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Skytron 6002 User manual

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Page 1
ELITE SERIES SURGICAL TABLES
MAINTENANCE MANUAL
REV 8/05
MODEL ELITE 6002
INCLUDING BATTERY MODELS
Page 59
Page 2
Page 52
Page 3
Table of Contents
SECTION I HYDRAULIC SYSTEM ...................................................................................................... 1
1-2. Component Operation .................................................................................................................... 2
a. Motor/Pump Operation ............................................................................................................. 2
b. Pressure Relief Valve .............................................................................................................. 2
c. Mini-Valves............................................................................................................................... 3
d. Mini-valve in Neutral Position ................................................................................................... 3
e. Mini-Valve Right Port Activated................................................................................................ 4
f. Mini-Valve Left Port Activated .................................................................................................. 4
g. Hydraulic Cylinders (Slave Cylinders) ..................................................................................... 5
h. Elevation Cylinder Return Circuit ............................................................................................. 6
i. Brake System ........................................................................................................................... 7
j. Emergency Brake Release ...................................................................................................... 8
k. Flex/Reflex System ................................................................................................................... 8
1-3. Hydraulic Adjustments ................................................................................................................... 9
a. Fluid Level. ............................................................................................................................... 9
b. Bleeding The Hydraulic System ............................................................................................... 9
c. Pressure Relief Valve .............................................................................................................. 9
d. Speed Controls......................................................................................................................... 9
SECTION II MECHANICAL TABLE ADJUSTMENTS........................................................................ 11
2-1. Back Section Gear Mesh Adjustment ........................................................................................... 1 1
2-2. Hydraulic Cylinder Adjustment ...................................................................................................... 11
a. Back Section ........................................................................................................................... 11
b. Leg Section ............................................................................................................................. 11
SECTION III HYDRAULIC TROUBLESHOOTING ............................................................................. 12
3-1. Precautions ................................................................................................................................... 12
3-2. Troubleshooting Notes .................................................................................................................. 12
3-3. ELEVATION DIAGNOSIS CHART .............................................................................................. 13
3-4. TRENDELENBURG DIAGNOSIS CHART.................................................................................. 14
3-5. LATERAL - TILT DIAGNOSIS CHART ........................................................................................ 15
3-6. FLEX SYSTEM DIAGNOSIS CHART.......................................................................................... 16
3-7. BACK SECTION DIAGNOSIS CHART ....................................................................................... 17
3-8. LEG SECTION DIAGNOSIS CHART .......................................................................................... 18
3-9. BRAKE CIRCUIT DIAGNOSIS CHART ..................................................................................... 19
3-10. Flexible Hose Identification and Placement................................................................................... 20
REV 8/05
Although current at time of publication, SKYTRON's policy of continuous development makes this manual subject to change without notice.
Page 53
Page 4
Table of Contents (continued)
SECTION IV ELECTRICAL SYSTEM.................................................................................................. 22
4-1. General.......................................................................................................................................... 22
4-2. Components.................................................................................................................................. 22
4-3. Battery Model Components........................................................................................................... 22
SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING ............................................................. 23
5-1. Troubleshooting Notes .................................................................................................................. 23
5-2. Main Switch................................................................................................................................... 23
5-3. Pendant Control ............................................................................................................................ 24
5-4. Relay Box...................................................................................................................................... 25
5-5. Solenoids....................................................................................................................................... 27
5-6. Motor/Pump Assembly .................................................................................................................. 29
5-7. Return To Level Micro-Switches................................................................................................... 31
5-8. Troubleshooting............................................................................................................................. 31
SECTION VI -6002B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING .............................. 36
6-1. General.......................................................................................................................................... 36
6-2. Troubleshooting Notes .................................................................................................................. 36
6-3. Main Switch................................................................................................................................... 37
6-4. Batteries ........................................................................................................................................ 37
6-5. Battery Charging Box/AC120V Transformer................................................................................. 38
6-6. Switch-Over Relay ........................................................................................................................ 39
6-7. Pendant Control ............................................................................................................................ 40
6-8. Auxiliary Switches......................................................................................................................... 42
6-9. Relay Box...................................................................................................................................... 43
6-10.Main Wire Harness Continuity Tests............................................................................................. 45
6-11. Solenoids....................................................................................................................................... 46
6-12. Motor/Pump Assembly.................................................................................................................. 47
SECTION VII ELECTRICAL SYSTEM ADJUSTMENTS .................................................................... 48
7-1. Relay Box Adjustments Models 6002 & 6002B............................................................................ 48
WARNING
Indicates a possibility of personal injury.
CAUTION
Indicates a possibility of damage to equipment.
Page 54
Indicates important facts or helpful hints.
NOTE
Page 5
BASIC RECOMMENDED TOOLS:
1/8". 1/4" STRAIGHT BLADE SCREWDRIVERS #2 PHILLIPS SCREWDRIVER HYDRAULIC PRESSURE GAUGE SKYTRON P.N. 6-050-02 METRIC ALLEN® WRENCHES 1.5mm-8mm ADJUSTABLE CRESCENT WRENCH DIGITAL VOLTMETER, TRUE RMS METRIC OPEN END WRENCHES 7mm-18mm LEVEL (CARPENTERS)
BASIC RECOMMENDED MAINTENANCE PROCEDURES
The basic items notes below should be inspected at a minimal interval period of 6 months (dependant on usage). For optimal usage, safety and longevity of the product, have it serviced only by an authorized Skytron representative with authentic Skytron replacement parts.
• Check Power Cord (if applicable) • Inspect Articulating Joints
• Check Pendant Control (if applicable) • Inspect Table Tops
• Check Oil Level in Reservoir • Check Operational Times and Pressure Values
• Check For Hydraulic Leaks • Check Pressure Relief Valve Setting
• Check All Table Functions • Check Side Rails
• Check Velcro • Check Lateral Tilt Housing Bolts
• Inspect Leg and Head Section detachment mechanisms for proper operation
• Lubricate Elevation Slider Assembly with SKYTRON Slider Grease P/N D6-010-89
• Tighten X-Ray Top Stand-Offs, Use Loc-tite
• Lubricate Casters
• Check brake pads for wear and inspect brake cylinders for proper operation.
Only facility-authorized SKYTRON trained, maintenance personnel should troubleshoot the SKYTRON 6002 Surgical Table. Trouble shooting by unauthorized personnel could result in personal injury or equipment damage.
How to contact us:
Skytron
5000 36th St. SE, Grand Rapids, MI 49512
PH: 1-800-759-8766 (SKY-TRON)
FAX: 616-957-5053
Page 55
Page 6
TYPE B
EQUIPMENT
EQUIPMENT LABELS AND SPECIFICATIONS
INDICATES DANGEROUS VOLTAGE, 120 V, 60 Hz
CLASS I DEFIBRILLATION PROOF, TYPE B EQUIPMENT- IPX4 RATED. INTERNALLY POWERED EQUIPMENT
PROTECTIVE GROUNDING. IN ORDER TO ENSURE PROPER GROUNDING RELIABILITY, THIS TABLE MUST BE CONNECTED TO A PROPERLY GROUNDED HOSPITAL GRADE OUTLET.
N
10A
IPX4
V A
HZ
CONNECTION FOR NEUTRAL CONDUCTOR SUPPLIED
UNIT TO BE USED ONLY IN SPECIFIED ENVIRONMENTAL CONDITIONS TEMPERATURE: 15˚ - 30˚ C (60˚ -85˚ F) HUMIDITY: 30% - 60% RELATIVE HUMIDITY, NON CONDENSING
AC VOLTAGE FUSE (2) 10 AMP FAST ACTING
ENCLOSURE CLASS
VOLTAGE RATING OF THE UNIT
AMPERAGE RATING OF THE UNIT
FREQUENCY OF THE UNIT ATTENTION, CONSULT MANUAL FOR FURTHER INSTRUCTIONS.
INDICATES SPECIAL USER ATTENTION.
BATTERY TYPE:
Page 56
FUSE:
POWERED BY AC VOLTAGE
BATTERY MODELS
POWERED BY BATTERY
SEALED LEAD ACID 12V, VALVE REGULATED 16AH, 10HR (530W/10MIN)
15 AMP FAST ACTING INTERNAL FUSE
15A
Page 7
.
.
6002 Series General Purpose Surgical Table Specifications
15"
10"
19-1/2"
21-1/2" 24"
60˚
90˚
13"
75"
TOP VIEW
76"
5-3/4"
8"
35-1/2"
3"
5-3/4"
SIDE VIEW
20"
22"
43" MAX
28" MIN
19"
END VIEW
Electrical Specifications
Power requirements Current Leakage
®
Power Cord
15 feet w/hospital grade connector
120 VAC, 60Hz, 300 Watts Less than 100 micro amps
(removeable on battery model)
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Page 9
M
E
1-1. General
Electro-Hydraulic System
SECTION I HYDRAULIC SYSTEM
The hydraulic system (with the exception of the hydraulic cylinders and hoses) is contained within the base of the table. The hydraulic valves and pump are electrically controlled by the use of a hand-held push button pendant control. The power requirements for the table are 120 VAC, 5 amp, 60 Hz.
The table contains the following components. Re­fer to the block diagram (figure 1-1) for relationship.
a. Oil Reservoir - Main oil supply. Approximately two quarts.
b. Motor/Pump Assembly - A positive displace­ment gear type pump provides the necessary oil pressure and volume.
TRENDELENBURG
LA TERAL TIL T
LEVATION
CYLINDER
c. Pressure Relief Valve - Provides an alternate oil
path when the hydraulic cylinders reach the end of their stroke.
d. Electro/Hydraulic Mini-Valve Assemblies -These direct the fluid to the appropriate hydraulic cylin­ders. e. Hydraulic Lines, Fittings, Connections - They provide a path for the hydraulic oil.
f. Hydraulic Cylinders - They convert the hydraulic fluid pressure and volume into mechanical motion.
BACK SECTION
LEG SECTION
BRAKE SYSTE
PLUMBING TERMINAL
EMERGENCY
MINI-VALVES
ELEV TREND TILT FLEX BACK LEG BRAKE
OIL RESERVOIR
BRAKE RELEASE
PRESSURE RELIEF V AL VE
MOTOR/PUMP ASSEMBLY
Figure 1-1. Hydraulic Block Diagram Model 6002
Page 1
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1-2. Component Operation
D
P G
D
P G
a. Motor/Pump Operation
The motor/pump assembly is a gear type pump that provides the oil pressure and volume for the entire hydraulic system. The pump has an inlet side and an outlet side. The inlet side is connected to the reservoir which provides the oil supply. The reservoir has a very fine mesh screen strainer which prevents foreign material from entering the oil system.
