Welch Allyn Exam Light 3 Service manual

Service Manual

Exam Light III Examination Light

Welch Allyn Medical Division

4341 State Street Road

P.O. Box 220

Skaneateles Falls, NY 13153-0220

488061 Rev. B Copyright 2002

Part# Revision Description ECN# Date Approved

488061 A New service manual 5-45435 01/20/03 DK

488061 B Page 24, Bubble 81, 488119

D* 08/12/09 D*

changed to new 714160

D*: See SAP DIR for change number, approver name, and date of approval.

Drawings and/or illustrations and/or part numbers contained in this document are for refer­ence purposes only. For current revisions call the Welch Allyn Customer Service phone
number listed in Section 1 page 3.

Service Manual 488061 Rev. B Welch Allyn Exam Light III i

Table Of Contents

Section 1: General Information

About the Exam Light....................................................................................................... 1

Features ............................................................................................................................ 1

Agency Approvals ............................................................................................................ 1

Cautions and Warnings..................................................................................................... 2

Help Information .............................................................................................................. 3

Section 2: Incoming Inspection

Incoming Inspection......................................................................................................... 1

Required Tools ..................................................................................................................1

Section 3: Troubleshooting

Initial Screening................................................................................................................ 1

Light Pipe.......................................................................................................................... 1

Focusing Sleeve ................................................................................................................ 1

Electrical Troubleshooting ............................................................................................... 1

Section 4: Disassembly and Repair

Cover Removal.................................................................................................................. 1

EMI Shield Removal......................................................................................................... 1

Lamp Clip Removal .......................................................................................................... 1

Lamp Removal .................................................................................................................. 2

Lamp Holder Removal...................................................................................................... 2

Lamp Baffle Removal........................................................................................................ 2

Light Pipe Connector Assembly Removal ....................................................................... 3

Transformer Removal ....................................................................................................... 3

Illuminated On/Off Switch Removal............................................................................... 4

Fan Removal .....................................................................................................................4

Rectifier Board Removal................................................................................................... 5

Light Pipe Connector Assembly Dissassembly................................................................ 6

Focusing Sleeve Assembly............................................................................................... 8

Appendix A: Repair Part Numbers
Appendix B: Expoded View Drawings/Photos
Appendix C: Electrical Schematic

ii Welch Allyn Exam Light III Service Manual 488061 Rev. B

Service Manual 488061 Rev. B Welch Allyn Exam Light III iii

iv Welch Allyn Exam Light III Service Manual 488061 Rev. B

General Information Section 1

has been tested to and conforms with the

within the 89/336/ECC

Electromagnetic Compatibility Directive.

provisions noted

About the Exam Light III

Welch Allyn’s Exam Light III
to fit on a wall, stand, or on an examination table. The Exam Light III delivers bright, white,
fiber optic illumination for better visibility and more accurate diagnosis.

TM

takes flexible illumination to a new level. It mounts easily

Features

• Durable fiber optic pipe provides cool illumination and is bendable to almost any posi­tion.

• Easy to position, small, non-obstrusive head does not block view for task areas.

• Light weight focusing sleeve optics are sealed for less dust.

• Provides homogenous spot and variable spot size.

• Easy to maintain dichronic halogen lamp provides brighter, whiter light (3,200°F).

• Multiple mounting options for greater flexibility.

• Special UV filters provide safe trans illumination of neonates to detect pneumothorax
conditions and intacranial hemorrhaging, perform infant venipuncture, and locate blood
vessels (Model 48760 only).

Agency Approvals

The CE mark on this product indicates that it

Australia EMC Framework Compliance

N344

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Section 1 General Information

Cautions and Warnings

Intense Light: Lamp is extremely bright. Do not stare at the lamp when in
use. May be harmful to eyes.

Caution: Remove power cord from electrical outlet and allow lamp to cool
10 minutes before replacing with a Welch Allyn lamp.

Danger: Electrical shock hazard. Refer servicing to qualified service per­sonnel.

Caution: Risk of explosion if used in the presence of flammable anesthet­ics.

Hot Surface: Lamp is hot. May be harmful to skin if touched.

NOTE: This product complies with the current required standards for electromagnetic inter­ference and should not interfere with other equipment or be affected by other compliant
devices. As a precaution, avoid using this device in close proximity to other equipment.

