from back side of

hand control board (2).

(4 ) Remove four screws (4) and standoffs (5) from

hand control board (2).

B. Installation

(1 ) Install four standoffs (5) on hand control board

(2) and secure with four screws (4).

Page 4-4Printed in U.S.A.

Page 39

SECTION IV

MAINTENANCE / SERVICE

4.6 Seat Cylinders Synchronization Procedure

CA7621

Figure 4-5. Hand Control Board

Removal / Installation

CAUTION

Use proper soldering techniques. Use a

rosin core solder with 60 - 40 mix. Use a heat sink to prevent damage to components on hand control board.

(2 ) Using a soldering iron, solder one wire (3) to

back side of hand control board (2).

(3 ) Using a solder iron, solder seven wires (1) to top

side of hand control board (2).

A. Synchronization of Cylinders

(1 ) If installed, remove section from RH (1, Figure

4-6) and LH (2) pins of pivot blocks at foot end.

NOTE

When seat function reaches level (neutral position), the function is stopped. This is not function's limit. Release button and repress it to continue moving to full up or down position.

(4 ) Using hand control, raise SEAT UP function all

the way up.

NOTE

Valve is located on patient's left side of table.

(5 ) Using a 14 mm socket and extension, unscrew

valve (3) approximately 1/2 turn, opening it.

NOTE

When seat function reaches level (neutral position), the function is stopped. This is not function's limit. Release button and repress it to continue moving to full up or down position.

(6 ) Using hand control, press SEAT DOWN button

to lower R.H. seat weldment (1) downward as far as it will go.

(7) Using a socket and extension, close valve (3)

by screwing it in until tight.

(8 ) Using hand control, press SEAT UP button to

raise L.H. seat weldment (2) upward as far as it will go.

(4 ) Install hand control button board (Refer to

para 4.4).

(9 ) Using a socket and extension, unscrew valve

(3) approximately 1/2 turn, opening it.

NOTE

When seat function reaches level (neutral position), the function is stopped. This is not function's limit. Release button and repress it to continue moving to full up or down position.

(10) Using hand control, press SEAT UP button to

raise R.H. seat weldment (1) upward as far as it will go.

Page 4-5Printed in U.S.A.

Page 40

SECTION IV

MAINTENANCE / SERVICE

STRAIGHT

EDGE

SEAT

ENABLE

LOCK

NORMAL

POSITION

TREND

HEIGHT UP

TILT L

SEAT UP SEAT DOWN

FLEX

SMI

DISABLE

REVERSE

POSITION

REV TREND

HEIGHT DOWN

TILT R

REFLEX

UNLOCKLEVEL

7300

END

VIEW

SEAT

DOWN

7100

Figure 4-6. Seat Cylinders Synchronization

(11) Using a socket and extension, close valve (3)

by screwing it in. Tighten valve (6) to 11 - 12.5 ft-lbs (15-17 N•m).

(12) Using hand control, use SEAT DOWN and

SEAT UP buttons to run seat weldments to their limits; then run R.H. (1) and L.H. (2) seat weldments to a level position.

(13) Use a straight edge, as shown in illustration, to

check synchronization of seat cylinders (R.H. seat weldment (1) should be even with L.H. seat weldment (2).

CA806200

NOTE

The R.H. seat cylinder is the adjustable cylinder. Use straight edge to see where R.H. seat weldment (1) is in relation to L.H. seat weldment (2); then perform following step to synchronize the right seat cylinder with the left seat cylinder.

During following step, only jog SEAT UP or SEAT DOWN functions a little at a time; it doesn't take much movement.

Page 4-6Printed in U.S.A.

Page 41

SECTION IV

MAINTENANCE / SERVICE

(14) If R.H. seat weldment (1) is too high in relation

to L.H. seat weldment (2), open valve (3), and press SEAT DOWN button on hand control to lower R.H. seat weldment.

If R.H. seat weldment (1) is too low in relation to L.H. seat weldment (2), open valve (3), and press SEAT UP button on hand control to raise R.H. seat weldment.

(15) Repeat steps 13 and 14 until R.H. seat weld-

ment (1) is even with L.H. seat weldment (2).

(16) If opened in step 14, use a socket and exten-

sion to close valve (3). Tighten valve (3) to 11 -

12.5 ft-lbs (15 - 17 N•m). (17) If removed, install leg section on table top. (18) Perform calibration of return to level / neutral

position (Refer to para 4.3).

4.7 Column Cylinder Slave Line Volume Adjustment

A. Volume Adjustment

(1 ) Using hand control, press TABLE UP button to

extend column assembly as high as it will go. See Figure 4-7.

DANGER

Tilt table sideways until weight of table

just starts to go "over center". Tilting table too far will put full weight of table on assistant. Table is very heavy and could cause serious back injury or table could get away from assistant, causing serious personal injury or damage to table.

NOTE

A tool for tipping table on side is available. See Table 1-2. Special Tools.

(2) With help of an assistant, tilt table toward left

until valve (1, Figure 4-7 ) can be accessed.

(3 ) Using a socket and extension, unscrew valve

(1) approximately 1/2 turn, opening it. (4 ) Lower table back onto floor. (5 ) Using hand control, press TABLE DOWN button

to lower column assembly downward as far as it

will go. (6 ) Using hand control, press TABLE UP button to

extend column assembly upward as far as it will

go.

CAUTION

Do not lower column assembly more than

1/16 in. (1.6 mm). Lowering column assembly more than 1/16 in. (1.6 mm) will reduce the maximum height capability of table. Not lowering column assembly at all leaves too much oil in slave line, resulting in over-compressed oil in slave line when column assembly is fully extended. Then, when column assembly is lowered, the over-compressed oil in slave line causes column cylinder to "jump" downward, making a noticeable noise and a noticeable jolting movement.

Page 4-7Printed in U.S.A.© Schaerer Mayfield USA, Inc. 2004

Page 42

SECTION IV

MAINTENANCE / SERVICE

(7 ) Using hand control, press TABLE DOWN button

to lower column assembly 1/32 to 1/16 in. (0.8 to 1.6 mm).

(8) With help of an assistant, tilt table over far

enough to access valve (1).

(9) Using a socket and extension, close valve (1).

Tighten valve (1) to 11-12.5 ft-lbs (15-17 N•m).

COLUMN

ASSEMBLY

(10) Using hand control, press TABLE UP and

TABLE DOWN buttons to run the column function all the way up and down. Check that column assembly does not jump downward when column assembly is lowered from a fully extended position. Check that maximum table height has not been compromised (Refer to Table 1-2 for specifications).

HEAD END

SMI

7300

ENABLE

LOCK

DISABLE

NORMAL

REVERSE

POSITION

TREND

POSITION

REV TREND

HEIGHT UP

HEIGHT DOWN

TILT L

TABLE

SEAT UP SEAT DOWN

FLEX

SMI

TILT R

REFLEX

UNLOCKLEVEL

7300

TABLE DOWN

CA806300

Figure 4-7. Column Cylinder Slave Line Volume Adjustment

Page 4-8Printed in U.S.A.

Page 43

SECTION IV

MAINTENANCE / SERVICE

4.8 Trendelenburg Cylinder Removal / Installation

A. Removal

(1 ) Support weight of table top with supports as

shown in Figure 4-8.

(2 ) Disconnect spring (1, Figure 4-8) from front

bridge cover (2).

(3 ) Remove two screws (3) and front bridge cover

(2) from seat weldments (4).

(4 ) Remove four screws (5) which secure column

covers (6) and upper column cover (7) to column assembly (8).

(5 ) Remove six screws (9), column covers (6), and

upper column cover (7) from column assem-

bly (8). (6 ) Tag two hoses (1, Figure 4-9). (7 ) Remove two fitting connectors (2), fitting seals

(3), and hoses (1) from trendelenburg cylin-

der (4). (8 ) Cut cable tie which secures two hoses (1) to

tube. (9 ) Remove two retaining rings (5) from cylinder

connecting pin (6).

Support

SMI

7300

CA806400

Figure 4-8. Covers Removal / Installation

Page 4-9Printed in U.S.A.

Page 44

SECTION IV MAINTENANCE / SERVICE

B. Installation

CABLE

TIE

CA762600

Figure 4-9. Trendelenburg Cylinder

Removal / Installation

DANGER

If weight of table top is not properly

supported, as described in step 1, before performing following steps, table top could fall when cylinder connecting pin is removed, causing serious personal injury or death to technician.

(1 ) Install pivot bracket (9, Figure 4-9) on

Trendelenburg cylinder (4) and secure with cylinder connecting pin (12).

(2 ) Secure cylinder connecting pin (12) in place by

tightening setscrew (11).

(3 ) Install pivot bracket (9) on pivot block (10) and

secure with four lockwashers (8) and screws (7). Tighten screws (7) to 51.6 ft-lbs (70 N•m).

(4 ) Coat o-rings on fitting connectors (2) and fitting

seals (3) with oil.

(5 ) Connect two hoses (1) to Trendelenburg cylinder

(4) and secure with fitting seals (3) and fitting connectors (2).

(6 ) Using hand control, extend or retract

Trendelenburg cylinder (4) until base of cylinder is aligned with bracket (13).

(7 ) Secure base of Trendelenburg cylinder (4) to

bracket (13) with cylinder connecting pin (6).

(8 ) Install two retaining rings (5) on cylinder con-

necting pin (6).

(9 ) Secure two hoses (1) to tube with cable tie.

(10) Using hand control, move table top until weight

of table top is no longer being supported by floor or supports.

(10) Using a hammer and punch, drive cylinder

connecting pin (6) out of trendelenburg cylinder (4).

(11) Remove four screws (7), lockwashers (8), and

pivot bracket (9) from pivot block (10). Remove

Trendelenburg cylinder (4) from table. (12) Loosen setscrew (11). (13) Using a hammer and punch, drive cylinder

connecting pin (12) out of pivot bracket (9), and

separate pivot bracket from Trendelenburg

cylinder (4).

(11) Install upper column cover (7, Figure 4-8) and

column covers (6) on column assembly (8) and secure with four screws (5).

(12) Secure column covers (6) together with six

screws (9).

(13) Install front bridge cover (2) on seat weldments

(4) and secure with two screws (3). (14) Connect spring (1) to front bridge cover (2). (15) Add oil to reservoir (Refer to para 4.2).

Page 4-10Printed in U.S.A.

Page 45

4.9 Trendelenburg Pilot Operated Check Valve Removal / Installation

A. Removal

(1 ) Support weight of table top with supports as

shown in Figure 4-10.

(2 ) Disconnect spring (1, Figure 4-10) from front

bridge cover (2).

SECTION IV

MAINTENANCE / SERVICE

DANGER

Make sure weight of table top is being

properly supported during following steps. When plugs are removed, hydraulic oil keeping Trendelenburg cylinder stationary, will no longer be constrained, allowing table top to lower. Failure to properly support table top could result in serious personal injury or death to technician.

(3 ) Remove four screws (3) which secures column

covers (4) and upper column cover (5) to column assembly (6).

(4 ) Remove six screws (7), column covers (4), and

upper column cover (5) from column assembly (6).

NOTE

The procedure to remove / install either pilot operated check valve is the same, with exception of an additional step for rod end input pilot operated check valve. The additional step is included in this procedure. Also, illustration shows removal / installation of both pilot operated check valves. Follow portion of art that applies.

Support

SMI

7300

CA806401

Figure 4-10. Covers Removal / Installation

Page 4-11Printed in U.S.A.

Page 46

SECTION IV MAINTENANCE / SERVICE

(5 ) Remove large plug (1, Figure 4-11) from mani-

fold (2).

(6 ) If removing pilot operated check valve which

affects input to base of Trendelenburg cylinder, remove small plug (A) from manifold (2); then proceed to step 8.

(7 ) If removing pilot operated check valve which

affects input to rod end of Trendelenburg cylinder, perform the following steps before proceeding to step 8:

a. Remove fitting connector (B), fitting seal (C),

and disconnect tube (D) from upper manifold (E).

CAUTION

There is an orifice in male connector (F).

Do not lose orifice or table speed will be affected.

c. Remove male connector (F) from mani-

fold (2).