The output line of the pump is connected to the main oil galley which is internal and common to all the hydraulic mini-valves and pressure relief valve. Also, common to the hydraulic mini-valves and pressure relief valve is an oil galley that internally connects to the oil reservoir to provide a return path for the hydraulic oil. See figure 1-2.
b. Pressure Relief Valve
The main component of the valve is an adjustable spring loaded plunger that is pushed off from its seat by the oil pressure. The oil then flows back into the reservoir. See figure 1-4 Turning the adjust­ment nut clockwise increases the amount of oil pressure required to open the valve, and turning it counterclockwise decreases the amount of oil pres­sure. (See adjustment section for specification.)
PRESSURE RELIEF ADJUSTMENT NUT
RESSURE
AUGE
SPRING LOADE PLUNGER
Figure 1-3. Pressure Relief Valve Not
Functioning
PRESSURE RELIEF ADJUSTMENT NUT
RESSURE
AUGE
Figure 1-2.
SPRING LOADE PLUNGER
This device provides an alternate oil path when the hydraulic cylinders reach the end of their stroke and the pump continues to run. If this path were not provided, the pump motor would stall because the oil cannot be compressed. The pressure relief valve is directly connected to the mini-valve bodies and shares both the common internal main pres­sure oil galley, and the return oil galley, that inter­nally connect to the reservoir. See figure 1-3.
Page 2
Figure 1-4 . Pressure Relief Valve
Functioning
Page 11
c. Mini-Valves
The operation of the mini-valves is identical for all table functions except the elevation and Single Action Brake circuits. These two hydraulic circuits use a 3-way (single check valve) type mini-valve. All other functions use a 4-way (dual check valve) type mini-valve.
Either type mini-valve is controlled by two pushing type, electrically operated solenoids. The sole­noids push the spool valve (located in the lower portion of the valve) one way or the other. This motion opens the main supply galley (which has pump pressure) allowing the oil to flow through the various parts of the mini-valve to the function. The spool valve also opens an oil return circuit which allows the oil to return to the oil reservoir.
The main components of the mini-valve and their functions are listed below:
1. Spool Valve - Opens the main oil galley (pump pressure) to either mini-valve outlet de­pending on which direction the spool valve is pushed. Also it provides a return path for the oil returning back into the reservoir.
Also, by using this control method, it doesn’t matter what size cylinder and piston is used because the speed can be controlled by restricting the return oil. If the pump puts out more volume to a certain slave cylinder than the speed control is allowing to go back to the reservoir, the pressure relief valve provides an alternate path for the pump oil.
d. Mini-Valve in Neutral Position
(No fluid flow) See figure 1-5.
1. Spool Valve Centered - This closes off both
oil pressure and oil return galleys.
2. Pilot Plungers Both Closed -The pilot plung­ers control the opening of the check valves. If they are closed, the check valves must be closed.
3. Check Valves - Both check valves are closed trapping the oil in the cylinder and oil lines.
4. Speed Adjustment - When the mini-valve is in the neutral position, the speed adjustment does not affect anything because there is not any oil flow.
2. Pilot Plunger - There are two plungers in a four-way mini-valve (one in a 3-way mini-valve), one under each check valve. The purpose of the pilot plungers is to mechanically open the return check valve allowing the oil to return back into the reservoir.
3. Check Valve - Two are provided in each four­way mini-valve to seal the oil in the cylinders and oil lines and prevent any movement of the table. One check valve is provided in a 3-way mini-valve.
4. Speed Adjustments - There are two speed adjustments in each mini-valve. They are needle valve type controls which restrict the volume of oil returning back into the reservoir, thereby control­ling the speed of the table surface movement. A 3­way mini-valve has only one speed adjustment.
The speed controls are always located in the return oil circuit. This prevents uncontrolled movement of the piston in the slave cylinder due to one side of the piston being loaded with hydraulic pressure and the other side having no load.
Figure 1-5. Mini-Valve in Neutral Position
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e. Mini-Valve Right Port Activated
(See figure 1-6)
Slave Cylinder Piston Moves to Left Right Mini-Valve Port is Supply Line Left Mini-Valve Port is Return Line
f. Mini-Valve Left Port Activated
(See figure 1-7.)
Slave Cylinder Piston Moves to Right Left Mini-Valve Port is Supply Line Right Mini-Valve Port is Return Line
INLET OUTLET
Figure 1-6. Mini-Valve Right Port Activated
1. Spool Valve - Pushed to the left by electric solenoid. This opens the internal oil pressure gal­ley allowing the fluid to go through the check valve and on to the cylinder. Also, the spool valve opens the oil return line providing an oil path through the internal oil galley back to the reservoir.
OUTLET
INLET
Figure 1-7. Mini-Valve Left Port Activated
1. Spool Valve -Pushed to the right by electric solenoid. This opens the internal oil pressure gal­ley allowing the fluid to go through the check valve and on to the cylinder. Also, the spool valve opens the oil return line providing an oil path through the internal oil galley back to the reservoir.
2. Pilot Plunger Valve - Left pilot plunger valve is pushed up by the incoming oil pressure mechani­cally opening the check valve located above it in the return circuit. This action allows the oil from the left side of the slave cylinder to go back into the reservoir. The right pilot plunger valve is not affected in this operation mode.
3. Check Valves - Both check valves are opened in this operation mode. The right check valve is pushed open by the oil pressure created by the pump. The oil then continues to go through the lines and pushes the slave cylinder piston to the left. At the same time, the left check valve is held open mechanically by the pilot plunger providing a return path for the oil through the mini-valve back to the reservoir.
4. Speed Adjustment - The right speed control (output side) does not have any effect in this operation mode because the oil is routed around the speed adjustment through a by-pass valve and then to the output port. The left speed adjustment controls the speed of the table function by restrict­ing the amount of oil going back into the reservoir.
2. Pilot Plunger Valve - Right pilot plunger valve is pushed up by the incoming oil pressure mechani­cally opening the check valve located above it in the return circuit. This action allows the oil from the right side of the slave cylinder to go back into the reservoir. The left pilot plunger valve is not affected in this operation mode.
3. Check Valves - Both check valves are opened in this operation mode. The left valve is pushed open by the oil pressure created by the pump. The oil then continues to go through the lines and pushes the slave cylinder piston to the right. At the same time, the right check valve is held open mechanically by the pilot plunger providing a return path for the oil through the mini-valve back to the reservoir.
4. Speed Adjustment - The left speed control (output side) does not have any effect in this oper­ation mode because the oil is routed around the speed adjustment through a by-pass valve and then to the output port. The right speed adjustment controls the speed of the table function by restrict­ing the amount of oil going back to the reservoir.
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N
E C
g. Hydraulic Cylinders (Slave Cylinders)
RAM
HYDRAULIC LINE
PISTON
O-RING
O-RING
R
S
There are several different types of hydraulic cylin­ders used in the table that activate the control functions. With the exception of the elevation and brake cylinders, all operate basically the same way. The control functions are listed below: (See figure 1-8.).
Back Section--2, double action cylinders Leg Section--2, double action cylinders Trendelenburg--1, double action cylinder Lateral Tilt--1, double action cylinder Elevation--1, single action cylinder Brakes--4, single action cylinders
TRENDELENBURG CYLINDER
BACK SECTIO CYLINDER
Figure 1-9. Back Section Cylinder
2. Trendelenburg Cylinder Assembly - This cylinder / piston arrangement has rack teeth cut into the top of each piston. These teeth mesh with a pinon gear that is connected directly to the table side frames. The pinion gear shaft and table side frames are supported by bearings at either side. When hydraulic fluid is pumped into one side of the cylinder, the pistons are pushed in one direction, moving the pinion gear and table side frames with them. Oil pressure can be applied to either side of the piston, making the table tilt end for end. See figure 1-10.
LEG SECTION
LEVATION YLINDER
CYLINDER
LA TERAL TIL T CYLINDER
T ABLE TOP
PINION GEA
PISTON
SIDE VIEW
Figure 1-10. Trendelenburg Cylinder Assy.
Figure 1-8. Cylinder Placement
1. Back Section and Leg Section Cylinders ­The double action cylinders are closed at one end and have a movable piston with hydraulic fluid on both sides. Connected to this piston is a ram or shaft that exits out of the other end of the cylinder. Through the use of either a gear, or clevis and pin
In order to remove any looseness or play in the table top, the trendelenburg pistons are made in two pieces as shown in figure 1-11. This arrange­ment eliminates any gear lash between the piston teeth and the table pinion gear due to oil pressure always being present on both sides of the pistons.
OIL PRESSURE
OIL PRESSURE
arrangement, this ram is connected to a movable table surface. The movable surface can be moved one way or the other by pumping hydraulic fluid into the cylin­der on either side of the piston. Obviously, if oil is pumped into one side of the cylinder, a return path must be provided for the oil on the other side. See figure 1-9.
Figure 1-11. Trendelenburg Cylinder Pistons
SPLIT PISTONS REMOVE GEAR LASH
TOP VIEW
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3. Lateral Tilt Assembly - The lateral tilt assem-
P
T
O
B P
N
bly consists of two cylinders, pistons and connect­ing rods. The connecting rods attach to the lateral tilt lever which connects to the table side frames. When hydraulic fluid is pumped into one cylinder, the piston and connecting rod pushes the lateral tilt lever which tilts the table top to one side. To tilt the table top in the opposite direction, fluid is pumped into the opposite cylinder. See figure 1-12.
T ABLE TOP
LA TERAL TIL LEVER
5. Brake Cylinders - The brake cylinders are single action type similar to the elevation cylinder. The movable piston's ram is connected to a brake pad. See figure 1-14. Oil pumped into the top of the cylinder pushes the piston down raising the table base off its casters. An internal return spring on the bottom of the piston, pushes the piston up to return the oil through the mini-valve to the reservoir.
PISTON
IL LINE
RETUR SPRING
ISTON PISTON
Figure 1-12. Lateral Tilt Cylinder Assembly
CONNECTING RODS
RAKE
AD
RAM
4. Elevation Cylinder - This single action cylin­der does not have hydraulic fluid on both sides of the piston. It depends on the weight of the table top assembly to lower it. The cylinder is set in the center of the elevation main column. The cylinder is elevated by the driven force of the oil pressure. When lowering, the oil that
Figure 1-14. Single Action Brake Cylinder
is accumulated in the cylinder is returned to the oil reservoir through the mini-valve due to the table top weight. A slider support assembly is used to support the
h. Elevation Cylinder Return Circuit
weight of the upper table section. A stainless steel shroud covers the flexible hydraulic hoses and slider. See figure 1-13.