2 Welch Allyn Exam Light III Service Manual 488061 Rev. B

General Information Section 1

Welch Allyn Inc.
State Street Plant /Corporate Headquarters
4341 State Street Road
Skaneateles Falls, NY 13153-0220, USA

tel: [phone]
315-685-4100
fax: [phone]
www.welchallyn.com/medical/support/tech

MD I nternational
11300 N.W. 41st Street
Miami, FL 33178 USA

tel: [phone]

Welch Allyn G MBH
Zollerstrasse 2-4
72417 Jungingen, Germany

tel: [phone]

Welch Allyn France SARL
814 rue Charles de Gaulle
77100 Mareuil les Meaux
France

tel: ( 011) 33 1.6009.3366
Fax: [phone]

Welch Allyn UK Ltd
St. Georges House
Vernon Gate, Derby
England DE1 1UQ

tel: [phone]-206208
fax: [phone]-206209

Welch Allyn Australia Pty
The Metro Centre Unit 5
38-46 South Street
Rydalmere NSW 2116, Australia
Postal address:
PO Box 132
Rydalmere NSW 1701, Australia

tel: [phone]

Welch Allyn Singapore Ltd

300 Beach Road, #25-08

The Concourse

Singapore 199589, Singapore

tel: (011)

65-291-0882

fax: (011)

65-291-5780

China Service Center
Room 708 Central Plaza
No. 277 Huang Pi Bei Rd.
Huang Pi District
Shanghai 200003
China

tel: [phone]

Welch Allyn Japan K.K.
Bon Marusan 8F, 3-5-1 Kanda

J

-Cho, Chiyoda-Ku

Tokyo 101-0051

J

tel: [phone]

Help Information

To assure correct operation and performance all service and repairs must be performed by
fully trained and properly equipped personnel, using genuine replacement parts and correct
procedures. Failure to do so will also invalidate the product warranty.

fax: [phone]

mob: [phone]

fax: [phone]

fax: [phone]

inbo

apan

fax: [phone]

Service Manual 488061 Rev. B Welch Allyn Exam Light III 3

fax: [phone]

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Service Section 2

Incoming Inspection

NOTE: Use the following guidelines when unpacking the Exam Light III from its shipping
carton.

1. Before opening the Exam Light shipping carton, check for damage.

2. If damage is apparent, stop unpacking the carton and contact the shipping company for

further instructions. If the carton is intact, unpack the Exam Light.

3. With the Exam Light out of its carton, check to see that all the items listed on the

packing slip are in the shipping carton.

4. If an item is missing, first check the carton, then check with your receiving

department. If necessary contact Welch Allyn at the Address and phone number
shown in Section 1.

5. Clean and disinfect by following the instructions printed in the Operator Manual.

NOTE: Perform all functional tests before and after servicing.

6. Operate the Exam Light to verify the customer complaint before making any changes to

the unit. Call the customer if the complaint is unclear.

7. If the unit has caused or is suspected of having caused an injury of any type:

DO NOT DISASSEMBLE OR REPAIR THE UNIT IN ANY WAY.

Contact Welch Allyn Customer Service immediately.

Required Tools

Phillips Screw Driver

Flat Head Screw Driver

Standard Needle Nose Pliers
11/32 Nut Driver

5/64 Nut Driver
3/8 Nut Driver
5/64 Hex wrench

Digital MultiMeter

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Blank Page

Troublshooting Section 3

Initial Screening

1. Inspect the Exam Light for physical damage - cracked cover, etc.

2. Attempt to confirm reason for return.

3. If reason can not be determined, contact the sender.

Light Pipe

1. Flex the light pipe at each bend and replace any that:

A. Have noisy monocoils.

B. Show signs of not holding position.

C. Have excessive springback when positioned in a “U” position.

NOTE: When the light pipe is placed in the “U” shape, at the center bend, the pipe
should not spring back by more than 8 to 9 inches. When the light pipe is bent in a “U”
shape at the light source bend, the spring back should not be more than 4 to 5 inches.

Focusing Sleeve

1. Check for cracks or damage.

2. Check for smooth operation of the lens when the sleeve is turned.

3. Replace any lens that have scratches.

Electrical Troubleshooting

WARNING: Turn off and unplug unit between each of the next steps.

1. Lamp does not light and the green rocker switch does not light.

A. Pull fuses out and check fuses with ohm meter.

B. Attach a known good power cord.

C. Replace the green rocker switch.

D. Check the AC connector for damage and cracks.

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Section 3 Troubleshooting

2. Green rocker switch light is illuminated but the lamp does not light.

A. Check for proper lamp. It should be 12 volt 35 watt, Welch Allyn #04200.

NOTE: If the lamp is replaced, burn the unit in for at least one hour to confirm there are not
other issues.