(8 ) Using a long, thin needle nosed pliers, unscrew

guide shaft (3) and remove spring (4), washer (5), nylon washer (6), and check valve (7) from manifold (2).

(9 ) Using a small punch or Allen wrench, push pilot

piston (8) out of manifold (2).

b. Disconnect tube (D) from male con-

nector (F).

ROD END

INPUT PILOT

OPERATED

CHECK VAL VE

BASE INPUT PILOT

OPERATED CHECK VALVE

CA7628

(10) Remove spring (9) from manifold (2).

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry. Flush out manifold (2, Figure 4-11) using clean oil.

(2 ) Install nylon washer (6) and washer (5) on check

valve (7).

(3 ) Install assembled check valve (7) and spring (4)

in manifold (2) and secure with guide shaft (3).

CAUTION

Make sure guide shaft bottoms out.

Failure to do so will result in improper functioning of check valve. However, do not use excessive force on guide shaft to prevent damaging components.

(4 ) Using a long, thin needle nosed pliers, screw

guide shaft (3) inward until it bottoms out in manifold (2); then unscrew guide shaft two full turns.

(5 ) Install spring (9) and pilot piston (8) in mani-

fold (2).

(6 ) Using a punch or Allen wrench, push on pilot

piston (8) to ensure that it moves freely (approximately 1/8 in. (3.2 mm) travel).

Figure 4-11. Trendelenburg Pilot Operated

Check Valve Removal / Installation

(7 ) If installing pilot operated check valve which

affects input to base of Trendelenburg cylinder, coat o-ring of small plug (A) with oil; then install small plug in manifold (2). Then, go to step 9.

Page 4-12Printed in U.S.A.

Page 47

SECTION IV

ROD END

ORIFICE

MAINTENANCE / SERVICE

(8 ) If installing pilot operated check valve which

affects input to rod end of Trendelenburg cylinder, perform the following steps before proceeding to step 9:

a. Install male connector (F) in manifold (2). b. Connect tube (D) to male connector (F). c. Coat o-rings on fitting connector (B) and

fitting seal (C) with oil.

d. Connect tube (D) to upper manifold (E) with

fitting seal (C) and fitting connector (B).

(9 ) Coat o-ring on large plug (1) with oil. (10) Install large plug (1) in manifold (2). (11) Using hand control, move table top until weight

of table top is no longer being supported by floor or supports. See Figure 4-10.

(12) Install upper column cover (5, Figure 4-10) and

column covers (4) on column assembly (6) and secure with four screws (3).

4.10 Trendelenburg Cylinder Orifice(s) Removal / Installation

A. Removal

(1 ) Using hand control, raise TABLE UP function all

the way up

(2) Press in on both sides of second column cover

(1, Figure 4-12) until catch of second column cover is free from catch of top column cover (2). Lower second column cover (1) down out of way.

NOTE

The base orifice for Trendelenburg cylinder is nonremovable; it is built into the cylinder.

(13) Secure column covers (4) together with six

screws (7).

(14) Connect spring (1) to front bridge cover (2).

CATCH

SMI

7300

CA765101

Figure 4-12 Trendelenburg Cylinder Orifice(s)

Removal / Installation

Page 4-13Printed in U.S.A.

Page 48

SECTION IV

CA7630

TERMINALS

INNER

WHEEL

EDGE OF WHEEL WHICH

IS CENTER POINT

FA CES TOW ARD

TERMINALS

MAINTENANCE / SERVICE

(3 ) Remove fitting connector (3) and fitting seal (4)

which secures tube (5) to manifold (6). (4 ) Remove tube (5) from male connector (7). (5 ) Remove male connector (7) from manifold (8). (6 ) Using a sharp knife, pry orifice (9) from male

connector (7).

B. Installation

(1 ) Install male connector (7) in manifold (8). (2 ) Install orifice (9) in male connector (7), making

sure orifice is fully seated. (3 ) Connect tube (5) to male connector (7). (4 ) Coat o-rings of fitting seal (4) and fitting connec-

tor (3) with oil. (5 ) Connect tube (5) to manifold (6) and secure with

fitting seal (4) and fitting connector (3).

B. Installation

(1 ) Using terminals of Trendelenburg position

sensor (2) as a reference point, rotate inner wheel in clockwise and counterclockwise direction as far as it will go and then determine the center point of the inner wheel's rotation.

(2 ) Rotate the edge of the inner wheel which

represents the center point of the inner wheel, so it is facing terminals of Trendelenburg position sensor (2).

(3 ) Install spacer (4) and Trendelenburg position

sensor (2) on R.H. tilt bracket (5) and secure with two screws (3), making sure center point is not rotated.

(4 ) Connect three wires (1) to terminals of

Trendelenburg position sensor (2).

(5 ) Perform calibration of Return to Level / Neutral

Position Procedure (Refer to para 4.3).

(6) Press in on both sides of second column cover

(1); then raise second column cover until its

catch is above catch of top column cover (2).

Release second column cover.

4.11 Trendelenburg Position Sensor Removal / Installation

A. Removal

(1 ) Using emergency override panel, run

Trendelenburg function until back section of table top is within ±3° of level from front-to-rear.

(2 ) Using emergency override panel, run LATERAL

TILT LEFT function all the way to its limit.

(3 ) Tag and disconnect three wires (1, Figure 4-13)

from terminals of Trendelenburg position sensor (2).

(4 ) Remove two screws (3), Trendelenburg position

sensor (2), and spacer (4) from R.H. tilt bracket (5).

+/- 3°

7100

Figure 4-13. Trendelenburg Position

Sensor Removal / Installation

Page 4-14Printed in U.S.A.

Page 49

SECTION IV

MAINTENANCE / SERVICE

4.12 Lateral Tilt Cylinder Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-14), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weldments (4).

(4 ) Remove upper front bridge cover (8) by pulling it

out of two snap receptacles (9).

(5 ) Cover distribution board (1, Figure 4-15) with rag

to protect it from oil.

(6 ) Tag and disconnect hose (2) from male connec-

tor (3).

(7 ) Using a knife with a sharp point, pry orifice (4)

from male connector (3).

(8 ) Remove male connector (3) from lateral tilt

cylinder (5).

(9 ) Remove fitting connector (6), fitting seal (7),

and disconnect hose (8) from lateral tilt cylinder (5).

(10) Remove two locknuts (9) and washers (10 and

11) from two mounting studs (12).

(11) While supporting table top, remove lateral tilt

cylinder (5) from mounting studs (12).

(12) Remove brass spacer (13) from mounting

stud (12).

POST

RAG

CA7632

CA807500

Figure 4-15. Lateral Tilt Cylinder

Removal / Installation

Figure 4-14. Covers Removal / Installation

Page 4-15Printed in U.S.A.

Page 50

SECTION IV MAINTENANCE / SERVICE

B. Installation

(1 ) Install brass spacer (13, Figure 4-15) on mount-

ing stud (12).

NOTE

If necessary, move table by hand to align lateral tilt cylinder with mounting studs. Also, use socket to get swivel bearings of lateral tilt cylinder started on mounting studs; the socket helps prevent the swivel bearings from getting cocked.

(2 ) Install lateral tilt cylinder (5) on mounting studs

(12) and secure with washers (10 and 11) and two locknuts (9).

(3 ) Coat o-rings on fitting connector (6) and fitting

seal (7) with oil.

(4 ) Connect hose (8) to lateral tilt cylinder (5) and

secure with fitting seal (7) and connector bolt (6).

(5 ) Install male connector (3) on lateral tilt cylin-

der (5).

(6 ) Install orifice (4) in male connector (3), making

sure orifice is fully seated.

4.13 Lateral Tilt Orifice(s) Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-16), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weld- ments (4).

(4 ) Cover distribution board (1, Figure 4-17) with rag

to protect it from oil.

(5 ) If removing orifice which affects input to rod end

of lateral tilt cylinder, perform the following:

a. Disconnect hose (2) from male connec-

tor (3).

(7 ) Connect hose (2) to male connector (3). (8 ) Install upper front bridge cover (8, Figure 4-14)

by pressing two posts of front bridge cover into two snap receptacles (9).

(9 ) Install two cover gaskets (5) and bridge cover

(7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

(10) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(11) Install four plugs (1) on back section table

top (3).

(12) Add oil to reservoir (Refer to para 4.2).

CA807000

Figure 4-16. Covers Removal / Installation

Page 4-16Printed in U.S.A.

Page 51

SECTION IV

PORT

MAINTENANCE / SERVICE

b. Using a knife with a sharp point, pry orifice

(4) from male connector (3).

(6) If removing orifice which affects input to base of

lateral tilt cylinder, perform the following:

a. Disconnect hose (5) from swivel fitting (6). b. Loosen fitting connector (7) and then rotate

swivel fitting (6) so its port is facing downward.

c. Using a knife with a sharp point, pry orifice

(8) out of port of swivel fitting (6).

ROD END

ORIFICE

BASE END

ORIFICE

B. Installation

(1) If installing orifice which affects input to base of

lateral tilt cylinder, perform the following steps before proceeding to step 3:

a. Rotate swivel fitting (6, Figure 4-17) so its

port is facing toward hose (5); then tighten fitting connector (7).

b. Install orifice (8) in port of swivel fitting (6),

making sure orifice is fully seated.

c. Connect hose (5) to swivel fitting (6).

(2) If installing orifice which affects input to rod end

of lateral tilt cylinder, perform the following steps before proceeding to step 3:

a. Install orifice (4) in male connector (3),

making sure orifice is fully seated.

b. Connect hose (2) to male connector (3). (3 ) Remove rag from distribution board (1). (4 ) Install two cover gaskets (5, Figure 4-16) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

(5 ) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(6 ) Install four plugs (1) on back section table

top (3).

RAG

Figure 4-17. Lateral Tilt Orifices

Removal / Installation

CA7634

Page 4-17Printed in U.S.A.

Page 52

SECTION IV MAINTENANCE / SERVICE

4.14 Lateral Tilt Pilot Operated Check Valves Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-18), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weldments (4).

(4 ) Cover distribution board (1, Figure 4-19) with rag

to protect it from oil.

NOTE

Procedure to remove / install either pilot operated check valve is the same, with exception of an additional step for base input pilot operated check valve. The additional step is included in this procedure. Also, illustration shows removal / installation of both pilot operated check valves. Follow portion of art that applies.

CA807200

(5 ) Remove large plug (2) from manifold (3). (6 ) If removing pilot operated check valve which

affects input to rod end of lateral tilt cylinder, remove small plug (A) from manifold (3); then proceed to step 8.

(7 ) If removing pilot operated check valve which

affects input to base of lateral tilt cylinder, perform the following steps before proceeding to step 8:

a. Disconnect tube (B) from swivel fitting (C). b. Remove fitting connector (D), fitting seal (E),

and disconnect tube (B) from manifold (3).

(8 ) Using a long, thin needle nosed pliers, unscrew

guide shaft (4) and remove spring (5), washer (6), nylon washer (7), and check valve (8) from manifold (3).

(9 ) Using a small punch or Allen wrench, push pilot

piston (9) out of manifold (3).

Figure 4-18. Covers Removal / Installation

(10) Remove spring (10) from manifold (3).

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry. Flush out manifold (3, Figure 4-19) using clean oil.

(2 ) Install nylon washer (7) and washer (6) on check

valve (8).

(3 ) Install assembled check valve (8) and spring (5)

in manifold (3) and secure with guide shaft (4).

CAUTION

Make sure guide shaft bottoms out. Fail-

ure to do so will result in improper functioning of check valve. However, use caution as using excessive force on guide shaft will damage components.

Page 4-18Printed in U.S.A.

Page 53

SECTION IV

MAINTENANCE / SERVICE

BASE INPUT PILOT

OPERATED CHECK VALVE

(7 ) If installing pilot operated check valve which

affects input to rod end of lateral tilt cylinder, install small plug (A) in manifold (3); then proceed to step 9.