Three-way (single check valve type) mini-valves control both the elevation and return circuits. The elevation circuit operation within the mini-valve is identical to the operation of the four-way valves previously described (inlet pressure opens the check valve allowing the oil to enter the cylinder). In the return position, inlet pressure pushes the pilot plunger up and opens the return check valve. See figure 1-15. The open check valve allows a path for the oil in the elevation cylinder to return to the reservoir. When the pilot plunger valve is opened, the continuing pump pressure opens the pressure relief valve which provides a return oil path to the reservoir.
Figure 1-13. Elevation Cylinder Assembly
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The mini-valve used in the elevation circuit con-
E
R R
tains only one check valve (all four-way mini­valves use two check valves). The check valve is used to trap the oil in the elevation cylinder thereby supporting the table top. When the top is being lowered the check valve is mechanically held open by the pilot plunger through pump pressure.
INLET
PLUMBING TERMINAL
ETURN TO ESERVOIR
BRAKE
BRAKE SYSTEM
EMERGENCY BRAKE RELEAS
RELIEF VALVE
TO RESERVOIR
THROUGH
PRESSURE
RELIEF V AL VE
RETURN TO RESERVOIR
Figure 1-15. Elevation Return Circuit
i. Brake System
The brake system consists of the following compo­nents: (figure 1-16)
1. Single action slave cylinders (4 each).
2. 3-way (single check valve type) mini-valve.
RESERVOIR
PUMP/MOTOR ASSEMBLY
Figure 1-16. Brake System Block Diagram
Each corner of the cast-iron table base has a hydraulic brake cylinder. These single action cyl­inders are hydraulically connected in parallel to the mini-valve and all four are activated together. It is normal for one corner of the table to raise before the others due to the weight distribution of the table.
An electronic timer in the relay box is activated when any function on the pendant control is pushed momentarily. The pump/motor and brake system mini-valve are activated and the brake cylinders are completely set. The electronic timer runs for approx. 8-10 seconds.
The brakes are released by pushing the BRAKE UNLOCK button momentarily. An electronic timer in the relay box activates the brake function hy­draulic mini-valve and pump/motor.
3. Manually controlled emergency brake re-
lease.
When activated, the return hydraulic circuit oper­ates similar to the elevation cylinder return circuit. Return springs inside the single action brake cylin-
4. Plumbing terminal, flexible hoses, copper
lines and "O" rings.
ders retract the brake pads and provide the pres­sure to return the hydraulic oil back to the reservoir. The electronic timer operates the return circuit for
5. Portions of the electrical system.
approximately 8-10 seconds.
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j. Emergency Brake Release
k. Flex/Reflex System
The emergency brake release is simply a manually operated bypass valve connected in parallel to the brake cylinders and the oil reservoir. See figure 1-
17. When the valve is opened (turned counter­clockwise) a return circuit for the brake hydraulic fluid is opened. The return springs force the pistons up pushing the hydraulic oil back into the reservoir and retracting the brake pads.
EMERGENCY BRAKE RELEASE LEVER
The Flex/Reflex system used on the present tables incorporates an additional mini-valve (7 total) which connects the trendelenburg and back section hy­draulic systems in a series. When FLEX is acti­vated by the pendant control, the Flex/Reflex mini­valve opens the oil pressure path to the Reverse Trendelenburg piston. The return oil path from the trendelenburg piston is routed through the back section cylinder to the mini-valve return port. See
TREND
REV TREND
BACK DOWN
BACK UP
PLUMBING TERMINAL
Figure 1-17.
NOTE
•The emergency brake release valve must be tightened securely when not in use.
•If the emergency brake release valve has been operated, the UNLOCK but­ton on the pendant control may have to be pressed before brakes will lock again.
If the emergency brake release valve is open or loose, two conditions could occur:
The brakes will release slowly- depending on how loose the valve is, this could take anywhere from a few minutes to several hours.
FLEX/REFLEX MINI-VALVE
figure 1-18.
Figure 1-18. Flex/Reflex System
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1-3. Hydraulic Adjustments
R
a. Fluid Level.
The fluid level should be approximately 1/2" below the filler hole or gasket surface. If additional fluid is needed, remove the filler vent cap with a phillips screwdriver and add fluid through this opening using a funnel. See figure 1-19.
NOTE
The elevation cylinder should be com­pletely down and all the other control functions in their neutral position when checking oil level.
FILLER VENT
FILLE CAP
c. Pressure Relief Valve
The pressure relief valve is adjusted by turning the adjustment nut until the desired pressure is reached.
To adjust:
1. Remove the blind cap and attach a hydraulic pressure gauge to the main oil galley using a 6mm plumbing bolt. See figure 1-20.
RESERVOIR OPENING
Figure 1-19.
The type of oil that should be used is Mobil DTE #25 or equivalent. This is a very high quality hydraulic oil. The table requires approximately two quarts of oil to operate properly.
b. Bleeding The Hydraulic System
To purge the air from the hydraulic system, operate each function back and forth at least two or three times.
NOTE
Whenever a hydraulic line or component is replaced, bleed the air out of the lines using the pump pressure before mak­ing the final connection. Then operate the function until it stalls in both direc­tions.
Figure 1-20.
2. Raise the table top until the piston reaches the end of its stroke and stalls. Observe reading on pressure gauge and turn the adjustment nut (clock­wise to increase oil pressure, counterclockwise to decrease) until desired reading is obtained. Pressure should be 80KG/CM† -1138 PSI.
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Page 18
d. Speed Controls
The speed controls restrict the volume of oil return­ing back to the reservoir thereby controlling the speed of each control function.
All four-way mini-valves, have two speed controls located in the ends of each valve body. All three­way mini-valves have only one speed control.
One speed control adjusts one direction of a particular function and the opposite speed control adjusts the other direction. They are adjustable by using a small straight blade screwdriver and turning the adjustment screw clockwise to de­crease the speed and counterclockwise to increase the speed. Refer to figure 1-21.
A pressure gauge should be used to set the speed of the back section, trendelenburg and flex control functions.
To adjust:
1. Attach the pressure gauge onto the main oil
galley as shown in figure 1-21.
2. The gauge should read the following values when operating the various control functions in either direction. Turn the speed controls until desired values are obtained.
Back Section Up 65KG/CM†-925PSI
Dn 65KG/CM†-925PSI
Trendelenburg Up 65KG/CM†-925PSI
Dn 65KG/CM†-925PSI Flex 70KG/CM†-995PSI Reflex 70KG/CM†-995PSI
Figure 1-21.
Any control function should move in either direc­tion at the same rate. If the rate of a certain function is too slow, open the speed control slightly and recheck. Use the second hand on a watch and time a particular function. Match that time in the oppo­site direction by opening or closing the speed control. Approximate operating times are as fol­lows:
Lateral Tilt 7 seconds Back Up 25 seconds Back Down 15 seconds
NOTE
When adjusting Flex/Reflex speed con­trols, set Reflex last.
Elevation - There is not a speed adjustment for raising the table. The speed control will only affect the rate of descent and it should equal the rate of elevation.
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E
LEG
SECTION
TABLE SIDE FRAME
LEG CYLINDER ECCENTRIC CAM
SP ANNER WRENCH
SECTION II MECHANICAL TABLE ADJUSTMENTS
S
R
2-1. Back Section Gear Mesh Adjustment
The gear mesh is adjusted by the use of an eccen­tric cam. This cam moves the gear teeth closer together to eliminate gear lash. This adjustment arrangement compensates for any wear between the gears that might occur.
To adjust: Loosen the cam locking nut and allen set screw. Use a spanner wrench to rotate the eccentric cam. Use firm pressure on the spanner wrench. See figure 2-1. Tighten the locking nut and set screw when adjustment is complete.
ECCENTRIC CAM
NUT
ET SCREW
SPANNE WRENCH
To adjust: Loosen the cam locking nuts located inside the table side frames. Use a spanner wrench to turn the cylinder eccentric cams as required to shift either cylinder fore or aft as needed so no twisting or flexing of the back section is observed when it is stalled in the full up position. See figure 2-2.
BACK SECTION
BACK SECTION CYLINDER ECCENTRIC CAM
SPANNER WRENCH
TABLE SID FRAME
Figure 2-2. Back Section Adjustment
b. Leg Section
Figure 2-1. Eccentric Cam Adjustment
2-2. Hydraulic Cylinder Adjustment
Back & Foot / Leg Sections The hydraulic cylinder rams that control both the
back and foot / leg sections must move together so that these sections are not twisted when operated. This is accomplished by the use of eccentric cams that move the cylinder bodies fore and aft to adjust their effective stroke.
NOTE
Adjust gear mesh before adjusting ec­centric cams for the back section.
a. Back Section
Position the back section all the way up until it stalls. Both sides of the back section should stop moving at the same time and should not show any signs of twisting.
Position the leg section all the way up. Both sides of the leg section should stop moving at the same time and should not show any signs of twisting.
Any twisting or flexing of the leg section as it approaches the stalled position indicates that one of the cylinders is not reaching its fully extended position at the same time as the other and an adjustment is required.
To adjust: Loosen the cam locking nuts located inside the
table side frames. Use a spanner wrench to turn the cylinder eccentric cams as required to shift either cylinder fore or aft as needed so no twisting or flexing of the leg section is observed when it is stalled in the above horizontal position. Tighten locking nuts when proper adjustment is achieved. See figure 2-3.
Any twisting or flexing of the back section as it approaches the stalled position indicates that one of the cylinders is not reaching its fully extended position at the same time as the other. This condition would require an adjustment.
Figure 2-3. Leg Section Adjustment
Page 11
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SECTION III HYDRAULIC TROUBLESHOOTING
3-1. Precautions
Before attempting to troubleshoot any hydraulic problem on the table, please read through the pre­cautions and notes below.
CAUTION
When disconnecting any of the hydrau­lic lines, fittings, joints, hoses, etc., for the following control functions, be sure these table surfaces are in their down position or completely supported.
•Elevation
•Back Section
•Leg Section
When working on the trendelenburg or lateral tilt hydraulic circuits, be sure to support the table top. When working on the brake system make sure the brakes are completely retracted.
Once the problem has been determined, concen­trate on that particular hydraulic circuit or control function.
Listed below are the hydraulic components that are common with all hydraulic circuits. If there is a problem with any of them, it could affect all control functions.
1. Motor/Pump Assembly
2. Reservoir
3. Pressure Relief Valve
4. Certain Oil Lines and Galleys
If there was a problem in the following components, only one control function would normally be af­fected.
1. Mini-Valve
2. Slave Cylinder
3. Oil Lines
NOTE
CAUTION
Failure to follow these precautions may result in an uncontrolled oil spray and damage to the table or personal injury.
3-2. Troubleshooting Notes
When troubleshooting a table malfunction, first determine the following:
1. Does the problem affect all control func-
tions?
2. Does the problem affect only one control
function?
3. If the problem affects one control function is
it in both directions?
Whenever a hydraulic line or compo­nent is replaced, bleed the air out of the lines using the pump pressure before making the final connection. After all connections are tight, cycle the control function back and forth two or three times to purge the remaining air from the system.
CAUTION
When installing new "O" rings use hy­draulic oil to thoroughly lubricate the "O" rings and cylinder. Keep every­thing clean.
Each complete oil circuit is shown on the following pages. When troubleshooting a particular function, refer to the appropriate oil circuit diagram and the list of possible problems
4. Is the problem intermittent?
5. Is the problem no movement of a table
surface or does the table surface lose position?
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3-3. ELEVATION DIAGNOSIS CHART
Problem Table will not elevate properly
Table will not descend properly
Table loses elevation
Reason Pressure Relief Valve Not Set Properly Low on Oil Spool Valve Not Centered Defective Pump Defective Mini-Valve Defective Solenoid or Wiring Defective Relay Box or Pendant Control
Incorrect Speed Adjustment Bad Check Valve Spool Valve Not Centered Galled Slider Assembly Defective Solenoid or Wiring Defective Relay Box or Pendant Control
Bad Check Valve Leaking Mini-Valve Loose Fittings, Joints, Hoses Leaking "O" Ring Inside Cylinder
Figure 3-1. Elevation Circuit
Page 13
Page 22
P
M
3-4. TRENDELENBURG DIAGNOSIS CHART
Problem Trendelenburg function moves improperly
Trendelenburg function chatters or loses position
PINION GEAR
O-RING
FRONT PIVOT BLOCK
Reason Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Bad Solenoid or Wiring Defective Relay Box or Pendant Control
Defective or Dirty Check Valve Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil
REAR PIVOT BLOCK
O-RING
TAIL CYLINDER CA
PISTON ASSEMBLY
HEAD CYLINDER CAP
HEAD DOWN CIRCUIT
COPPER LINES
CHECK VALVE
SPEED CONTROL
INI-VALVE
PLUMBING TERMINAL
O-RING FLEXIBLE HOSES
HEAD UP CIRCUIT
INTERNAL OIL FROM PUMP
INTERNAL OIL RETURN TO RESERVOIR
Figure 3-2. Trendelenburg Circuit
Page 14
Page 23
3-5. LATERAL TILT DIAGNOSIS CHART
Problem Lateral tilt function moves improperly
Lateral tilt function chatters or loses position
Reason Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control
Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil
Figure 3-3. Lateral Tilt Circuit
Page 15
Page 24
3-6. FLEX SYSTEM DIAGNOSIS CHART
Problem Back Section or Trendelenburg function moves improperly
NOTE
If Flex System does not function prop­erly, check the back section and tren­delenburg functions before adjusting the flex system.
Back Section or Trendelenburg function chatters or loses position
Reason Incorrect Speed Adjustment (Trendelenburg, Back section or Flex - check with gauge) Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control
Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil
Page 16
Figure 3-4. Flex System Circuit
Page 25
3-7. BACK SECTION DIAGNOSIS CHART
Problem Back Section function moves improperly
Back Section function chatters or loses position
Reason Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control
Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil
Figure 3-5. Back Section Circuit
Page 17
Page 26
3-8. LEG SECTION DIAGNOSIS CHART
Problem Leg function moves improperly
Leg function chatters or loses position
Reason Incorrect Speed Adjustment Spool Valve Not Centered Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Bad Solenoid Defective Relay Box or Pendant Control
Defective or Dirty Check Valves Oil Leakage in Circuit Air Inside Cylinder Pinched Hose Low on Oil
Page 18
Figure 3-6. Leg Section Circuit
Page 27
C
E
3-9. BRAKE CIRCUIT DIAGNOSIS CHART
Problem Brakes will not set properly
NOTE
If brakes have been released with the Emergency Brake Release Valve, brakes will not reset until BRAKE UN­LOCK Circuit has been activated.
Brakes Will Not Stay Locked
Brakes will not retract properly
Reason Emergency Brake Release Valve Open or Defec­tive Spool Valve Not Centered Bad Check Valve Low on Oil Pressure Relief Valve Not Set Properly Pinched Hose Defective Mini-Valve Defective Relay Box or Pendant Control
Emergency Brake Release Valve Open or Defec­tive Defective or Dirty Check Valve Oil Leakage in Circuit Leaking "O" Ring Inside Cylinder
Incorrect Speed Adjustment Bad Check Valve Spool Valve Not Centered Defective Mini-Valve Pinched Hose Defective Solenoid or Wiring Defective Relay Box or Pendant Control
BRAKE CYLINDER
PLUMBING TERMINAL
BRAKE CYLINDER
HECK V AL VE
SPEED CONTROL
MINI-VALVE
INTERNAL OIL FROM PUMP
INTERNAL OIL RETURN TO RESERVOIR
FLEXIBLE HOSES
BRAKE CYLINDER
COPPER LINE
FLEXIBLE HOSES
FLEXIBLE HOSE
RETURN TO RESERVOIR
EMERGENCY BRAKE RELEAS
RELEASE LEVER
Figure 3-7. Brake System Circuit
Page 19
Page 28
F P
T
F P B
)
3-10. Flexible Hose Identification and Placement
The following figures will show the correct place­ment of the flexible hydraulic hoses used in the table and their respective number codes.
Figure 3-8 shows the hose connections to the plumbing terminal.
2468
13579
NUMBER
1 2 3 4 5 6 7 8 9
FUNCTION
ELEVATION REV TREND TREND LA T TIL T LEFT LA T TIL T RIGHT BACK DOWN BACK UP LEG UP LEG DOWN
Figure 3-8. Main Plumbing Terminal
Figure 3-9 shows the placement of the short flex­ible hoses which connect to the back section cylinders.
BACK CYLINDER, RAM (RIGHT)
Figure 3-10. Leg Section Hoses
Figure 3-11 shows the placement and number code for the long flexible hoses which connect from the plumbing terminal to the front and rear pivot blocks.
NOTE
The number codes will be stamped into the elevation clamp ring and the plumb­ing terminal.
(3) TREND.
RONT IVOT BLOCK
(5) LAT. TILT RIGHT
(4) LAT. TILT LEFT
TOP VIEW
REAR PIVO BLOCK
(2) REV. TREND
BACK CYLINDER, RAM (LEFT)
Figure 3-11. Pivot Block Hoses
Figure 3-12 shows the placement and number code for the long flexible hoses that connect from
RONT
TOP VIEW
IVOT
LOCK
BACK CYLINDER, PISTON (RIGHT
BACK CYLINDER, PISTON (LEFT)
the elevation clamp ring to the plumbing terminal.
Figure 3-9. Back Section Hoses
Figure 3-10 shows the placement of the short flexible hoses which connect to the leg section cylinders.
Page 20
Figure 3-12. Elevation Clamp Ring Hoses
Page 29
Figure 4-1. 6002 Electrical Circuit Block Diagram
Page 21
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SECTION IV ELECTRICAL SYSTEM
4-1. General
The complete electrical system (with the excep­tion of the hand-held pendant control and the return circuit micro-switches) is contained within the base of the table. The pump motor and the hydraulic valves are controlled electrically with the pendant control.
The electrically operated functions are as follows:
- ELEVATION - Up and Down
- TRENDELENBURG - Head up and down
- LATERAL TILT - Right and left
- BACK SECTION - Up and Down
- LEG SECTION - Up and Down
- FLEX / REFLEX
- RETURN TO LEVEL
4-2. Components
Refer to figure 4-1 for the relationship of the elec­trical components.
a. Wires, Connectors, Switches, Fuse - These
provide the path for the various electrical circuits.
b. Relay Box - Contains the step down trans­former, full wave rectifier, and relay switches. The relay switches are activated by the pendant control and in turn energize the solenoid.
c. Hand-Held Pendant Control - Closes micro­switches to activate relay box. Operates on 5 VDC.
d. Solenoids - These electrically open and close the hydraulic ports of the mini-valve to direct the fluid to the correct cylinders. They operate on 120 VAC.
e. Motor/Pump Assembly - 120 VAC, 60 HZ, 200 Watt capacitor induction motor.
- BRAKE UNLOCK - Brake release
The power requirements are 120 VAC, 60 Hz, fuse protected. The main power on-off switch is an enclosed DPST type and the power cord is a three­wire, fifteen foot long, UL listed cord with a three­prong hospital grade plug.
4-3. Battery Model Components
The functions of the battery model tables are the same as the standard 120 VAC models. The electrical components and operation however, vary greatly between the two models. To simplify the troubleshooting procedures, the battery model tables are covered separately in Section VI.
Page 22
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SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING
5-1. Troubleshooting Notes
The basic operation of each component will be defined along with a drawing and explanation on how to check it out.
NOTE
This section does not cover the bat­tery table components. They are
covered separately in Section 6.
Certain defective components could cause the entire table to stop functioning or only one control function to stop. It would depend on what part of the component failed. Other defective components would only cause one control function to stop.
The following defective components could cause all control functions to be affected:
a. Motor/Pump Assembly (starting capacitor) b. Main Switch Circuit and Wiring
The following defective components could cause all control functions to be affected or only one control function:
a. Relay Box b. Pendant Control
The component listed below would only affect one control function:
Solenoid
1. Plug the power cord into the 120VAC power supply (wall receptacle) and turn ON the main switch.
2. Disconnect connector CN4 from the relay box. See figure 5-1. Leave all other connectors connected.
RELAY BOX
CN4
Figure 5-1. Main Power Test
WARNING
Line voltage (120 VAC) will be mea­sured in this test. Do not touch uninsu­lated connector pins or meter test leads.
3. Use an AC voltmeter capable of measuring 120 VAC and measure the voltage between pins 1 and 2 (black and white wires) located in connec­tor CN4. See figure 5-2. You should receive line voltage 120 VAC.
When troubleshooting an electrical circuit, start at the problem and work back to the power source.
5-2. Main Switch
The main power supply, 120 VAC, 60 HZ, comes in through the power cord and through the main switch. The main switch opens both lines when in the "OFF" position. An 8 amp or two 10 amp fuses are used to protect the complete electrical system and are located next to the main switch.
a. Main Switch Test
The following test will determine if line voltage is applied to connector CN4, which in turn would power the table.
ACV
5
3
2
4
1
PIN NO. COLOR
1 White 2 Black 3 Red 4 Blue 5 Yellow
Figure 5-2. Connector CN4
Page 23
Page 32
b. Test Results
If you do not receive the correct voltage measure­ment, the problem would have to be in the wires, main switch, fuses, or power cord. If the correct voltage is obtained, everything is good up to this point and the problem would have to be in another area.