(8 ) If installing pilot operated check valve which

affects input to base of lateral tilt cylinder, perform the following steps before proceeding to step 9:

a. Coat o-rings of fitting connector (D) and

fitting seal (E) with oil.

b. Connect tube (B) to manifold (3) and secure

with fitting seal (E) and fitting connector (D).

c. Connect tube (B) to swivel fitting (C).

(9 ) Install large plug (2) in manifold (3).

ROD END INPUT PILOT

OPERATED CHECK VALVE

(10) Remove rag from distribution board (1). (11) Install two cover gaskets (5, Figure 4-19) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

RAG

Figure 4-19. Lateral Tilt Pilot Operated

Check Valve Removal / Installation

(4 ) Using a long, thin needle nosed pliers, screw

guide shaft (4) inward until it bottoms out in manifold (3); then unscrew guide shaft two full turns.

(5 ) Install spring (10) and pilot piston (9) in mani-

fold (3).

(6 ) Using a punch or Allen wrench, push on pilot

piston (9) to ensure that it moves freely (approximately 1/8 in. (3.2 mm) travel).

(12) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(13) Install four plugs (1) on back section table

top (3).

CA807300

Page 4-19Printed in U.S.A.

Page 54

SECTION IV

TERMINALS

INNER

WHEEL

EDGE OF

WHEEL WHICH

IS CENTER POINT

FA CES TOW ARD

TERMINALS

MAINTENANCE / SERVICE

4.15 Lateral Tilt Position Sensor Removal / Installation

A. Removal

NOTE

If necessary, cut cable ties and move hoses out of way.

(1 ) Remove four plugs (1, Figure 4-20), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weld- ments (4).

(4 ) Using emergency override panel, run lateral tilt

function until back section of table top is within ±3° of level from side-to-side. See Figure 4-21.

(5 ) Tag and disconnect three wires (1, Figure 4-21)

from terminals of lateral tilt position sensor (2).

(6 ) Remove two screws (3), lateral tilt position

sensor (2), and spacer (4) from rear cross member (5).

B. Installation

(1 ) Using terminals of lateral tilt position sensor (2,

Figure 4-21) as a reference point, rotate inner wheel in clockwise and counterclockwise direction as far as it will go and then determine the center point if the inner wheel's rotation.

CA807200

Figure 4-20. Covers Removal / Installation

( +/- 3°)

CA807400

Figure 4-21. Lateral Position

Sensor Removal / Installation

Page 4-20Printed in U.S.A.

Page 55

SECTION IV

MAINTENANCE / SERVICE

(2 ) Rotate the edge of the inner wheel which

represents the center point of the inner wheel, so it is facing terminals of lateral tilt position sensor (2).

(3 ) Install spacer (4) and lateral tilt position sensor

(2) on rear cross member (5) and secure with two screws (3), making sure center point does not get changed.

(4 ) Connect three wires (1) to terminals of lateral tilt

position sensor (2).

(5 ) Install any cable ties which were removed. (6 ) Perform calibration of return to level / neutral

position procedure (Refer to para 4.3).

(7 ) Install two cover gaskets (5, Figure 4-20) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

(8 ) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(9 ) Install four plugs (1) on back section table

top (3).

4.16 Seat Cylinder Removal / Installation

A. Removal

(1) If installed, remove Pelvic Base or any other

section from pins of pivot blocks on foot end.

(2 ) Remove four plugs (1, Figure 4-22), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(3 ) Carefully bend up lip of two cover gaskets (5)

and remove four screws (6).

(4 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weldments (4).

(5 ) Remove upper front bridge cover (8) by pulling it

out of two snap receptacles (9).

NOTE

It will be necessary to swing lateral tilt cylinder out of the way in order to use pin extractor to remove connecting pin.

POST

CA807500

Figure 4-22. Covers Removal / Installation

Page 4-21Printed in U.S.A.

Page 56

SECTION IV

HOLE

SCREWDRIVER

CRAFTSMAN

MAINTENANCE / SERVICE

(6 ) Depending on which seat cylinder is being

removed, remove locknut (1, Figure 4-23 ), and washer (2) from side of lateral tilt cylinder that is on same side of seat cylinder being removed. Swing cylinder up, out of way.

(7 ) Remove one hole plug (1, Figure 4-24) from side

weldment (2).

NOTE

If the seat function cannot be moved, disconnect hydraulic lines to allow manual extension of the cylinders.

EXTRACTOR

(8 ) Using hand control or emergency override panel,

run SEAT UP function until connecting pins (3) can be accessed.

(9 ) Loosen two setscrews (4) in side weldment (2).

(10) Using pin extractor, pull connecting pin (3) out

of side weldment (2). Refer to Table 1-2 for special tool.

Figure 4-23. Seat Cylinder

Disconnection / Connection

CA807600

Figure 4-24. Seat Cylinder

Disconnection / Connection

WARNING

Do not use small or weak screwdrivers to hold up seat spar weldment.

(11) Raise seat spar weldment (5) up by hand and

insert a screwdriver thru pin hole to hold in position.

Page 4-22Printed in U.S.A.

Page 57

SECTION IV

MAINTENANCE / SERVICE

(12) Remove hole plug (6) from side weldment (2). (13) Using pin extractor, remove pivot pin (7) from

side weldment (2). Refer to Table 1-2 for special tool.

(14) If removing R.H. seat cylinder, remove two

screws (1, Figure 4-25) and lower R.H. control valve assembly (2) out of side weldment (3).

If removing L.H. seat cylinder, remove two screws (A) and lower L.H. control valve assembly (B) out of side weldment (C).

NOTE

Cut cable ties as necessary for the following step.

(15) If removing R.H. seat cylinder, tag and discon-

nect three hoses (4) from fittings (5). If removing L.H. seat cylinder, tag and discon-

nect three hoses (D) from fittings (E).

NOTE

Because of tight fit, hoses may need to be pulled out before seat cylinder.

(16) Pull seat cylinder (1, Figure 4-26) out of side

weldment (2).

(17) If removing R.H. seat cylinder, perform the

following steps:

a. Tag three hoses (3).

d. Disconnect hose (E) from male connec-

tor (F).

e. Remove male connector (F) from L.H. seat

cylinder (D).

B. Installation

(1 ) If L.H. seat cylinder is being installed, perform

the following steps:

a. Install male connector (F, Figure 4-26) in

L.H. seat cylinder (D). b. Connect hose (E) to male connector (F). c. Coat o-rings of two fitting seals (C) and

fitting connectors (B) with oil. d. Connect two hoses (A) to L.H. seat cylinder

(D) with two fitting seals (C) and fitting

connectors (B). e. Secure hoses (A) together with a cable tie.

(2 ) If R.H. seat cylinder is being installed, perform

the following step:

a. Coat o-rings of three fitting seals (5) and

fitting connectors (4) with oil. b. Connect three hoses (3, Figure 4-26) to R.H.

seat cylinder (1) with three fitting seals (5)

and fitting connectors (4).

b. Cut cable tie securing three hoses (3)

together.

c. Remove three fitting connectors (4), fitting

seals (5) and hoses (3) from R.H. seat cylinder (1).

(18) If removing L.H. seat cylinder, perform the

following steps:

a. Tag two hoses (A, Figure 4-26). b. Cut cable ties securing hoses (A) together. c. Remove two fitting connectors (B), fitting

seals (C), and hoses (A) from L.H. seat cylinder (D).

c. Secure hoses (3) together with a cable tie.

(3 ) Position seat cylinder (1) in side weldment (2). (4) If installing L.H. seat cylinder, connect three

hoses (D, Figure 4-25) to fittings (E). If installing R.H. seat cylinder, connect three

hoses (4) to fittings (5).

(5) If installing L.H. seat cylinder, raise L.H. control

valve assembly (B) into side weldment (C) and secure with two screws (A).

If installing R.H. seat cylinder, raise R.H. control valve assembly (2) into side weldment (3) and secure with two screws (1).

Page 4-23Printed in U.S.A.

Page 58

SECTION IV MAINTENANCE / SERVICE

Figure 4-25. Hoses Disconnection / Connection

NOTE

Assure threaded hole in pivot pin(s) can be accessed through hole in side weldment when installing.

(6 ) Align base of seat cylinder (8, Figure 4-24) with

side weldment (2) and secure with pivot pin (7).

(7 ) Install hole plug (6) in side weldment (2). (8 ) Remove screwdriver and lower seat spar

weldment (5) down.

Page 4-24Printed in U.S.A.

Page 59

SECTION IV

MAINTENANCE / SERVICE

NOTE

Hand control may be used to run SEAT UP or SEAT DOWN function to help align seat section weldment with rod of seat cylinder.

(9 ) Align seat spar weldment (5) with rod of seat

cylinder (8) and secure with connecting pin (3), making sure flat surface of connecting pin is facing two setscrews (4) and threaded hole in pivot pin is accessible through hole in side weldment.

(10) Secure each connecting pin in place by tighten-

ing two setscrews (4). (11) Install hole plug (1) in side weldment (2). (12) Install back section table top (3, Figure 4-22)

on side weldment (4) and secure with four

screws (2). (13) Install four plugs (1) on back section table

top (3). (14) Install upper front bridge cover (8) by pressing

two posts of front bridge cover into two snap

receptacles (9). (15) Install two cover gaskets (5) and bridge cover

(7) on R.H. and L.H. side weldments (4); then

bend lip of cover gaskets back and install four

screws (6). (16) Add oil to reservoir (Refer to para 4.2). (17) Perform seat cylinder synchronization procedure

(Refer to para 4.6).

Figure 4-26. Seat Cylinder Removal / Installation

Page 4-25Printed in U.S.A.

Page 60

SECTION IV MAINTENANCE / SERVICE

4.17 Seat Cylinder Orifice(s) Removal / Installation

A. Removal

(1 ) Remove seat cylinder (Perform steps 1 thru 16

of para 4.16A).

NOTE

Orifice in L.H. seat cylinder is non-removable; it is built into cylinder.

(2 ) If removing orifice from R.H. seat cylinder,

perform the following steps:

a. Remove fitting connector (A, Figure 4-27)

and fitting seal (B) which secures tube (C) to R.H. seat cylinder (D).

b. Disconnect tube (C) from male connector (E)

and remove tube.

c. Remove male connector (E) from R.H. seat

cylinder (D).

ORIFICE REMOVAL

FROM R.H. SEAT

CYLINDER

PORT

ORIFICE REMOVAL

FROM L.H. SEAT

CYLINDER

d. Using a knife with a sharp point, pry orifice

(F) out of male connector (E).

B. Installation

(1 ) Install male connector (E) on R.H. seat cylinder

(D).

(2 ) Install orifice (F) in male connector (E), making

sure orifice is fully seated.

(3 ) Connect tube (C) to male connector (E). (4 ) Coat o-rings of fitting seal (B) and fitting con-

nector (A) with oil.

(5 ) Connect other end of tube (C) to R.H. seat

cylinder (D) with fitting seal (B) and fitting connector (A).

(6) Install seat cylinder (Perform steps 3 thru 19 of

para 4.16B).

(7 ) Add oil to reservoir (Refer to para 4.2).

CA7661

Figure 4-27. Orifice Removal / Installation

(8 ) Perform seat cylinder synchronization procedure

(Refer to para 4.6).

Page 4-26Printed in U.S.A.© Schaerer Mayfield USA, Inc. 2004

Page 61

SECTION IV

MAINTENANCE / SERVICE

4.18 Seat Cylinder Pilot Operated Check Valve Removal / Installation

A. Removal

(1 ) Remove seat cylinder (Perform steps 1 thru 16

of para 4.16).

(2 ) If removing pilot operated check valve which

affects input to rod end of seat cylinder, perform the following steps before proceeding to step 4:

a. Remove large plug (1, Figure 4-28) from

lower manifold (2).

b. Remove fitting connector (3) and fitting seal

(4) which connects tube (5) to upper manifold (6).

c. Disconnect tube (5) from male connector (7).

ADDITIONAL

COMPONENTS ON

BASE INPUT

PILOT OPERATED

CHECK VAL VE

L.H. CYLINDER

d. Remove male connector (7) from lower

manifold (2).

(3 ) If removing pilot operated check valve which

affects input to base of seat cylinder, perform the following steps before proceeding to step 4:

a. Remove small plug (A, Figure 4-28) from

lower manifold (2).

b. For R.H. seat cylinder, remove large plug (B)

from lower manifold (2). For L.H. seat cylinder, disconnect hose (C) from male connector (D); then remove male connector (D) and reduction fitting (E) from lower manifold (2).

(4 ) Using a long, thin needle nosed pliers, unscrew

guide shaft (8) and remove spring (9), washer (10), nylon washer (11), and check valve (12) from lower manifold (2).

(5 ) Using a small punch or Allen wrench, push pilot

piston (13) out of lower manifold (2).

(6 ) Remove spring (14) from lower manifold (2).

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry. Flush out lower manifold (2, Figure 4-28) using clean oil.

(2 ) Install nylon washer (11) and washer (10) on

check valve (12).

ROD END

INPUT PILOT

OPERATED

CHECK VAL VE

Figure 4-28. Seat Cylinder Pilot Operated

Check Valve Removal / Installation

(3 ) Install assembled check valve (12) and spring

(9) in lower manifold (2) and secure with guide shaft (8).

CAUTION

Make sure guide shaft bottoms out. Fail-

ure to do so will result in improper functioning of check valve. However, do not use excessive force on guide shaft to prevent damaging components.

(4 ) Using a long, thin needle nosed pliers, screw

guide shaft (8) inward until it bottoms out in

CA7662

lower manifold (2); then unscrew guide shaft two full turns.

(5 ) Install spring (14) and pilot piston (13) in lower

manifold (2).

Page 4-27Printed in U.S.A.

Page 62

SECTION IV MAINTENANCE / SERVICE

(6 ) Using a punch or Allen wrench, push on pilot

piston (13) to ensure that it moves freely (approximately 1/8 in. (3.2 mm) travel).

(7 ) If installing pilot operated check valve which

affects input to base of seat cylinder, perform the following steps before proceeding to step 9:

a. For R.H. seat cylinder, install large plug (B)

in lower manifold (2). For L.H. seat cylinder, install reduction fitting (E) and male connector (D) in lower manifold (2); then connect hose (C) to male connector (D).

b. Install small plug (A) in lower manifold (2).

(8 ) If installing pilot operated check valve which

affects input to rod end of seat cylinder, perform the following steps before proceeding to step 9:

a. Install male connector (7) in lower mani-

fold (2).

b. Connect tube (5) to male connector (7).

4.19 Seat Position Sensor Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-29), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weld- ments (4).

NOTE

The seat position sensor is located on the right hand side of the table in the R.H. side weldment.

(4 ) Remove screw (1, Figure 4-30) and cover (2)

from seat position sensor (3).

(5 ) Loosen setscrew (4).

c. Coat o-rings of fitting seal (4) and fitting

connector (3) with oil.

d. Connect tube (5) to upper manifold (6) with

fitting seal (4) and fitting connector (3).

e. Install large plug (1) in lower manifold (2).

(9) Install seat cylinder (Perform steps 3 thru 19 of

para 4.16). (10) Add oil to reservoir (Refer to para 4.2). (11) Perform seat cylinders synchronization proce-

dure (Refer to para 4.6).

CA807000

Figure 4-29. Covers Removal / Installation

Page 4-28Printed in U.S.A.© Schaerer Mayfield USA, Inc. 2004

Page 63

SECTION IV

MULTIMETER

LEADS

MAINTENANCE / SERVICE

2" (5 cm)

SHRINK WRAP

TUBING

(6.35mm)

INSULATION

1/4"

OUTER

(7.6 cm)

3/4"

(1.9 cm)

1/2" SHRINK

WRAP TUBING

OUTER

INSULATION

MATCH

MARK

INNER

WHEEL

(6) Pull seat position sensor (3) off of drive

shaft (5).

(7 ) Cut wire harness (6) approximately 3 in. (7.6

cm) from seat position sensor (3).

(8 ) If necessary, remove screw (7) and retainer

plate (8) from side weldment (9).

(9 ) If necessary, unscrew drive shaft (5) from pivot

shaft (10).

B. Installation

(1 ) Cut wire harness (6, Figure 4-30) of new seat

position sensor (3) approximately 3 in. (7.6 cm) from seat position sensor.

(2) Strip 3/4 in. (1.9 cm) of outer insulation off of

wires (11 and 12).

(3 ) Strip approximately 1/4 in. (6.35 mm) insulation

off of three wires (11) and three wires (12).

(4 ) Slide a 2 in" (5 cm) long piece of shrink wrap

tubing on outer insulation of three wires (12).

Figure 4-30. Seat Position Sensor

Removal / Installation

DRIVE

SHAFT

SET

SCREW

CA807800

(5 ) Slide a 1/2 in. (12.7 cm) piece of shrink wrap

tubing on each wire (12).

(6 ) Twist three wires (11) to three wires (12),

making sure the same colored wires are secured together.

NOTE

Use proper solder techniques and 60/40 resin core solder.

(7 ) Solder each wire connection together. (8 ) Slide each 1/2 in. piece of shrink wrap tubing

over bare connections of wires (11 and 12). Using a heat source, heat shrink wrap tubing until it has shrunk securely in place.

(9 ) Slide 2 in. piece of shrink wrap tubing over

smaller shrink wrap tubings. Using a heat source, heat shrink wrap tubing until it has shrunk securely in place.

(10) Coat threads of drive shaft (5) with removable

threadlocking adhesive (Loctite 242).

(11) Install drive shaft (5) on pivot shaft (10).

Page 4-29Printed in U.S.A.

Page 64

SECTION IV MAINTENANCE / SERVICE

(12) Coat screw (7) with removable threadlocking

adhesive (Loctite 242). (13) Install retainer plate (8) on side weldment (9)

and secure with screw (7). (14) Level entire table top (Perform steps 1 thru 9 of

para 4.3). (15) Install seat position sensor (3) on drive shaft

(5). Do not tighten setscrew (4) at this time.

CAUTION

Multimeter readings hand control / foot control disabled and

connector ST32

must

be disconnected from distribu-

tion board during the adjustment procedure.

(16) Attach one lead of multimeter to terminal 3 of

connector ST32 (connected to distribution

board) and the other lead to terminal 5 of

connector ST32. See Figure 4-31 or para 5-1. (17) Set multimeter to Kohms range.

SEAT POSITION

SENSOR

must

be taken with

(18) Rotate inner wheel of seat position sensor (3,

Figure 4-30) in a counterclockwise direction until multimeter reading is approximately 0 Kohm. Rotate inner wheel approximately one full turn until multimeter reading returns to 0 Kohm again, while observing multimeter to determine maximum Kohm reading just before reading returns to 0 Kohm (maximum reading should be 9 to 10 Kohms).

(19) Divide maximum Kohm reading by 2 to obtain

center of seat position sensor range (Max. Kohm ÷ 2 = center range Kohm).

(20) Rotate inner wheel until multimeter reading is

equal to center range value determined in step 19.

(21) Using a pen, matchmark inner wheel of position

sensor (3) to drive shaft (5), making sure matchmark line is drawn in line with setscrew (4).

(22) Remove seat position sensor (3) from drive

shaft (5). If a flat surface does not exist on drive shaft (5) at point where setscrew (4) will contact drive shaft, use a file to file a flat surface onto drive shaft.

CA805600

YELLOW

Figure 4-31

RED

GREEN

1 3 5

St32

(23) Install seat position sensor (3) on drive

shaft (5).

(24) Rotate inner wheel of seat position sensor (3)

until matchmarks on inner wheel and drive shaft (5) are aligned. Secure inner wheel in position by tightening setscrew (4).

(25) Disconnect multimeter leads from connector

ST32.

(26) Install two cover gaskets (5, Figure 4-29) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets

2 4 6

back and install four screws (6).

(27) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(28) Install four plugs (1) on back section table

top (3).

(29) Perform calibration of return to level / neutral

position (Refer to para 4.3).

Page 4-30Printed in U.S.A.

Page 65

SECTION IV

SPANNER

WRENCH (MO7236)

SPANNER

WRENCH (MO7235)

1 1

RETAINING

BOLT

(MO7407)

MAINTENANCE / SERVICE

4.20 Column Cylinder Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-32), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weld- ments (4).

(4) Lay table onto its side. (5 ) Disconnect spring (1, Figure 4-33) from rear

bridge cover (2).

(6 ) Remove two screws (3) and rear bridge cover

(2) from L.H. and R.H. side weldments (4).

CABLE

TIE

CA7666

Figure 4-33. Locking Nuts Removal / Installation

(7) Cut two cable ties securing hoses to cable tie

anchors (5).

CA807000

(8 ) Cut cable ties securing hoses together.

Figure 4-32. Covers Removal / Installation

NOTE

Propping table top up slightly will prevent oil from running out of top of column cylinder.

Page 4-31Printed in U.S.A.

Page 66

SECTION IV MAINTENANCE / SERVICE

(9 ) Remove fitting connector (6), hose (7), and two

fitting seals (8) from rod of column cylinder (9).

(10) Remove two screws (10) and retainer plate (11)

from column assembly (12).

(11) Install retaining bolt (M07407) onto rod of

column cylinder (9). Refer to Table 1-2 for special tool.

(12) While holding retaining bolt stationary, use large

spanner wrench (M07235) to remove locking nut (13) from column assembly (12). Refer to Table 1-2 for special tool.

NOTE

If necessary, use TABLE UP function to extend rod of column cylinder slightly for better access to brass pivot puck. Do not run TABLE DOWN function - oil will spray out of hose (7).

(13) While holding retaining bolt stationary, use small

spanner wrench (M07236) to remove brass pivot puck (14) from rod of column cylinder (9). Refer

to Table 1-2 for special tool. (14) Tag two hoses (1, Figure 4-34). (15) Remove two fitting connectors (2), four fitting

seals (3), and two hoses (1) from column

cylinder (4). Pull hoses down thru hose

opening. (16) Using a screwdriver, pry square column grom-

met (5) off of base weldment (6). (17) Remove four screws (7) securing bottom column

cover (8) to base weldment (6); then push

bottom column cover up out of way. (18) Loosen four locknuts (9) and remove two

casters (10) from caster forks (11). (19) Using access hole, remove screw (1, Figure 4-

35 and retaining plate (2) from cylinder connect-

ing pin (3). (20) Push cylinder connecting pin (3) out of column

weldment (4).

Figure 4-34. Access To Column Cylinder

(22) Remove retaining ring (6) and bearing (7) from

base of column cylinder (5).

(23) Using a wrench on flats of rod to hold rod

stationary, remove retaining bolt from rod.

B. Installation

(1 ) Using a wrench on flats of column cylinder (5,

Figure 4-35) rod to hold rod stationary, install retaining bolt on rod of column cylinder.

(21) Remove column cylinder (5) from column

weldment (4).

(2 ) Coat mating surfaces of bearing (7) and base of

column cylinder (5) with Lithium White grease.

Page 4-32Printed in U.S.A.

Page 67

SECTION IV

MAINTENANCE / SERVICE

RETAINING

BOLT

(MO7407)

FLATS

ROD

(8 ) Install square column grommet (5) by pressing

into place against base weldment (6).

(9 ) Pull hoses (1) up thru hose opening.

(10) Coat o-rings of four fitting seals (3) with oil. (11) Connect two hoses (1) to column cylinder (4)

with four fitting seals (3) and fitting connectors (2).

(12) Connect hose (7, Figure 4-33) to rod of column

cylinder (9) with two fitting seals (8) and fitting connector (6).

CAUTION

Use care when performing the following step to make sure rod extends

thru hole in column assembly and does not contact inside of column assembly.

(13) Use hand control to run TABLE UP function to

extend rod of column cylinder (9) until all threads can be seen above top of column assembly.

CA7668

Figure 4-35. Column Cylinder

Removal / Installation

(3 ) Install bearing (7) in base of column cylinder (5)

and secure with retaining ring (6).

(4 ) Install column cylinder (5) in column weldment

(4) and secure with cylinder connecting pin (3).

(5 ) Using access hole, secure cylinder connecting

pin (3) in place with retaining plate (2) and screw (1).