5-3. Pendant Control
The Pendant Control consists of 14 micro-switches (buttons). When any of the circuits are completed (by depressing a control button) the appropriate relay contacts (located in the relay box) close applying 120V potential to the appropriate solenoid to operate the mini-valve and the pump/motor. The Pendant Control has only 5-6 volts applied to it.
a. Pendant Control Test
The following test will determine if the micro­switches inside the Pendant Control are func­tioning correctly.
1. Unplug the pendant control from the base of the table. You will be checking the cord side connector.
2. Use an ohmmeter R x 1 scale and check the continuity between pin 1 and pins 4 through 19. See figure 5-3.
3. Ohmmeter must show continuity between the pins that are indicated when the appropriate buttons are pressed.
NOTE
Pins 2 and 3 are connected to the LED (power on light on the pendant control) and cannot be checked with an ohm­meter. Pins 17 & 18 are not used.
Page 24
Figure 5-3. Pendant Control Test
Page 33
b. Test Results:
If you do not receive continuity between any of the pins, either the micro-switch in the Pendant Control is defective or a wire is broken. Either of these problems can be repaired easily.
If you receive correct readings with the meter, the Pendant Control is okay.
c. Wiring Harness Test
The following test checks the wires leading from the relay box connector CN8 to the 19 pin connec­tor table socket. These wires apply low voltage to the pendant control buttons.
1. The power cord should be plugged into the
wall socket and the main switch turned ON.
d. Test Results:
If you do not receive the correct voltage reading, the wiring or connector pins may be faulty. Discon­nect connector CN8 from the relay box and using an ohmmeter, test the continuity between the corre­sponding pins in connectors CN8 and the table base connector. See figure 5-5. If the correct readings are obtained, this part of the circuit is okay.
OHM
CN8
2. Disconnect the pendant control from the base connector. All other connectors should be connected.
3. Use a DC voltmeter 10V scale and measure the following pins located in the 19 pin table base connector. See figure 5-4.
NOTE
Pin 19 will have no voltage potential un­less one of the return-to-level micro­switches are activated, i.e. trend or tilt . Pins 17 & 18 are not used.
PIN NO.
1 2 3 4 5 6 7 8 9
10
COLOR PIN NO. COLOR
Red/White
White
Black
Red
White/Red
Yellow Brown
White/Brown
Blue/White
Orange
11 12 13 14 15 16 17 18 19
White/Orange
White/Gray White/Yellow Purple/White
Black/White
White/Purple
Blue/Yellow
Gray
Purple
Figure 5-5. Base Connector Continuity Test
5-4. Relay Box
The 120 volt power supply is directly connected to the relay contacts. When these contacts are closed, 120 volts is supplied to the solenoids which are mounted on the hydraulic mini-valves. One relay is used to supply 120V to the pump/motor and is always activated no matter what control function is selected. The brake locking circuit relay is also activated when any control function other than BRAKE UNLOCK is initially selected.
Also, inside the relay box is a step-down transformer and full-wave rectifier which decreases the line volt­age to 5.5 volts. This low voltage potential controls the relays by the use of the hand-held pendant control buttons. Basically the relays enable a 5.5 volt potential to control the 120 volt circuit.
Figure 5-4. Table Base Connector
The following tests will determine if the relay box is functioning correctly.
a. Relay Box Input Connector CN4
1. Plug the power cord into the 120 VAC power supply (wall receptacle) and turn the main switch ON. Leave all connectors connected.
Page 25
Page 34
WARNING
d. Test Results:
Line voltage (120 VAC) will be mea­sured in this test. Do not touch uninsu­lated connector pins or meter test leads.
2. Use an AC voltmeter capable of measuring 120 volts and measure the voltage between pins 1 (white) and 2 (black) of connector CN4 for input voltage. See figure 5-6. Meter should read line voltage 120 VAC.
3. Activate any table function with the Pendant Control and using an AC voltmeter, test the voltage at pins 3 and 4 of CN4 for output to the pump. Meter should read 120 VAC.
4
5
PIN NO.
1 2 3 4 5
COLOR WHITE
BLACK RED BLUE YELLOW
ACV
Figure 5-6. Connector CN4
b. Test Results:
If you do not receive the correct meter readings, the relay box or wiring is defective. If the correct readings are obtained, this part of the relay box is okay. Proceed to the next step.
If you do not receive the correct meter readings, the relay box or wiring is defective. If the correct readings are obtained, this part of the relay box is okay. Proceed to the next step.
e. Relay Box Output Connectors CN6 & CN7
This test checks the high voltage (120V) that is used to energize the solenoids.
WARNING
120 VAC will be measured in this test. Do not touch uninsulated connector pins or meter test leads.
1. The power cord should be plugged into the
wall receptacle and main switch turned ON.
2. Disconnect the motor connector CN15. All other connectors should be connected. Test con­nectors CN6 and CN7 from the back while attached to the relay box.
3. Activate each of the Pendant Control but­tons and using an AC voltmeter capable of measur­ing 120VAC, measure the voltage between the appropriate connector pins located in connector CN6 or CN7. See figure 5-7. Polarity of meter test leads is not important. Meter should read 120VAC.
ACV
c. Relay Box Output Connector CN8
This test checks the low voltage applied to the pen­dant control buttons.
1. The power cord should be plugged into the
wall receptacle and main switch turned ON.
2. Disconnect Pendant Control connector. All
other connectors should be connected.
3. Using a DC voltmeter, measure the voltage between pin 1(+) and pins 4 through 19(-) of the table base connector. See figure 5-4. Meter should read 5-6 volts.
Page 26
1
CN6 OR CN7
16
Leg Up
Flex
Reflex
CN7
1 - 2 3 - 4
9 - 10 11 - 12 13 - 14 15 - 16
CN6
FUNCTION PINS FUNCTION PINS
Table Up
Table Down
Rev Trend
Trend
Back Up
Back Down
Tilt Right
Tilt Left
1 - 2 3 - 4 5 - 6 7 - 8
9 - 10 11 - 12 13 - 14 15 - 16
Leg Down Brake Set
Brake Unlock
Figure 5-7. Relay Box Output Connectors
CN6 and CN7
Page 35
f. Test Results:
If you do not receive the correct meter readings, the relay box or wiring is defective and should be replaced.
NOTE
Before deciding the relay box is de­fective, check the wires and pins in the connector blocks to make sure they are not loose or making a bad connection with their mate.
5-5. Solenoids
The solenoids are energized by 120 volt potential that is controlled by the relays located inside the relay box.
The solenoid windings are protected from exces­sive heat with an internal thermal fuse that will open after approximately seven (7) minutes of continu­ous operation. The solenoid must be replaced if the internal thermal fuse has been blown. The solenoids are mounted directly on either side of the hydraulic mini-valves and push the spool valve in one direction or the other depending upon which solenoid is activated.
WARNING
Line voltage will be measured in this test. Do not touch uninsulated connec­tor pins or meter test leads.
b. Step #1
1. Plug the table cord into the wall receptacle
and turn main switch ON.
2. Disconnect the 2 pin connector from the
solenoid in question. See figure 5-8.
3. Use a voltmeter capable of measuring 120 VAC and measure the voltage across the 2 pin connector. Polarity of meter leads is not important.
NOTE
The appropriate pendant control but­ton must be pushed during this test. The motor will run when this test is performed, and the brake locking sole­noid will be activated by any function other than UNLOCK.
c. Test Results:
a. Solenoid Test
The following tests check the voltage applied to the solenoids and the resistance of the solenoid coil.
NOTE
If a solenoid does not function when the pendant control button is pushed, the problem could be the pendant control, the relay box, or the solenoid.
NOTE
Each solenoid is controlled with 120V source coming from the relay box. This source can easily be checked by mea­suring the voltage at the 2 pin connec­tor in question.
If you do not receive the correct voltage, the prob­lem could be in the wires leading to connectors CN6 and CN7. The problem could also be in the relay box or the Pendant Control (refer to appropri­ate section for troubleshooting).
If the correct voltage is obtained, everything is good up to that point and the problem is more than likely the solenoid.
d. Step #2
The solenoid can be checked out using an ohm­meter R x 1 scale.
1. Measure the resistance between the two pins of the connector in question. See figure 5-8. Connector being tested must be disconnected. Polarity of meter leads is not important.
2. The meter should read approximately 80-90 ohms at room temperature.
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Y
Y
3. Measure the resistance between either pin
and ground.
4. Meter should read infinity.
e. Test Results:
If the solenoid does not check out with the meter, it is more than likely defective and must be replaced.
OHM ACV
NOTE
Whenever there are several compo­nents of the same type, a defective unit can also be detected by substituting a known good unit or wire connector. In some cases this may be faster than using a multi-meter.
UP
DN.
TABLE TREND
HD.
DN.
UP
BLUE
WHITE/BLUE
UN-
DN.UPREFXRT.HD.
LCK.
LAT. TILT
LT.
FLEX
BACK
FLEX
SECT.
DN. UP SET
LEG SECT.
BRAKE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
BROWN
BLUE
ORANGE
BLUE
BROWN/WHITE
BLUE
WHITE/BROWN
BLUE
WHITE/GRAY
BLUE
BLACK/WHITE
BLUE
WHITE/BLACK BLUE
GRAY BLUE
BLUE/WHITE BLUE
RED/WHITE BLUE
WHITE/ORANGE BLUE
YELLOW BLUE
WHITE/RED
BLUE
RED
CN6
16
TO RELA BOX
1
CN7
16
TO RELA BOX
1
Page 28
Figure 5-8. Solenoid Test
Page 37
5-6. Motor/Pump Assembly
The electric motor is a capacitor start type with a rating of 120 VAC, 200 watts. The field windings are protected with a thermal protector that will open the winding circuit if the motor is run continuously for approximately 10 minutes. This protector will take about 10 minutes to automatically reset. The oil pump unit is attached to the bottom of the motor and is a gear type displacement pump with a pumping capacity of .4 liter per min. The Motor/ Pump Assembly is mounted on an insulated motor plate in the base of the table. The starting capacitor is mounted along side the motor/pump assembly
a. Motor/Pump Test
The following tests will check the voltage applied to the motor and the resistance of the motor field windings.
3. Use a voltmeter capable of measuring 120 VAC and measure the following connector pins in connector CN15. See figure 5-10.
ACV
3
2
1
PIN NO
1 - 2 1 - 3 2 - 3
AC VOLTS
120 120
0
Figure 5-10. Connector CN15
WARNING
Line voltage will be measured in this test. Do not touch uninsulated connec­tor pins or meter test leads.
b. Step #1
1. Plug the power cord into 120 VAC power
supply (wall receptacle). Turn main switch ON.