(6 ) Install one caster (10, Figure 4-34) on each

caster fork (11) and secure by tightening two locknuts (9).

(7 ) Push bottom column cover (8) down against

base weldment (6) and secure in this position with four screws (7).

(14) Remove fitting connector (6), hose (7), and two

fitting seals (8) from rod of column cylinder (9).

(15) Install retaining bolt. While holding retaining bolt

(M07407) stationary, use small spanner wrench (M07236) to install brass pivot puck (14) on rod of column cylinder (9). Refer to Table 1-2 for special tool. Tighten brass pivot puck until all threads are used up.

(16) Remove retaining bolt from rod of column

cylinder (9).

(17) Connect hose (7) to rod of column cylinder (9)

with two fittings seals (8) and fitting connector (6) and then retract rod of column cylinder using TABLE DOWN function on hand control, until brass pivot puck is firmly seated in column assembly (12).

(18) Remove fitting connector (6), hose (7), and two

fitting seals (8) from rod of column cylinder (9) and re-install retaining bolt.

(19) While holding retaining bolt stationary, use large

spanner wrench (M07235) to install locking nut (13) in column assembly (12). Refer to Table 1-2 for special tool.

Page 4-33Printed in U.S.A.

Page 68

SECTION IV MAINTENANCE / SERVICE

(20) Install retainer plate (11) on column assembly

(12) and secure with two screws (10).

(21) Remove retaining bolt (M07407) from rod of

column cylinder (9). (22) Coat two o-rings of fitting seals (8) with oil. (23) Connect hose (7) to rod of column cylinder (9)

with two fitting seals (8) and fitting connec-

tor (6). (24) Secure hoses together with cable ties. (25) Secure hoses to two cable tie anchors (5) with

cable ties. (26) Install rear bridge cover (2) on L.H. and R.H.

side weldments (4) and secure with two

screws (3). (27) Connect spring (1) to rear bridge cover (2). (28) Raise table to an upright position.

4.21 Column Pilot Operated Check Valve Removal / Installation

A. Removal

(1 ) Remove column cylinder (Refer to para 4.20). (2 ) Remove large plug (1, Figure 4-36) from mani-

fold (2).

(3 ) Remove small plug (3) from manifold (2). (4 ) Using a long, thin needle nosed pliers, unscrew

guide shaft (4) and remove spring (5), washer (6), nylon washer (7), and check valve (8) from manifold (2).

(5 ) Using a small punch or Allen wrench, push pilot

piston (9) out of manifold (2).

(6 ) Remove spring (10) from manifold (2).

(29) Install two cover gaskets (5, Figure 4-32) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

(30) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(31) Install four plugs (1) on back section table

top (3). (32) Add oil to reservoir (Refer to para 4.2). (33) Perform column cylinder slave line volume

adjustment procedure (Refer to para 4.6).

CA7669

Figure 4-36. Column Pilot Operated Check

Valve Removal / Installation

Page 4-34Printed in U.S.A.

Page 69

SECTION IV

MAINTENANCE / SERVICE

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry. Flush out manifold

(2) using clean oil.

(2 ) Install nylon washer (7) and washer (6) on check

valve (8).

(3 ) Install assembled check valve (8) and spring (5)

in manifold (2) and secure with guide shaft (4).

CAUTION

Make sure guide shaft bottoms out. Fail-

ure to do so will result in improper functioning of check valve. However, do not use excessive force on guide shaft to prevent damaging components.

(4 ) Using a long, thin needle nosed pliers, screw

guide shaft (4) inward until it bottoms out in manifold (2); then unscrew guide shaft two full turns.

4.22 Typical L.H. and R.H. Control Valve Solenoids Removal / Installation

A. Removal

NOTE

Removal of Trendelenburg (foot down) solenoid from L.H. control valve assembly is shown. Removal of other solenoids are the same.

(1 ) Remove two screws (1, Figure 4-37) and lower

R.H. or L.H. control valve assembly (2) down out of side weldment (3).

(2 ) Remove nut (4), cap (5), o-ring (6), and partially

remove solenoid (7) from solenoid mounting shaft (8).

(3 ) Remove solenoid gasket (9) from valve manifold

block (10).

(4 ) Loosen screw (11) and disconnect connector

plug (12) from solenoid (7).

(5 ) Install spring (10) and pilot piston (9) in

manifold (2).

(6)Using a punch or Allen wrench, push on pilot

piston (9) to ensure that it moves freely (approximately 1/8 in. (3.2 mm) travel).

(7 ) Install small plug (3) and large plug (1) in

manifold (2). (8 ) Install column cylinder (Refer to para 4.20). (9 ) Add oil to reservoir (Refer to para 4.2).

(10) Perform column cylinder slave line volume

adjustment procedure (Refer to para 4.6).

(5 ) Remove plug gasket (13) from solenoid (7).

B. Installation

(1 ) Install plug gasket (13) on solenoid (7). (2 ) Connect connector plug (12) to solenoid (7) and

secure by tightening screw (11).

(3 ) Install solenoid gasket (9) on valve manifold

block (10). (4 ) Coat o-ring (6) with a very light coat of oil. (5 ) Install solenoid (7) on solenoid mounting shaft

(8) and secure with o-ring (6), cap (5), and

nut (4). (6 ) Make sure speednuts (14) are aligned with

screw holes, then carefully push R.H. or L.H.

control valve assembly (2) up into side

weldment (3) and secure with two screws (1).

Page 4-35Printed in U.S.A.

Page 70

Figure 4-37. Control Valve Solenoids Removal / Installation

Page 4-36Printed in U.S.A.

Page 71

4.23 Typical Base Mounted Control Valve Solenoids Removal / Installation

(2 ) Remove six screws (1, Figure 4-38) and main

cover (2) from base weldment (3).

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side.

(3 ) Remove two screws (4), two screws (5),

mounting bracket (6), two spacers (7), and partially remove manifold assembly (8) from base weldment (3).

(4 ) Remove nut (9), cap (10), o-ring (11), and

partially remove solenoid (12) from solenoid mounting shaft (13).

9 17

COLUMN DOWN

ALL FLOOR LOCK (UNLOCK)

COLUMN UP

Figure 4-38. Control Valve Solenoids Removal / Installation

MAIN FLOOR

OUTRIGGER FLOOR LOCK (LOCK)

CA817000

HA5486-00

Page 4-37Printed in U.S.A.

Page 72

SECTION IV MAINTENANCE / SERVICE

(5 ) Remove solenoid gasket (14) from valve

manifold block (8).

(6 ) Loosen screw (15) and disconnect connector

plug (16) from solenoid (12).

(7 ) Remove plug gasket (17) from solenoid (12).

B. Installation

(1 ) Install plug gasket (17) on solenoid (12). (2 ) Connect connector plug (16) to solenoid (12)

and secure by tightening screw (15).

(3 ) Install solenoid gasket (14) on valve manifold

block (8).

(4 ) Coat o-ring (11) with a very light coat of oil. (5 ) Install solenoid (12) on solenoid mounting shaft

(13) and secure with o-ring (11), cap (10), and nut (9).

(6 ) Install manifold assembly (8) in base weldment

(3) and secure with two spacers (7), mounting bracket (6), two screws (5), and two screws (4).

(7 ) Install main cover (2) on base weldment (3) and

secure with six screws (1).

(8 ) Raise table to an upright position.

Page 4-38Printed in U.S.A.

Page 73

SECTION IV

MAINTENANCE / SERVICE

4.24 Discharge Filter Replacement

A . Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove six screws (1, Figure 4-39) and main

cover (2) from base weldment (3).

(3 ) Remove two screws (4), two screws (5),

mounting bracket (6), and partially remove control box (7) from base weldment (3).

(4 ) Remove two screws (8), two screws (9),

mounting bracket (10), two spacers (11), and partially remove manifold assembly (12) from base weldment (3).

(5 ) Remove fitting connector (13), fitting seal (14),

and tube assembly (15) from motor pump (16).

(6 ) Work tube assembly (15) around and pull tube

and discharge filter (17) out base weldment (3).

Figure 4-39. Discharge Filter Removal / Installation

CA817100

Page 4-39Printed in U.S.A.

Page 74

SECTION IV MAINTENANCE / SERVICE

(7 ) Disconnect tube assembly (15) from discharge

filter (17).

(8 ) Disconnect tube assembly (18) from discharge

filter (17) and remove discharge filter.

(9 ) Wrap discharge filter (17) in a cloth and then

place in a vise.

(10) Remove one male connector (1, Figure 4-40)

from each end of discharge filter (2).

B. Installation

(1 ) Install one male connector (1, Figure 4-40) on

each end of discharge filter (2).

(8 ) Install manifold assembly (12) on base

weldment (3) and secure with two spacers (11), mounting bracket (10), two screws (9), and two screws (8).

(9 ) Install control box (7) on base weldment (3) and

secure with mounting bracket (6), two screws (5), and two screws (4).

(10) Install main cover (2) on base weldment (3) and

secure with six screws (1). (11) Raise table to its upright position. (12) Add oil to reservoir (Refer to para 4.2).

HA5488-00

Figure 4-40. Filter Removal / Installation

(2 ) Remove discharge filter (17, Figure 4-39) from

vise.

(3 ) Connect tube assembly (18) to discharge

filter (17).

(4 ) Connect tube assembly (15) to discharge

filter (17).

(5 ) Position tube assembly (15) in base weld-

ment (3).

(6 ) Coat o-rings on fitting seal (14) and fitting

connector (13) with oil.

(7 ) Connect tube assembly (15) to motor pump (16)

and secure with fitting seal (14) and fitting connector (13).

Page 4-40Printed in U.S.A.

Page 75

SECTION IV

MAINTENANCE / SERVICE

4.25 Main Floor Lock or Outrigger Floor Lock Cylinder Removal / Installation

A. Removal

CAUTION

If floor locks are not unlocked (retracted),

there will be oil inside floor lock cylinders. Then, when hoses are disconnected, spring in floor lock will contract, spraying oil out of hose port.

(1 ) Using hand control or emergency override panel,

run UNLOCK function to unlock (retract) floor lock cylinders.

(2) Lay table onto its left side.

NOTE

Removal of one floor lock cylinder is shown. Removal of other floor lock cylinders are similar.

(3 ) Loosen two locknuts (1, Figure 4-41) and then

remove caster (2) from caster fork (3).

(7 ) Raise table to its upright position. (8 ) Add oil to reservoir (Refer to para 4.2).

(4 ) Remove jam nut (4). (5 ) Remove setscrew (5) and pull floor lock cylinder

(6) out of base weldment (7).

(6 ) Remove fitting connector (8), two fitting seals

(9), and hose (10) from floor lock cylinder (6) and then remove floor lock cylinder from table.

(7 ) Remove plug (11) from floor lock cylinder (6).

B. Installation

(1 ) Install plug (11) in floor lock cylinder (6). (2 ) Coat o-rings of two fitting seals (9) with oil. (3 ) Connect hose (10) to floor lock cylinder (6) and

secure with two fitting seals (9) and fitting connector (8).

(4 ) Install floor lock cylinder (6) in base weldment

(7) and secure with setscrew (5).

(5 ) Secure setscrew (5) in place with jam nut (4).

HA-5490-00

Figure 4-41. Floor Lock Cylinder

Removal / Installation

(6 ) Install caster (2) on caster fork (3) and secure

by tightening two locknuts (1).

Page 4-41Printed in U.S.A.

Page 76

SECTION IV MAINTENANCE / SERVICE

4.26 Motor Or Motor Pump Removal / Installation

A. Removal

(1 ) Remove hole plug (1, Figure 4-42) from base

weldment (2).

(2 ) Unscrew breather cap (3) from reservoir (4). (3 ) Install shipping plug in reservoir (4).

Figure 4-42. Shipping Plug Removal / Installation

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(4) Lay table onto its left side. (5 ) Remove five screws (1, Figure 4-43) and battery

cover (2) from base weldment (3).

CAUTION

If battery power is not disconnected,

there is a potential of shorting 24 VDC against the base weldment. If this happens, both the main controller board and charging / power driver board will probably be damaged.

(6 ) Disconnect four hot wires (4) from terminals of

batteries (5).

(7 ) Remove six screws (6) and main cover (7) from

base weldment (3).

(8 ) Remove two screws (1, Figure 4-44), two

screws (2), mounting bracket (3), and partially remove control box (4) from base weldment (5).

CA817300

Figure 4-43. Batteries Disconnection / Connection

(9 ) Remove two screws (6), two screws (7),

mounting bracket (8), two spacers (9), and partially remove manifold assembly (10) from base weldment (5).

(10) Remove fitting connector (11), fitting seal (12),

and tube assembly (13) from manifold of motor pump (14).

(11) Remove fitting connector (15), fitting seal (16),

and hose (17) from manifold of motor pump (14).

(12) Remove four screws (1, Figure 4-45), four

screws or nuts (2), and two mounting brackets (3) from base weldment (4).

(13) Pull tube assembly (5) w/ discharge filter toward

foot end of base weldment (4) until it is out of way.

Page 4-42Printed in U.S.A.

Page 77

SECTION IV

MAINTENANCE / SERVICE

CA817400

(14) Remove motor pump (6) from base weld-

ment (4).

(15) Unscrew caps (1, Figure 4-46 ) from electrical

fittings (2) on motor cover (3).

(16) Remove plastic plugs (4) and electrical fittings

(2) from motor cover (3).

(17) Remove four screws (5), lockwashers (6), motor

cover (3), and gasket (7) from manifold (8).

(18) Tag four wires (9); then remove two nuts (10),

lockwashers (11), and four wires (9) from two terminal posts of motor (12).

Figure 4-44. Access To Motor Pump

(19) Cut two cable ties and remove primary

thermosat (13) and secondary thermostat (14) from motor (12).

(20) Remove two screws (15), lockwashers (16), and

motor (12) from manifold (8).

B. Installation

(1 ) Install motor (12, Figure 4-46) on manifold (8)

and secure with two lockwashers (16) and screws (15).

(2 ) Position secondary thermostat (14) and primary

thermostat (13) on motor (12) and secure with two cable ties.

Page 4-43Printed in U.S.A.

Page 78

SECTION IV MAINTENANCE / SERVICE

(3 ) Feed wires (9) thru wire hole in motor cover (3).

Figure 4-45. Motor Pump Assembly

Removal / Installation

CA817500

(4 ) Install four wires (9) on two terminal posts of

motor (12) and secure with two lockwashers (11)

and nuts (10). (5) Coat gasket (7) with a light coat of oil. (6 ) Install gasket (7) on motor cover (3). (7 ) Install motor cover (3) on manifold (8) and

secure with four lockwashers (6) and

screws (5). (8 ) Screw electrical fitting (2) into motor cover (3). (9 ) Push plastic plug (4) into electrical fitting (2).

(10) Screw cap (1) onto electrical fitting (2). (11) Position motor pump (6, Figure 4-45) in base

weldment (4).

(12) Pull tube assembly (5) w/discharge filter back

into position in base weldment (4).

Figure 4-46. Motor Removal / Installation

Page 4-44Printed in U.S.A.

Page 79

SECTION IV

MAINTENANCE / SERVICE

(13) Secure motor pump (6) to base weldment (4)

with two mounting brackets (3), four screws nuts (2), and four screws (1).

(14) Coat o-rings on fitting seals (12 and 16, Figure

4-44) and fitting connectors (11 and 15) with oil.

(15) Connect hose (17) to manifold of motor pump

(14) with fitting seal (16) and fitting connector (15).

(16) Connect tube assembly (13) to manifold of

motor pump (14) with fitting seal (12) and fitting connector (11).

(17) Install manifold assembly (10) on base

weldment (5) and secure with two spacers (9), mounting bracket (8), two screws (7), and two screws (6).

(18) Install control box (4) on base weldment (5) and

secure with mounting bracket (3), two screws (2), and two screws (1).

(19) Install main cover (7, Figure 4-43) on base

weldment (3) and secure with six screws (6).

(20) Connect four hot wires (4) to terminals of

batteries (5).

(21) Install battery cover (2) on base weldment (3)

and secure with five screws (1). (22) Raise table to its upright position. (23) Remove shipping plug from reservoir

(4,Figure 4-42). (24) Add oil to reservoir (Refer to para 4.2).

4.27 Pump Unit Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 14 of para 4.26 A, Re-

moval.

(2 ) Place drain pan under shipping plug (See

Figure 4-47).

(3 ) Remove shipping plug from pump cover (1,

Figure 4-47) and allow all oil to drain into drain pan.

(4 ) Remove four screws (2), lockwashers (3), pump

cover (1), and gasket (4) from manifold (5).

(5 ) Remove two screws (6), lockwashers (7), pump

unit (8), o-ring (9), and o-ring (10) from mani-

fold (5). (6 ) Remove coupler (11) from motor shaft (12). (7 ) Remove filter assembly (13) from tube assem-

bly (14). Discard filter assembly. (8 ) Remove tube assembly (14) from pump

unit (8).

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry.

NOTE

The side of the pump unit (8) which does not have tube assembly (14) installed on it must have a plug installed. If not, remove plug from old pump unit and install in new pump unit.

(25) Screw breather cap (3) into reservoir (4). (26) Install hole plug (1) in base weldment (2).

(2 ) Install tube assembly (14, Figure 4-47 ) on

pump unit (8). (3 ) Install filter assembly (13) on tube assem-

bly (14). (4 ) Install coupler (11) on end of motor shaft (12). (5 ) Coat o-rings (9 and 10) with oil. (6 ) Install o-rings (9 and 10) on pump unit (8).

Page 80

SECTION IV MAINTENANCE / SERVICE

Figure 4-47. Pump Unit Removal / Installation

(7 ) Install pump unit (8) on manifold (5) and secure

with two lockwashers (7) and screws (6), making sure shaft of pump unit is mated with

coupler (12). (8 ) Coat gasket (4) with oil. (9 ) Install gasket (4) on pump cover (1).

(10) Install pump cover (1) on manifold (5) and

secure with four lockwashers (3) and screws (2).

(11) Install shipping plug in pump cover (1). (12) Perform steps 11 thru 25 of para 4.26 B,

Installation.

(13) Dispose of used oil in accordance with local

regulations.

Page 4-46Printed in U.S.A.

Page 81

4.28 Motor Pump Output Check Valve Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove six screws (1, Figure 4-48) and main

cover (2) from base weldment (3).

(3 ) Remove plug (1, Figure 4-49) from manifold (2). (4 ) Using a long, thin needle nosed pliers, unscrew

guide shaft (3) and remove spring (4), washer (5), nylon washer (6), and check valve (7) from manifold (2).

SECTION IV

MAINTENANCE / SERVICE

B. Installation

(1 ) Clean all metal components with degreasing

solution and allow to air dry. Flush out manifold (2, Figure 4-49) using clean oil.

(2 ) Install nylon washer (6) and washer (5) on check

valve (7).

(3 ) Install assembled check valve (7) and spring (4)

in manifold (2) and secure with guide shaft (3).

CAUTION

Make sure guide shaft bottoms out. Fail-

ure to do so will result in improper functioning of check valve. However, do not use excessive force on guide shaft to prevent damaging components.

(4 ) Using a long, thin needle nosed pliers, screw

guide shaft (3) inward until it bottoms out in manifold (2); then unscrew guide shaft two full turns.

Figure 4-48. Motor Pump Access

CA818000

(5 ) Install plug (1) in manifold (2). (6 ) Install main cover (2, Figure 4-48) on base

weldment (3) and secure with six screws (1).

(7 ) Raise table to its upright position.

Figure 4-49. Motor Pump Output Check

Valve Removal / Installation

Page 4-47Printed in U.S.A.

CA818100

Page 82

SECTION IV MAINTENANCE / SERVICE

4.29 Motor Pump Pressure Relief Valve Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove six screws (1, Figure 4-50) and main

cover (2) from base weldment (3).

NOTE

There are two pressure relief valves; one for motor pump #1 and one for motor pump #2. The procedure for removing pressure relief valves is the same. Procedure for installation is slightly different and is explained in the text.

(3 ) Remove cap (1, Figure 4-51) from adjusting

screw (2).

(4 ) Place a rag under port.

PRESSURE

RELIEF

VALVE FOR

PUMP #2

PRESSURE

RELIEF

VALVE FOR

PUMP #1

Figure 4-51. Motor Pump Pressure Relief

Valve Removal / Installation

CA818200

NOTE

Oil will run out of port when adjusting screw is removed. Plug port with clean rag or reinstall adjusting screw temporarily.

(5 ) Remove adjusting screw (2), spring seat (3),

spring (4), and check valve (5) from manifold (6).

Figure 4-50. Motor Pump Access

B. Installation

(1 ) Install spring (4, Figure 4-51) and check valve

(5) on spring seat (3).

(2 ) Install assembled spring seat (3) in manifold (6)

and secure with adjusting screw (2). Tighten

CA818000

Page 4-48Printed in U.S.A.

adjusting screw (2) only 1 to 1-1/2 turns.

(3 ) Disconnect tube (1, Figure 4-52) from swivel

fitting (2).

Page 83

SECTION IV

MAINTENANCE / SERVICE

Figure 4-52. Pressure Relief Valve Adjustment

(4 ) Disconnect hose (3) from swivel fitting (4).

CAUTION

Make sure 0 - 5000 PSI (0 - 344.8 BAR) gauge is installed and not 0 - 200 PSI

(0 - 13.8 BAR) gauge.

(5 ) Connect hose (A) of Test Gauge Assembly to

swivel fitting (2).

(6 ) Connect hose (B) of Test Gauge Assembly to

swivel fitting (4).

PRESSURE GAUGE

0-344.8 BAR

0-5000 PSI

If adjusting motor pump #2 pressure relief valve, use

emergency override panel

or SEAT DOWN function, while observing pressure gauge reading.

(10) Pressure gauge reading should be between 247

to 253 BAR (3581.5 to 3668.5 PSI). If pressure relief valve setting needs adjusted, go to step

11. If pressure relief valve setting does not need adjusted, go to step 15.

(11) Lay table onto its left side.

SHUTOFF VALVE HANDLE

CA818300

to run SEAT UP

(7) Close shutoff valve of Test Gauge Assembly. (8 ) Raise table to its upright position. (9 ) If adjusting motor pump #1 pressure relief valve,

use

hand control

DOWN function while observing pressure gauge reading.

to run SEAT UP or SEAT

(12) Open shutoff valve of Test Gauge Assembly to

allow oil pressure to dissipate; then close shutoff valve.

NOTE

Screwing adjusting screw inward raises pressure setting of pressure relief valve. Unscrewing adjusting screw lowers pressure setting of pressure relief valve.

Page 4-49Printed in U.S.A.

Page 84

SECTION IV MAINTENANCE / SERVICE

(13) Screw adjusting screw (5) inward or outward as

necessary (approximately 1/4 turn at a time).

(14) Repeat steps 8 thru 13 until pressure gauge

reading is between 247 to 253 BAR (3581.5 to

3668.5 PSI).

(15) Secure adjusting screw (5) in place with cap (6).

Then repeat steps 8 thru 13 one more time to ensure reading was not changed.

(16) Lay table onto its left side.

DANGER

There is high oil pressure in Test

Gauge Assembly. Failure to release pressurized oil, as instructed in following step, before removing Test Gauge Assembly will result in release of pressurized oil. This could result in serious personal injury.

(17) Open shutoff valve of Test Gauge Assembly to

allow oil pressure to dissipate.

(18) Disconnect hose (B) of Test Gauge Assembly

from swivel fitting (4).

(19) Disconnect hose (A) of Test Gauge Assembly

from swivel fitting (2).

4.30 Outrigger Pressure Relief Valve Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove six screws (1, Figure 4-53) and main

cover (2) from base weldment (3).

(3 ) Remove cap (1, Figure 4-54) from adjusting

screw (2).

(4 ) Place a rag under port.

NOTE

Oil will run out of port when adjusting screw is removed. Plug port with rag or reinstall adjusting screw temporarily.