2. Disconnect the 3 pin connector CN15 at the motor. Leave all other connectors connected. See figure 5-9.
CAPACITOR
CN15
PUMP
c. Test Results:
If you do not receive the correct meter readings, the problem could be in the wires, connectors, relay box, or main switch (refer to appropriate section for troubleshooting).
If the correct voltage is obtained, everything is good up to that point and the problem could be either the motor or the starting capacitor.
d. Step #2
If the starting capacitor is shorted or grounded, the motor will not run. Capacitors very seldom fail, and it requires a dielectric tester to accurately test one. However, an ohmmeter can be used to determine if the capacitor will store a low voltage charge and most of the time this is adequate.
1. Turn the main switch OFF.
Figure 5-9.
2. Connector CN15 should be disconnected.
3. Use the R x 100 scale of the ohmmeter and touch pins 2 and 3 of connector CN15. See figure 5-10.
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Page 38
e. Test Results:
The meter needle should move up scale and then back down to infinity. This would indicate that the capacitor is storing an electrical charge.
NOTE
The capacitor may have to be dis­charged first (by shorting pins 2 and 3 together) before you will be able to see the ohmmeter needle swing up the scale.
OHM
f. Step #3
The motor windings can be statically checked for resistance using an ohmmeter.
1. Turn main power switch OFF.
2. Connector CN15 should be disconnected.
3. Use the R x 1 scale of the ohmmeter and measure the resistance between the pins located in the pump connector CN15. See figure 5-11.
PIN NO
1 - 2 1 - 3 2 - 3
METER
Approx. 5 ohms Approx. 4 ohms Approx. 8 ohms
Figure 5-11. Pump Connector CN15
g. Test Results:
If you do not receive the correct meter readings, the motor or wiring is defective.
Page 30
Page 39
5-7. Return-to-Level Micro-Switches.
The return-to-level feature is activated by a single button on the pendant control and automatically levels the major table functions, lateral tilt, tren­delenburg, back section, and leg section.
The return-to-level system consists of 6 micro­switches, 2 electrical connectors, and the related wiring. The micro-switches are mounted on or adjacent to the function they control and are wired for normally open or normally closed operation. The micro-switches are lever actuated and can be adjusted at the individual switch mounting brack­ets. See figure 5-12.
The micro-switches operate on low voltage, and control the function circuits (pump/motor and ap­propriate solenoid valves) when activated by the pendant control RETURN button.
The micro-switches are wired to the relay box through a riser cord and to the 15 pin connector CN2. See figure 5-12 for switch location and identification.
5-8. Troubleshooting
If a problem is suspected in the return circuits, disconnect the connector CN2 from the Relay Box to eliminate the circuits. Ensure that all table functions operate properly using the Pendant Con­trol. If the functions do not work properly using the Pendant Control, refer to the appropriate test sec­tion and make all needed repairs before working on the return circuits.
Figure 5-12.
Page 31
Page 40
B
NOTE
It is normal for the back section to move up if the RETURN button is pushed when connector CN2 is disconnected from the relay box.
operation at the appropriate pin numbers for the micro-switch in question as shown in figures 5-14 through 5-18.
NOTE
All of the micro-switches are connected to the relay box via a wiring harness and the micro-switch riser
Be sure to isolate the circuit when mak-
ing continuity checks. cord using connectors CN2 and CN10. Connector CN10 is located under the slider shroud in the same area as the hydraulic hoses. Connector CN2 plugs
NOTE
into the relay box and is the most convenient location to make circuit continuity checks. See figure 5-13 for connector pin locations.
If you do not receive the proper continu-
ity results at connector CN2 it does not
necessarily mean the micro-switch is
a. Switch Test
defective. There could be a problem
with the riser cord between connectors Turn Main Power ON, lock the table brakes, and place the table top sections in a level position. Disconnect connector CN2 from the relay box and using an ohmmeter, test the wiring and switch
16 15
8 7
13
BR/WHITE
BACK UP
ACK DOWN
TILT LEFT
TREND
NS-6
NS-5
TILT RIGHT
NS-4
NS-3
REVERSE TREND
NS-2
NS-1
6
12
5
11
4
3
10
2 1 9
CN10
PURPLE BLUE PINK GREEN YELLOW BROWN WHITE RED ORANGE
CN2 and CN10, or in the wiring from the switch to connector CN10. Further tests will have to be made to determine the exact problem.
15
PINK
BLACK/WHITE
14 13 12 11
10
9 8 7 6 5 4
3 2 1
CN2
Page 32
RISER CORD
Figure 5-13. Return Micro-Switch Test
Page 41
Figure 5-14. Trendelenburg Return Switches
CN10 CN2
10
9
Test at pins 3 & 9
Test at pins 4 & 9
Figure 5-15. Lateral Tilt Return Switches
Page 33
Page 42
G
M
NS-6
T
L M
T
14
NO
NO
NS-5
est at pins 5 & 14
COM
COM
PURPLE
WHITE/BLUE
BLUE
PINK
12
6
CN10
5
11
CN10
RISER CORD
RISER CORD
6
CN10
5
14
CN2
Test at pins 6 & 14
Figure 5-16. Back Section Return Switches
b. Switch Adjustment.
2. For all switches except the Leg Section
switches, carefully loosen the switch retaining If proper readings are not obtained during test or if table does not properly return to level, use the
screws, and adjust the switches as needed. See
figure 5-17. following procedure to adjust the switches.
3. To adjust the Leg Section switches remove
1. Apply table brakes and (using a level) level the table top using the TRENDELENBURG and LATERAL-TILT function buttons on the pendant control.
RETAININ SCREWS
ICRO-SWITCH
seat section top, loosen the 2 phillips head screws securing bracket, adjust the switch, tighten the screws and replace the seat section top. See figure 5-18.
PHILLIPS HEAD SCREWS
EG SECTION
ICRO-SWITCH
BRACKE
Figure 5-17. Micro-Switch Adjustment
Figure 5-18. Leg Section Micro-Switch
JAM NUTS
Adjustment
Page 34
Page 43
SOLENOID
R
C
COIL 24VDC
MINI-VALVES
6002B
PENDANT
PENDANT CONTROL
CONTROL
TO RETURN CIRCUIT
CN10
RELAY BOX
APACITOR
BATTERIES
CN4
CN51
CN14
CN9CN2
CN1
CN6
CN7
CN8
PUMP
CN19
CHARGER BOX
AUXILIARY CONNECTOR
CN14
CN12
AUXILIARY SWITCHES
SWITCH-OVER RELAY
22 VA C FROM TRANSFORMER
FUSE 15AMP
CN18
CN13
120 VA C T O TRANSFORME
CN15
POWER CORD
MAIN POWER
ICN1
BATTERY CHARGE INDICATOR
SWITCH
FUSE 10AMP
Figure 6-1. Electrical Circuit Block Diagram, Model 6002B
Page 35
Page 44
6002B
SECTION VI -6002B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING
6-1. General
The battery table components operate on 24VDC. The internal charging system also incorporates the components to transform the 120VAC input to 24VDC output to the components.
NOTE This section covers the electrical troubleshooting for the 6002B model ONLY.
6-2. Troubleshooting Notes
The basic operation of each component will be defined along with a drawing and explanation on how to check it out.
Certain defective components could cause the entire table to stop functioning or only one control function to stop. It would depend on what part of the component failed. Other defective components would only cause one control function to stop.
The following defective components could cause all control functions to be affected:
a. Motor/Pump Assembly b. Main Switch Circuit and Wiring
The following defective components could cause all control functions to be affected or only one control function:
a. Relay Box b. Pendant Control
The component listed below would only affect one control function:
Solenoid
When troubleshooting an electrical circuit, start at the problem and work back to the power source.
NOTE
•On the battery model tables, trouble­shooting should begin by switching the operating mode. For example; if a function fails when attempting to oper­ate the table in the AC120V mode, switch to the BATTERY mode. If the function now operates, the problem is probably located between the power cord and the relay box. If the function also fails when in battery operation, use the auxiliary switches to operate the function. If the function now operates, the problem is probably in the pendant control, connectors or wiring from the pendant control to the relay box.
•All connector pins are numbered usu­ally with very small numbers.
6-3. Main Switch
The main power supply, 120 VAC, 60 HZ, comes in through the power cord and through the main switch. The main switch opens both lines when in the "OFF" position. Two 10 amp fuses are used to protect the complete electrical system and are located next to the main switch.
a. Main Switch Test
The following test will determine if line voltage is applied to connector CN15, which in turn would supply 120VAC power to the table.
1. Plug the power cord into the 120VAC supply
(wall receptacle) and turn the main switch ON.
2. Disconnect connector CN15. See figure
6-1. Leave all other connectors connected.
WARNING
Page 36
Line voltage (120 VAC) will be mea­sured in this test. Do not touch uninsu­lated connector pins or meter test leads.
Page 45
6002B
DCV
BATT 1 BATT 1
3. Use an AC voltmeter capable of measuring 120 VAC and measure the voltage between pins 1 and 2 (black and white wires) located in connector CN15. See figure 6-3. You should receive line voltage 120 VAC.
BLACK (2)
ACV
WHITE (1)
Figure 6-3. Connector CN15 Test
b. Test Results
If the correct voltage is obtained, everything is good up to this point and the problem would have to be in another area. If you do not receive the correct measurements, the problem would have to be in the wires, main switch, fuses, or power cord. Check the continuity from the power cord connec­tor ICN1, through the fuses, switch and wiring to connector CN15. Remove the power cord, discon­nect CN15 (black and white wires), and test as shown in figure 6-4.
charging system automatically keeps the batteries at the proper charge level when the AC120V oper­ating mode is ON. The charging system will oper­ate while the table is being operated in the AC120V mode.
a. Battery System Test
1. Disconnect the main power cord and using a DC voltmeter, test each individual battery at its terminals. Meter should read 12VDC ± 1V.
2. To accurately test the batteries, they must be tested under a full load. Disconnect the main power cord and make sure all other connectors are connected.
3. Turn BATTERY power ON and elevate the table to its full up position.
4. Continue to press the TABLE UP button on the pendant control so that the pump motor contin­ues to run and using a DC voltmeter, check the voltage drop of each battery individually. See figure 6-5.
5. Meter should read 12VDC ± 1VDC.
TO GROUND
ICN1
L
CN15
2
1
N
BLACK
WHITE
OHM
Figure 6-4. CN15 to ICN1 Continuity Test
6-4. Batteries
The BATTERY operating mode is powered by two 12 volt batteries connected in series to provide the 24 volt operating power.
The battery system voltage should be 24VDC at a range of 22VDC to 26VDC. If the battery charge level falls below 23.5 volts the BATTERY operation indicator on the pendant control will blink indicating that the batteries require recharging. The built-in
Figure 6-5.
b. Test Results
A reading of 11 volts or below indicates the battery needs charging.
After batteries have been fully charged, repeat the full load test. If either battery's voltage drops below 11VDC it should be replaced.
Page 37
Page 46
9
(
6002B
6-5. Battery Charging Box/AC120V Transformer
The Battery Charging Box contains the battery charging system as well as the components for AC120V operation (except the transformer).
a. Transformer Test
1. Confirm 120VAC input at CN15 using Main
Switch test in 6-3a.
2. Connect CN15, disconnect CN18 (brown and red wires) and using an AC voltmeter, test the transformer output at CN18. See figure 6-6.
3. Meter should read 22VAC.
BROWN (2)
CN51
5
3
1
(1) BROWN
DCV
(5) RED / WHITE
6) BLUE / WHITE
BLACK (4)
RED (3)
(2) BROWN
Figure 6-7. Connector CN51
2. Meter should read 26.5 ±0.5VDC.
3. Test pin 5(+) and pin 6(-) of CN51 with DC voltmeter to test operation of CHARGING indicator light (next to power cord connector).
4. Meter should read 26.5 ±0.5VDC if charger is operating. If batteries are fully charged there will be under 5 volts at pins 5 and 6.
ACV
RED (1)
Figure 6-6. Connector CN18 Test
b. Test Results
If the correct voltage is obtained, everything is good up to this point and the problem would have to be in another area. If you do not receive the correct measurements, the problem may be in the wires, connectors, or transformer. The transformer is located in the rear of the base under the stainless steel base cover. The stainless steel cover will have to be discon­nected and lifted from the base for access to the transformer for further testing.
c. Battery Charging Box Test
d. Test Results
If you do not receive the correct readings, the charger system, connectors, wires, or the trans­former may be defective.
e. Charging System Output Adjustment
If output reading at pins 3 and 4 is not 26.5 ±
0.5VDC, the output can be adjusted at the variable resistor VR-R59 on the circuit board inside the Charging Box. See figure 6-8. Turn the adjuster clockwise to decrease the voltage. Counterclock­wise to increase the voltage.
NOTE
The battery connectors must be dis­connected to adjust the battery charger output.
1. Make sure all connectors are connected and
turn AC120V operation ON. Using a DC voltmeter,
VR-5
test pin 3(+) and pin 4(-) of CN51. DO NOT disconnect connector CN51. See figure 6-7.
Page 38
Figure 6-8
Page 47
-)
)
6002B
6-6. Switch-Over Relay
a. Switch-Over Relay in OFF Position
The Switch-Over Relay supplies the 24 volt input power from either the BATTERY or AC120V oper­ating modes to the relay box for table operation. In the normal OFF position, BATTERY power is sup­plied to the relay box. See figure 6-9.
RELAY BOX
FUSE
15A
CN4
S-O RELAY
2
1
3 4
7
(
8 6
5
RELAY BOX
CN4
FUSE 15A
CAPACITOR
CN15
CHARGING BOX
RELAY BOX SIGNAL OUT
S-O RELAY
2
1
8
3
6
4
5
BATTERY(+)
CN14
7
Figure 6-10. Relay in Activated Position
c. Switch-Over Relay Test
(-)
BATTERY (+
Figure 6-9. Relay in OFF Position
b. Switch-Over Relay in Activated Position
When the AC120V mode is activated by the main switch, a signal from the relay box activates the Switch-Over Relay. The relay then supplies the AC operating mode output power to the relay box and also activates the battery charging circuit. See figure 6-10.
NOTE
The battery charging circuit is only op­erational when the table is in the AC120V operating mode.
Using a DC voltmeter, test the operation of the relay in both the OFF (AC120V- OFF ) and Acti­vated (AC120V - ON ) positions. See figure 6-11.
NOTE
The Switch-Over Relay mounting block may have to be removed from the base for test access.
OFF: (AC120V - OFF)
term. 7(-) and term. 1(+) = 24 to 28VDC term. 7(-) and term. 6(+) = 0VDC
Activated: (AC120V - ON)
term. 7(-) and term. 6(+) = 26.5±1VDC
27
18
DCV
3
6
45
Figure 6-11. Switch-Over Relay
Page 39
Page 48
6-7. Pendant Control
6002B
The Pendant Control consists of 15 micro-switches (buttons). When any of the circuits are completed (by depressing a function button) the appropriate relay contacts (located in the relay box) close and a 24V potential is applied to the solenoid to operate the hydraulic mini-valve and to the hydraulic pump motor. The Pendant Control has 5 volts applied to it.
a. Pendant Control Test
The following test will determine if the micro­switches inside the Pendant Control are function­ing correctly.
1. Unplug the 24 pin Pendant Control connec­tor from the base of the table. You will be checking the cord side connector.
2. Use an ohmmeter R x 1 and check the continuity between pins 1 and pins 4 through 19 while pressing the appropriate button. Also test
between pins 21 and 22. See figure 6-12.
3. Ohmmeter must show continuity between the pins that are indicated when the appropriate buttons are pressed.
NOTE
Pins 2 and 3 are connected to the LEDs (AC120V and BATTERY indicator lights on the pendant control) and cannot be checked with an ohmmeter. Pins 17, 18, 20, 23 & 24 are NOT USED.
b. Test Results:
If you do not receive continuity between any of the pins, either the micro-switch in the Pendant Con­trol is defective or a wire is broken. Either of these problems can be repaired easily.
If you receive correct readings with the meter, there is nothing wrong with the Pendant Control.
Page 40
Figure 6-12. Pendant Control Test
Page 49
CN - 14 PIN NO.
CN1
CN13
OHM
CN - 1
WIRE COLOR
CN - 14 PIN NO.
CN - 1
WIRE COLOR
Red/White
White Black
Red
White/Red
Yellow Brown
White/Brown
Blue/White
Orange
White/Orange
Gray
White/Gray White/Yellow Purple/White
Black/White
Purple
White/Purple
Blue/Green Brown/White
Blue/Purple
1 2 3 4 5 6 7 8
9 10 11
12 13 14 15 16 17 18 19 20 21 22
c. LED Test
The BATTERY and AC120V power ON indicators can be checked with an LED tester. Test BAT­TERY indicator at pin 1(+) and pin 2(-) of 24 pin Pendant Control connector. Test AC120V indica­tor at pin 1(+) and pin 3(-). See figure 6-12.
If no LED tester is available the LEDs can be tested by applying 5 volts to the appropriate pins. To avoid damage to the LED a 330 ohm resistor must be placed between the power source and the connector pins. See figure 6 -13.
6002B
Figure 6-14. Table Base Connector
e. Test Results:
Figure 6-13. LED Test
d. Wiring Harness Test
The following test checks the wires leading from the relay box connector to the 24 pin connector table socket. These wires apply low voltage to the pendant control buttons.
1. Activate the AC120V operating mode.
2. Disconnect the pendant control from the table base connector. All other connectors should be connected.
3. Use a DC voltmeter and measure the following pins located in the 24 pin table base connector CN13. See figure 6-14.
NOTE
•A fine wire or a paper clip may be needed to accurately test the small sockets in the connector. The connec­tor is low voltage and there is no danger of electrical shock.
•Pin 19 will have no voltage potential unless one of the return-to-level micro­switches are activated.
If you do not receive the correct voltage reading, the wiring or connector pins may be faulty. Discon­nect connector CN1 from the Relay Box and using an ohmmeter, test the continuity between the cor­responding pins in connectors CN1 and CN13. See figure 6-15. If the correct readings are ob­tained, this part of the circuit is okay and the problem may be the relay box.
Figure 6-15. Base Connector Continuity Test
Page 41
Page 50
6-8. Auxiliary Switches
6002B
The following tests will determine if the auxiliary switches are functioning properly.
a. Switch Test
Disconnect connector CN9 at the Relay Box and using an ohmmeter check for continuity at the connector pins (pin 1A common) while activating the appropriate switch. See figure 6-16. Meter should read 0 ohms.
b. Test Results
If proper meter readings are not received, test the individual switches as necessary. Using an ohm-
meter, test the operation of an individual switch with the (+) test lead at the center terminal of the switch and the (-) test lead at the terminal opposite the direction of the switch actuation. See figure 6-
17. Meter should read 0 ohms. If the switches check out, the problem would have to be in the wires or connector CN9.
OHM
Figure 6-17. Auxiliary Switch Test
Page 42
Figure 6-16. Auxiliary Switch Connector CN9
Page 51
6-9. Relay Box
The power supply is directly connected to the relay contacts. When these contacts are closed, 24 volts is supplied to the solenoids which are mounted on the hydraulic mini-valves. One relay is used to supply power to the pump/motor and is always activated no matter what control function is se­lected. The brake locking circuit relay is also activated when any control function other than BRAKE UNLOCK is initially selected.
Also, inside the 6002B relay box is a step-down transformer and full-wave rectifier which decreases the voltage to 5-6 volts. This low voltage potential controls the relays by the use of the hand-held pendant control buttons. Basically the relays en­able a 5-6 volt potential to control the 24 volt circuit.
The following tests will determine if the relay box is functioning correctly.
6002B
Figure 6-18. Relay Box Input
a. Checking Relay Box Input Power
1. Plug the power cord into the 120VAC supply (wall receptacle). Disconnect connector CN4, leave all other connectors connected.
2. Using a DC voltmeter, test input power for both the BATTERY and AC120V operating modes. See figure 6-18. Meter should read approximately 24-28 volts.
BATTERY mode AC120V mode
pin 1=(+) pin 5=(+) pin 2=(-) pin 6=(-)
Connector CN4 Color Code
Pin 1 Red Pin 5 White Pin 2 Blue Pin 6 Black Pin 3 Yellow Pin 7 Yellow Pin 4 Blue
b. Test Results:
If you do not receive the correct meter readings, the problem is in the input wiring, connectors or components. If the correct readings are obtained, proceed to the next step.
c. Checking Output to Pump
1. Disconnect pump connector CN12, connect all other connectors and activate the AC120V oper­ating mode.
2. Test CN12 at pin 1(+) and pin 2(-) with a DC voltmeter. Meter should read approximately 24-28 volts when any function button is activated. If no voltage is present, use an ohmmeter to test the continuity from CN12 to CN4 (yellow and blue wires). Refer to figure 6-18 for pin locations.