(5 ) Remove adjusting screw (2), spring seat (3),

spring (4), and check valve (5) from manifold (6).

(20) Connect hose (3) to swivel fitting (4). (21) Connect tube (1) to swivel fitting (2). (22) Install main cover (2, Figure 4-50) on base

weldment (3) and secure with six screws (1).

(23) Raise table to its upright position.

CA818000

Figure 4-53. Access to Base Components

Page 4-50Printed in U.S.A.

Page 85

SECTION IV

MAINTENANCE / SERVICE

CAUTION

Make sure 0 - 200 PSI (0 - 13.8 BAR) gauge is installed and not 0 - 5000 PSI (0 -

344.8 BAR) gauge. (6 ) Connect hose (B) of Test Gauge Assembly to

male connector (2) (Port 12).

(7) Connect TEE of Test Gauge Assembly to

swivel fitting (4).

(8 ) Connect hose (A) of Test Gauge Assembly to

TEE of Test Gauge Assembly.

(9 ) Connect hose (3) to TEE of Test Gauge Assem-

bly.

CA818400

Figure 4-54. Outrigger Pressure Relief

Valve Removal / Installation

B. Installation

(1 ) Install spring (4, Figure 4-54) and check valve

(5) on spring seat (3).

(2 ) Install assembled spring seat (3) in manifold (6)

and secure with adjusting screw (2). Tighten adjusting screw (2) only 1 to 1-1/2 turns.

(3 ) Use hand control to UNLOCK floor lock cylin-

ders - otherwise, floor lock cylinder spring (which is under tension) will cause oil to spray during step 4.

PORT

(10) Close shutoff valve of Test Gauge Assembly. (11) Raise table to its upright position.

NOTE

The main floor lock function operates first, taking about 8 seconds, then the outrigger floor lock function operates second, for about six seconds. Observe the pressure gauge during the end of the six second period. Error code E01 will appear after this step because Outrigger Floor Lock status switch will not change its status, because R.H. side Outrigger floor lock cylinder will not extend since it has been disconnected.

(12) Using

(13) Pressure gauge reading should be 9 to 10 BAR

(14) Use emergency override panel to UNLOCK floor

(15) Lay table onto its left side.

hand control

observing pressure gauge reading.

(130.5 to 145.0 PSI). If pressure relief valve setting is correct, go to step 19. If pressure relief valve setting needs adjusted, go to step 14.

lock cylinders.

, run LOCK function while

(4 ) Disconnect hose (1, Figure 4-55) from male

connector (2).

(5 ) Disconnect hose (3) from swivel fitting (4).

(16) Open shutoff valve of Test Gauge Assembly to

allow oil pressure to dissipate; then close shutoff valve.

Page 4-51Printed in U.S.A.

Page 86

SECTION IV MAINTENANCE / SERVICE

TEE

PRESSURE GAUGE

0-13.8 BAR

0-200 PSI

Figure 4-55. Pressure Relief Valve Adjustment

NOTE

Screwing adjusting screw inward raises pressure setting of pressure relief valve. Unscrewing adjusting screw lowers pressure setting of pressure relief valve.

(17) Screw adjusting screw (5) inward or outward as

necessary (approximately 1/4 turn at a time).

(18) Repeat steps 10 thru 17 until pressure gauge

reading is 9 to 10 BAR (130.5 to 145.0 PSI).

(19) Secure adjusting screw (5) in place with cap

(6). Then repeat steps 10 thru 17 one more time to ensure reading was not changed.

(20) Lay table onto its left side.

SHUTOFF VALVE HANDLE

CA818500

DANGER

There is high oil pressure in Test

(21) Open shutoff valve of Test Gauge Assembly to

allow oil pressure to dissipate.

(22) Disconnect hose (A) of Test Gauge Assembly

from TEE of Test Gauge Assembly.

(23) Disconnect hose (3) from TEE of Test Gauge

Assembly.

(24) Disconnect TEE from swivel fitting (4). (25) Disconnect hose (B) of Test Gauge Assembly

from male connector (2).

Page 4-52Printed in U.S.A.

Page 87

SECTION IV

MAINTENANCE / SERVICE

(26) Connect hose (3) to swivel fitting (4). (27) Connect hose (1) to male connector (2). (28) Install main cover (2, Figure 4-53) on base

weldment (3) and secure with six screws (1). (29) Raise table to its upright position. (30) Check adjustment by LOCKING floor locks.

Outrigger floor lock cylinders should not raise

table off of ground (with leg section installed).

4.31 Main Controller Board Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove five screws (1, Figure 4-56) and battery

cover (2) from base weldment (3).

Figure 4-56. Control Box Removal / Installation

CA818600

Page 4-53Printed in U.S.A.

Page 88

SECTION IV MAINTENANCE / SERVICE

CAUTION

If battery power is not disconnected,

there is a potential of shorting 24 VDC against the base weldment. If this happens, both the main controller board and charging / power driver board will probably be damaged.

(8 ) Remove two screws (7) and lockwashers (8)

from main controller board (6).

(9 ) Remove two screws (9) and main controller

board (6) from control box (3).

B. Installation

(3 ) Disconnect four hot wires (4) from terminals of

batteries (5).

(4 ) Remove six screws (6) and main cover (7) from

base weldment (3).

(5 ) Remove two screws (8), two screws (9),

mounting bracket (10), and partially remove control box (11) from base weldment (3).

(6 ) Loosen four captive screws (1, Figure 4-57) and

separate cover (2) from control box (3).

(7 ) Tag and disconnect seven wire harnesses (4)

and wire (5) from main controller board (6).

NOTE

Assure two dip switches ( #1 & #2 ) on Main Controller Board (6, Figure 4-57) are both in

(1 ) Coat threads of two screws (7, Figure 4-57) and

two screws (9) with hydraulic sealant (Loctite

569).

(2 ) Install main controller board (6) in control box (3)

and secure with two screws (9), two lockwashers (8), and screws (7).

(3 ) Connect wire (5) and seven wire harnesses (4)

to main controller board (6).

(4 ) Install cover (2) on control box (3) and secure

by tightening four captive screws (1), making sure no wires are being pinched by cover.

(5 ) Position control box (11, Figure 4-56) in base

weldment (3) and secure with mounting bracket (10), two screws (9), and two screws (8).

(6 ) Install main cover (7) on base weldment (3) and

secure with six screws (6).

OFF

position.

Figure 4-57. Main Controller Board

Removal / Installation

(7 ) Connect four hot wires (4) to terminals of

batteries (5).

(8 ) Install battery cover (2) on base weldment (3)

and secure with five screws (1).

(9 ) Raise table to its upright position.

(10) Perform calibration of return to level / neutral

position (Refer to para 4.3).

HA5485-00

Page 4-54Printed in U.S.A.

Page 89

4.32 Charging / Power Driver Board Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side.

DANGER

Make sure power cord is unplugged

before working on table. Failure to do so could result in electrical shock which could cause serious personal injury or death.

(2 ) Unplug power cord from table.

SECTION IV

MAINTENANCE / SERVICE

(3 ) Remove five screws (1, Figure 4-58) and battery

cover (2) from base weldment (3).

CAUTION

If battery power is not disconnected,

there is a potential of shorting 24 VDC against the base weldment. If this happens, both the main controller board and charging / power driver board will probably be damaged.

(4 ) Disconnect four hot wires (4) from terminals of

batteries (5).

(5 ) Loosen two locknuts (6) and remove caster (7)

from caster fork (8).

(6 ) Remove two screws (9) and cover (10) from

base weldment (3).

(7 ) Loosen four captive screws (11) and separate

box cover (12) from electrical box (13).

(8 ) Using a 3mm Allen Wrench, remove two or four

screws (1, Figure 4-59) and partially two remove electrical box (2) from base welent (3).

(9 ) Tag and disconnect three wire harnesses (4)

from charging / power driver board (5).

(10) Tag and disconnect six wires (6) from charging /

power driver board (5).

Figure 4-58. Electrical Box Access

(11) Remove two screws (7) from charging / power

driver board (5).

(12) Remove two screws (8), lockwashers (9), and

charging / power driver board (5) from electrical box (2).

B. Installation

(1 ) Coat threads of two screws (7, Figure 4-59)

and two screws (8) with hydraulic sealant (Loctite 569).

HA5502-00

Page 4-55Printed in U.S.A.

Page 90

SECTION IV MAINTENANCE / SERVICE

(4 ) Connect three wire harnesses (4) to charging /

power driver board (5).

(5 ) Install electrical box (2) on base weldment (3)

and secure with two or four screws (1).

(6 ) Install box cover (12, Figure 4-58) on electrical

box (13) and secure by tightening four captive screws (11).

(7 ) Install cover (10) on base weldment (3) and

secure with two screws (9).

(8 ) Install caster (7) on caster fork (8) and secure

by tightening two locknuts (6).

(9 ) Connect four hot wires (4) to terminals of

batteries (5).

(10) Install battery cover (2) on base weldment (3)

and secure with five screws (1).

(11) Raise table to its upright position.

Figure 4-59. Charging / Power Driver Board

Removal / Installation

(2 ) Install charging / power driver board (5) in

electrical box (2) and secure with two lockwashers (9), screws (8), and two screws (7).

(3 ) Connect six wires (6) to charging / power driver

board (5).

HA5503-00

Page 4-56Printed in U.S.A.

Page 91

4.33 Emergency Override Panel Removal / Installation

A. Removal

(1 ) Raise cover (1, Figure 4-60) up out of way.

NOTE

One of the spring retainers must be depressed in order to remove Emergency Override Panel.

(2 ) Insert a small allen wrench or equivalent in one

of the access holes (2) on side of mounting panel weldment (3).

(3 ) Insert a thin, straight blade screwdriver, on the

same side as the allen wrench, in the notched out section (4) on the switch plate assembly (5).

SECTION IV

MAINTENANCE / SERVICE

CAUTION

Pull switch plate mounting panel out carefully. Pulling quickly could

damage emergency override board or connector.

(4 ) While pushing in on the allen wrench to depress

the spring retainer, carefully pry upward on the switch plate assembly (5).

(5 ) Disconnect wire harness (6) from emergency

override board (7).

NOTE

Place the switch plate assembly face down to prevent the switch actutor plates from falling out when removing the emergency override board.

(6 ) Place switch plate assembly (5) face down and

remove eight mounting screws (8), then remove emergency override board (7).

B. Installation

NOTE

Assure all switch actuator plates are in place before installing emergency override board.

Figure 4-60. Emergency Override Board

Removal / Installation

(3 ) Carefully install switch plate assembly (5) onto

table, pressing down on switch plate assembly until it snaps securely in place.

(4 ) Lower cover (1) down to closed position.

(1 ) Install emergency override board (7) on switch

and secure with eight screws (8).

(2 ) Connect wire harness

Page 4-57Printed in U.S.A.

Page 92

SECTION IV

LOCKING

TAB

MAINTENANCE / SERVICE

4.34 Distribution Board Removal / Installation

A. Removal

(1 ) Remove four plugs (1, Figure 4-61), four screws

(2), and back section table top (3) from R.H. and L.H. side weldments (4).

(2 ) Bend lip of two cover gaskets (5) and remove

four screws (6).

(3 ) Remove bridge cover (7) and two cover gaskets

(5) from R.H. and L.H. side weld- ments (4).

(4 ) Cut any cable ties which are holding wire

harnesses in place around distribution board (1, Figure 4-62).

(5 ) Disconnect wire (2) from terminal of distribution

board (1).

(6 ) Disconnect four wire harnesses (3) from front

terminals of distribution board (1).

CABLE

TIE

CA807000

Figure 4-61. Covers Removal / Installation

CA818800

Figure 4-62. Distribution Board

Removal / Installation

(7 ) Tag and disconnect seven wire harnesses (4)

from middle terminals of distribution board (1).

(8 ) Tag and disconnect one wire harness (5) from

rear terminals of distribution board (1).

(9 ) While pressing in on locking tab of standoff (6),

raise that corner of distribution board (1) past locking tab.

(10) Repeat step 9 for three remaining standoffs (6)

and then remove distribution board (1) from standoffs (6).