Page 43
Page 52
d. Checking Output to Pendant Control
6002B
NOTE
The Relay Box connectors CN1 (Pen­dant Control), and CN8 (Auxiliary Base Connector), are interchangeable.
1. Disconnect the Pendant Control connector from the base connector, connect all other connec­tors and use a DC voltmeter to measure the follow­ing sockets located in the table base connector CN13. See figure 6-19.
NOTE
•A fine wire or a paper clip may be needed to accurately test the small sockets in the connector. The connec­tor is low voltage and there is no danger of electrical shock.
•To make sure all operating modes are OFF, connect the pendant control, turn AC120V power OFF at the main switch, wait approximately 5 seconds to make sure BATTERY operating mode is not activated and disconnect the pendant control.
4. Activate BATTERY operating mode by switching Main Power Switch OFF and momen­tarily placing a jumper wire between pin 21 and pin
22. Test pin 1(+) and pins 2 through 16(-). Meter should read 0VDC for pin 3; 5-6VDC for pins 2 and 4 through 16.
2. With the AC120V and BATTERY operating modes in the OFF position, test connector CN13 at pin 1(+) and pins 2 through 16(-). Meter should read 0VDC. Test at pin 21(+) and 22(-), meter should read 24-28VDC.
3. With AC120V power ON (Main Power Switch activated), test connector CN13 at pin 1(+) and pins 3 through 16(-). Meter should read 5-6VDC.
Page 44
Figure 6-19. Table Base Connector CN13
e. Test Results:
If you do not receive the correct meter readings, the relay box or wiring is defective. Test appropriate wires and connectors as necessary. If the correct readings are obtained, this part of the relay box is okay. Proceed to the next step.
Page 53
f. Checking Output to Solenoids
This test checks the voltage that is used to energize the solenoids.
1. Activate either BATTERY or AC120V oper-
ating mode.
NOTE
•The Brake Lock function is activated by pressing any function button (except BRAKE UNLOCK). A timer in the Relay Box allows continuous output for about 7 seconds. If the brakes are already locked, no output is provided.
•The BRAKE UNLOCK button activates another timer in the relay box which allows continuous output for the brake release function for approximately 7 seconds. If the brakes are already released (using the BRAKE UNLOCK button) no output is provided.
2. Test connectors CN6 and CN7 from the back while attached to the relay box. All connectors should be connected.
3. Activate each of the pendant control buttons and measure the output voltage for the corre­sponding connector pins with a DC voltmeter. See figure 6-20.
Figure 6-20. Connector CN6 or CN7
g. Test Results:
If you do not receive the correct meter readings, the relay box is defective and should be replaced.
NOTE
•Before deciding the relay box is de­fective, check the wires and pins in the connector blocks to make sure they are not loose or making a bad connec­tion with their mate.
•If the battery power is ON and no table functions have been activated for 3 hours, the power off circuit will interrupt the battery power.
Page 45
Page 54
5
7
6
5
6002B
6-10. Main Wire Harness Continuity Tests
If correct meter readings are not received in tests between components, before replacing the com­ponents, test the Main Wire Harness to be sure all connectors and wires are making a good connec­tion.
a. CN4 to Batteries Test
1. Disconnect connectors CN4 and the (+) and (-) connectors from the batteries. Leave all other connectors connected.
2. Using an ohmmeter, test for continuity between pin 1 of CN4 and battery (+) connector. Also test between pin 2 of CN4 and battery (-) connector. See figure 6-21.
NOTE
The 15 amp battery protection fuse is in the line between CN4 pin 1 and the battery connector. Test the continuity of the fuse if correct meter reading is not received.
b. CN4 to CN12 Test
1. Disconnect connectors CN4 and CN12.
Leave all other connectors connected.
2. Using an ohmmeter, test for continuity between pins 3 and 4 of CN4 and pins 1 and 2 of CN12. See figure 6-22.
4 3
2
1
CN-4
3 4
CN4
2
1
CN-12 OHMS
1 2
CN12
0 0
OHM
Figure 6-22.
c. CN4 to Charging Box Test
1. Disconnect connectors CN4, CN11 and CN51. Leave all other connectors connected.
7
4
OHM
3
6
2
5
1
CN4
(+)
(-)
Figure 6-21.
2. Using an ohmmeter, test for continuity between pins 4, 5 and 6 of CN4, pins 1 and 2 of CN11, and pin 4 of CN51. See figure 6-23.
CN51
5
3
6
4
2
CN-4
1
CN11
OHM
CN-51
5 6 4
OHMS
4
0 0 0
CN4
7
4
3
6
2 1
CN-11
1 2
Figure 6-23. CN4, CN11, and CN51
Page 46
Page 55
Y
Y
6002B
6-11. Solenoids
The solenoids are energized by 24 volt potential that is controlled by the relay box. The solenoid windings are protected from exces­sive heat by an internal thermal fuse that will open after approx. 7 minutes of continuous operation. The solenoid must be replaced if the internal ther­mal fuse has been blown. The solenoids are mounted directly on either side of the hydraulic mini-valves and push the spool valve in one direction or the other depending upon which solenoid is activated.
a. Solenoid Test
The following tests will check the voltage applied to the solenoids and the resistance of the solenoid coil.
b. Test #1
1. Activate either BATTERY or AC120V oper-
ating mode.
2. Disconnect the 2 pin connector from the solenoid in question, all other connectors should be connected. See figure 6-24.
3. Use a DC voltmeter and measure the voltage across the 2 pin connector. Pin 1(+), and pin 2(-). Meter should read approximately 24-28 volts.
UP
DN.
TABLE TREND
HD.
DN.
UP
OHM ACV
BLUE
WHITE/BLUE
UN-
DN.UPREFXRT.HD.
LCK.
LAT. TILT
LT.
FLEX
FLEX
BACK
LEG SECT.
BRAKE
SECT.
DN. UP SET
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
WHITE/BLUE
BLUE
BROWN BLUE
ORANGE BLUE
BROWN/WHITE BLUE
WHITE/BROWN BLUE
WHITE/GRAY BLUE
BLACK/WHITE
BLUE
WHITE/BLACK BLUE
GRAY BLUE
BLUE/WHITE BLUE
RED/WHITE BLUE
WHITE/ORANGE BLUE
YELLOW BLUE
WHITE/RED
BLUE RED
CN6
16
TO RELA BOX
1
CN7
16
TO RELA BOX
1
Figure 6-24. Solenoid Test
Page 47
Page 56
NOTE
•The appropriate pendant control but­ton must be pushed during this test. The motor will run when this test is performed, and the brake locking sole­noid will be activated by any function other than MOVE.
6002B
d. Test #2
The solenoid can be checked out using an ohm­meter R x 1 scale.
1. Measure the resistance between the two pin connector in question as shown in figure 7-24. Connector must be disconnected. Polarity of meter leads is not important.
•If a solenoid does not function when the pendant control button is pushed, the problem could be the pendant con­trol, the relay box, or the solenoid.
c. Test Results:
If you do not receive the correct voltage, the prob­lem could be in the wires leading down to the connector. The problem could also be in the relay box or the Pendant Control (refer to appropriate section for troubleshooting).
If the correct voltage is obtained, everything is good up to that point and the problem is more than likely the solenoid.
2. The meter should read approximately 16 ohms at room temperature.
3. Measure the resistance between either pin and ground.
4. Meter should read infinity.
e. Test Results:
If the solenoid does not check out with the meter, it is more than likely defective and must be replaced.
NOTE
Whenever there are several compo­nents of the same type, a defective unit can also be detected by substi­tuting a known good unit or wire con­nector. In some cases this may be faster than using a multi-meter.
Page 48
Page 57
CN12
OHM
6-12. Motor/Pump Assembly
b. Motor Resistance Test
The hydraulic pump motor is a 24 volt DC electric motor. The oil pump unit is attached to the bottom of the motor and is a gear type displacement pump with a pumping capacity of .4 liter per min. The Motor/Pump Assembly is mounted on insula­tors in the base of the table.
a. Motor/Pump Test
1. Disconnect motor connector CN12. Leave all other connectors connected and activate either BATTERY or AC120V operating mode.
2. Activate any function and use a DC voltme­ter to measure across the two pin connector. Pin 1(+) and pin 2(-). See figure 6-25. Meter should read 24-28 volts.
The motor can be statically checked for resistance using an ohmmeter. This test is not 100% accurate because you are checking the motor with very low voltage from the meter and without any load.
1. Using an ohmmeter R x 1 scale, measure the resistance between the two pins of CN12. See figure 6-26.
2. The meter should read 1 to 2 ohms at room temperature.
3. Measure the resistance between either pin and ground.
4. Meter should read infinity.
CN12
DCV
2 1
Figure 6-25. Motor Input Voltage
NOTE
If the pump has been activated continu­ously for 1-1/2 to 2 minutes, the thermal relay will interrupt the power to the pump.
Figure 6-26. Motor Connector CN12
c. Test Results:
If you do not receive the correct meter readings, the motor or wiring is defective.
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SECTION VII ELECTRICAL SYSTEM ADJUSTMENTS
7-1. Relay Box Adjustments - Models 6002 & 6002B
The Relay Box contains variable resistors for ad­justing the operating timers for the BRAKE SET and BRAKE UNLOCK functions. The Relay Box for the battery model tables (6002B) also has variable resistors for setting the Power Off timer and the battery recharge warning circuit. These timers are set at the factory and usually never need adjustment. If an adjustment is necessary, remove the relay box cover and use the following proce­dures. See figures 7-1 and 7-2.
a. Brake Release Timer
The Brake Release Timer is set for about 7 sec­onds and is controlled by the variable resistor VR1 on the relay box circuit board. Turn the adjuster clockwise to increase the operating time. Counter­clockwise to decrease the operating time.
VR1 VR2
b. Brake Set Timer
The Brake Set Timer is set for about 7 seconds and is controlled by the variable resistor VR2 on the relay box circuit board. Turn the adjuster clockwise to increase the operating time. Counterclockwise to decrease the operating time.
c. Battery Low Voltage Indicator
When the battery voltage drops below 23.5 volts, the BATTERY power indicator will begin to "Flash" indicating low battery power. This circuit is con­trolled by the variable resistor VR3 and should be set at 23.5 volts. Turn the adjuster clockwise to increase the voltage at which the circuit is acti­vated, counterclockwise to decrease.
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Figure 7-1. Relay Box Adjustments Model 6002
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VR2
VR3
VR1
Figure 7-2. Relay Box Adjustments Model 6002B
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Original printing -------------- 5/03 Revised--------------------------8/05
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5000 36th Street S.E., Grand Rapids, MI 49512
1-800-SKYTRON or 1-616-957-0500 • FAX 1-616-957-5053
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