(11) Remove four screws (7) and four cable tie

standoff assemblies (8) from distribution board (1).

Page 4-58Printed in U.S.A.

Page 93

SECTION IV

MAINTENANCE / SERVICE

(12) If broken, remove standoffs (6) from pivot block

(9) by unscrewing them.

B. Installation

(1 ) If removed, install standoffs (6, Figure 4-62) on

pivot block (9).

(2 ) Install four cable tie standoff assemblies (8) on

distribution board (1) and secure with four screws (7).

(3 ) Install distribution board (1) on four standoffs

(6). Push down on corners of distribution board until locking tabs of standoffs pop back outward, locking distribution board in place.

(4 ) Connect one wire harness (5) to rear terminals

of distribution board (1).

(5 ) Connect seven wire harnesses (4) to middle

terminals of distribution board (1).

(6 ) Connect four wire harnesses (3) to front termi-

nals of distribution board (1).

4.35 RFI Filter Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side.

DANGER

Make sure power cord is unplugged

before working on table. Failure to do so could result in electrical shock which could cause serious personal injury or death.

(2 ) Unplug power cord from table. (3 ) Remove five screws (1, Figure 4-63) and battery

cover (2) from base weldment (3).

(4 ) Loosen two locknuts (4) and remove caster (5)

from caster fork (6).

(7 ) Connect one wire (2) to terminal of distribution

board (1).

(8 ) Secure wire and wire harnesses to cable tie

standoff assemblies (8) with cable ties.

(9 ) Install two cover gaskets (5, Figure 4-61) and

bridge cover (7) on R.H. and L.H. side weldments (4); then bend lip of cover gaskets back and install four screws (6).

(10) Install back section table top (3) on R.H. and

L.H. side weldments (4) and secure with four screws (2).

(11) Install four plugs (1) on back section table

top (3).

(5 ) Remove jam nut (7). (6 ) Remove setscrew (8) and partially pull floor lock

cylinder (9) out of base weldment (3).

(7 ) Remove two screws (10) and partially remove

bracket assembly (11) from base weldment (3).

(8 ) Tag and disconnect two wires (1, Figure 4-64)

and three wire groups (2) from terminals of RFI filter (3).

(9 ) Remove two locknuts (4) and RFI filter (3) from

bracket assembly (5).

B. Installation

(1 ) Install RFI filter (3, Figure 4-64) on bracket

assembly (5) and secure with two locknuts (4).

(2 ) Connect three wire groups (2) and two wires (1)

to terminals of RFI filter (3).

(3 ) Install bracket assembly (11, Figure 4-63) on

base weldment (3) and secure with two screws (10).

Page 4-59Printed in U.S.A.

Page 94

SECTION IV MAINTENANCE / SERVICE

Figure 4-64. RFI Filter Removal / Installation

(7 ) Install battery cover (2) on base weldment (3)

and secure with five screws (1).

(8 ) Raise table to its upright position.

HA5512-00

Figure 4-63. RFI Filter Access

(4 ) Install floor lock cylinder (9) on base weldment

(3) and secure with setscrew (8). (5 ) Secure setscrew (8) in place with jam nut (7). (6 ) Install caster (5) on caster fork (6) and secure

by tightening two locknuts (4).

HA5504-00

Page 4-60Printed in U.S.A.

Page 95

SECTION IV

MAINTENANCE / SERVICE

4.36 Transformer Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 7 of para 4.32A (removing

charging / power driver board). (2 ) Perform steps 1 thru 7 of para 4.35A (removing

RFI filter). (3 ) Tag and disconnect two wire harnesses (1,

Figure 4-65) from RFI filter (2). (4 ) Remove two screws (3) and cover (4) from base

weldment (5). (5 ) Remove screw (6), washer (7), and partially

remove transformer (8) from base weld-

ment (5). (6 ) Disconnect connector (9) from charging / power

driver board (10). (7 ) Tag four wires (11). Press on release tabs and

pull four wires (11) from connector (9).

B. Installation

(1 ) Secure four wires (11,Figure 4-65) together

using cable ties. (2 ) Connect "fish wire" to ends of four wires (11). (3 ) Using "fish wire", pull four wires thru Slot A and

B in base weldment (5). (4 ) Disconnect four wires (11) from "fish wire". Pull

"fish wire" out of base weldment (5). (5 ) Install wire cap (12) and seal (14) on four wires

(11). (6 ) Feed four wires (11) thru electrical fitting (13). (7 ) Press on release tabs of connector (9) and

insert four wires into connector. (8 ) Connect connector (9) to charging / power driver

board (10). (9 ) Screw wire cap (12) onto electrical fitting (13).

(8 ) Remove wire cap (12) from electrical fit-

ting (13).

(9 ) Pull four wires (11) thru electrical fitting (13).

(10) Remove wire cap (12) and seal (14) from four

wires (11).

NOTE

If step 11 is not successful, removal of motor pump is necessary. Refer to para 4.26.

(11) Attach a "fish wire" to ends of four wires (11);

then pull four wires out of Slots B and A in base weldment (5).

(12) Disconnect four wires (11) from "fish wire",

making sure "fish wire" remains in base

weldment (5) to assist in installation. (13) Cut cable ties securing four wires (11) together. (14) Remove transformer (8).

(10) Connect two wire harnesses (1) to terminals of

RFI filter (2).

(11) Install transformer (8) on base weldment (5) and

secure with washer (7) and screw (6).

(12) Install cover (4) on base weldment (5) and

secure with two screws (3).

(13) Perform steps 3 thru 7 of para 4.35B (installing

RFI filter).

(14) Perform steps 6 thru 10 of para 4.32B (installing

charging / power driver board).

(15) Raise table to its upright position.

Page 4-61Printed in U.S.A.

Page 96

SECTION IV MAINTENANCE / SERVICE

RELEASE

T ABS

SLOT "B"

SLOT "A"

Figure 4-65. Transformer Removal / Installation

Page 4-62Printed in U.S.A.

HA5505-00

Page 97

SECTION IV

MAINTENANCE / SERVICE

4.37 Line Power Pilot Lamp Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 7 of para 4.35A (removing

RFI filter).

(2 ) Disconnect two wires (1, Figure 4-66) from

terminals of line power pilot lamp (2).

(3 ) Remove line power pilot lamp (2) from bracket

assembly (3).

B. Installation

(1 ) Push line power pilot lamp (2) into bracket

assembly (3).

(2 ) Connect two wires (1) to terminals of line power

pilot lamp (2).

(3 ) Perform steps 3 thru 8 of para 4.35B (installing

RFI filter).

4.38 Plug Receptacle Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 7 of para 4.35A (removing

RFI filter).

(2 ) Tag and disconnect three wires (1, Figure 4-67)

from terminals of plug receptacle (2).

(3 ) Depress two locking tabs and remove plug

receptacle (2) from bracket assembly (3).

B. Installation

(1 ) Push plug receptacle (2) into bracket assembly

(3) until it "snaps" into place.

(2 ) Connect three wires (1) to terminals of plug

receptacle (2).

(3 ) Perform steps 3 thru 8 of para 4.35B (installing

RFI filter).

Figure 4-66. Line Power Pilot Lamp

Removal / Installation

HA5506-00

LOCKING

TAB

Figure 4-67. Plug Receptacle Removal / Installation

HA5507-00

Page 4-63Printed in U.S.A.

Page 98

SECTION IV MAINTENANCE / SERVICE

4.39 Batteries Removal / Installation

A. Removal

DANGER

Table is very heavy. Use an assistant to lay table onto its side. Failure to do

so could result in serious personal injury.

(1) Lay table onto its left side. (2 ) Remove five screws (1, Figure 4-68) and battery

cover (2) from base weldment (3).

(3 ) Pull on both ends of pull strap (4) until terminals

of four batteries (5) can be accessed.

(4 ) Tag and disconnect eight wires (6) from termi-

nals of four batteries (5).

(5 ) Remove four batteries (5) from base weld-

ment (3).

B. Installation

(1 ) Position pull strap (4, Figure 4-68) in base

weldment (3).

(2 ) Install four batteries (5) in base weldment (3).

Do not push batteries all the way in base weldment so terminals are not accessible.

(3 ) Connect eight wires (6) to terminals of four

batteries (5).

(4 ) Push four batteries (5) into base weldment (3)

fully.

(5 ) Install battery cover (2) on base weldment (3)

and secure with five screws (1).

(6 ) Raise table to its upright position.

HA5508-00

Figure 4-68. Batteries Removal / Installation

Page 4-64Printed in U.S.A.

Page 99

SECTION IV

MAINTENANCE / SERVICE

4.40 Primary Thermostat Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 17 of para 4.26A (removing

motor pump).

(2 ) Remove nut (1, Figure 4-69), lockwasher (2),

and three wires (3) from terminal post of motor (4).

(3 ) Remove shrink wrap tubing and then desolder

wire of primary thermostat (5) from wire (6).

(4 ) Cut two cable ties and remove primary thermo-

stat (5) from motor (4).

B. Installation

(1 ) Slide a 3/4" piece of shrink wrap tubing on wire

of primary thermostat (5).

NOTE

Use proper solder techniques and 60/40 resin core solder.

(2 ) Solder wire of primary thermostat (5) to

wire (6).

(3 ) Slide shrink wrap tubing over bare wire; then

use a heat source to shrink the tubing firmly into place.

(4 ) Install three wires (3) on terminal post of motor

(4) and secure with lockwasher (2) and nut (1).

(5 ) Position primary thermostat (5) and secondary

thermostat (7) on motor (4) and secure with two cable ties.

(6 ) Perform steps 5 thru 25 of para 4.26B (installing

motor pump).

3/4" PIECE OF

SHRINK WRAP

TUBING

CABLE

TIES

TERMINAL

POST

Figure 4-69. Primary Thermal Fuse

Removal / Installation

CA818900

Page 4-65Printed in U.S.A.

Page 100

SECTION IV MAINTENANCE / SERVICE

4.41 Secondary Thermostat Removal / Installation

A. Removal

(1 ) Perform steps 1 thru 17 of para 4.26A (removing

motor pump).

(2 ) Tag and disconnect two wires (1, Figure 4-70)

from secondary thermostat (2).

(3 ) Cut two cable ties and remove secondary

thermostat (2) from motor (3).

B. Installation

(1 ) Position primary thermostat (4) and secondary

thermostat (2) on motor (3) and secure with two cable ties.

(2 ) Connect one wire (1) to each terminal of sec-

ondary thermostat (2).

(3 ) Perform steps 5 thru 25 of para 4.26B (installing

motor pump).

4.42 Floor Lock Status Switch Removal / Installation

A. Removal

NOTE

There are two floor lock status switches; a main floor lock status switch and an outrigger floor lock status switch. Both status switches are removed same way. Main floor lock status switch is shown in the illustration.

(1 ) If not already extended, use hand control to run

LOCK function to extend floor lock cylinders.

(2 ) Remove two screws (1, Figure 4-71) and pull

switch bracket (2) out of base weldment (3) as far as possible.

(3 ) Disconnect connector of status switch (4) from

wire harness (5).

(4) Using a pencil, mark position of status switch

(4) on switch bracket (2).

(5 ) Remove two nuts (6), screws (7), and status

switch (4) from switch bracket (2).

CABLE TIES

Figure 4-70. Secondary Thermal Fuse

Removal / Installation

CA819000

B. Installation

(1 ) Align new status switch (4) with pencil marks on

switch bracket (2) and then secure in position with two screws (7) and nuts (6).

(2 ) Connect connector of status switch (4) to wire

harness (5).

(3 ) Install switch bracket (2) on base weldment (3)

and secure with two screws (1).

CAUTION

When adjusting status switch, use care to

adjust status switch so trip arm will not be bent or broken by floor lock cylinder when cylinder is unlocked (retracted).

(4 ) Sight down edge floor lock cylinder and deter-

mine if trip arm of status switch (4) is positioned properly. Trip arm is positioned properly when trip arm will be tripped when the floor lock cylinders are in unlocked (retracted) position and will not be tripped when floor lock cylinders are in locked (extended) position.

Page 4-66Printed in U.S.A.