B. Check transformer output. It should measure 12vac.

C. Lift lamp out of bracket and check filter and gasket.

NOTE: The gasket should not be blocking the light. The filter should not be cracked,
chipped or dirty.

2 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Disassembly and Repair Section 4

Observe All ESD
Precautions!

Turn unit off. Unplug the
power cord from the outlet
and from the light box!

1. Cover Removal

Unscrew the captured screw at the bottom of
the main housing. Push the cover up and for­ward.

NOTE: Take extreme care when removing the
cover. The tabs on the cover may break if you
do not push the cover all the way up before
removal.

2. EMI Shield Removal

Remove the 5 phillips head screws.

NOTE: Notice manufactured date stamp on
the EMI shield.

3. Lamp Clip Removal

For first time lamp removal, grasp the wire
clip at the top of the lamp. Rotate the clip
toward the base of the unit it pops out.

NOTE: Discard the clip. It is used only for
shipping.

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Section 4 Disassembly and Repair

4. Lamp Removal

Grasp the lamp connector and pull the lamp
straight out of its holder.

5. Lamp Holder Removal

Remove the two nuts.

6. Lamp Baffle Removal

Remove the one phillips head screw.

2 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Disassembly and Repair Section 4

LLight
Blue

Blue

Black

Brown

7

. Light Pipe Connector Assembly Removal

With a 5/64 hex wrench, slightly back the hex
nut off the pipe connector assembly. Slide the
pipe connector assembly out. The pipe con­nector assembly can only be removed from
the inside of the main housing

8. Transformer Removal

Remove the 4 phillips head screws.

NOTE: Note the wire orientation and wire
color on the illuminated off/on switch
wires must be removed from the illuminated
switch before the illuminated switch can be
removed.

The photo shows the wiring as wired for
domestic 120V. See the wiring diagram in
Appendix C for the wiring in your local area.

. The

Service Manual 488061 Rev. B Welch Allyn Exam Light III 3

Section 4 Disassembly and Repair

9. Illuminated Switch Removal

Squeeze the outer tabs on the switch and
push outward.

NOTE: Notice the orientation of the switch
when properly installed.

10. Fan Removal

Use a 3/16 driver on the hex nut and a flat bed
screw driver on the screw and remove all four
fasteners. Disconnect the fan connector from
the PCB.

4 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Disassembly and Repair Section 4

CC

B

A

GGreen

Blue

Brown

NOTE:

A. Notice how the wires are secured
to the chassis.

B. Notice how wires are routed
through the channel with rubber
grommets.

C. Notice wire ties on brown wires.

Note
the IEC connector and wire colors

: Notice the wiring orientation to

11. Rectifier board removal

Remove all four phillips head screws.

Service Manual 488061 Rev. B Welch Allyn Exam Light III 5

Section 4 Disassembly and Repair

12. Light Pipe Connector Assembly Disassembly.

A. Remove the retaining ring.

B. Remove the square heat filter.

C. Remove the heat filter gasket.

6 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Disassembly and Repair Section 4

D. Remove the two hex set screws that
secure the insulator to the retaining collar.

E. Pull the retaining collar from the insulator.

F. Remove the brake from the inside of the
insulator.

Service Manual 488061 Rev. B Welch Allyn Exam Light III 7

Section 4 Disassembly and Repair

13. Focusing Sleeve Assembly

A. Insert the rear lens inside the main body.

NOTE: The rear lens is the lens with the
smaller diameter convex shape in the middle
of the lens. The convex shape should be fac­ing outward.

B. Insert the front lens into the main body.

NOTE: The front lens is the lens with the
larger convex shape. The convex shape
should be facing outward.

C. Insert the end window into the main body.

NOTE: There are three very small tabs on the
lip of the end window. Line those three tabs
with the three long slots of the main body.

8 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Disassembly and Repair Section 4

FFront
Lens
Tab

Rear Lens
Tab

NNote the slot

D. Attach the three cam sleeves to the main
body. Align the cam slots of the cam sleeve
with the front and rear lens tabs.

NOTE: Align one sleeve with the front and the
rear lens and the other two sleeves with go on
easier.

NOTE:
lens tabs, on the front and rear lens, fit in the
cam sleeve.

Note:
at the rear of the cam sleeve. The slot must
face toward the rear of the assembly.

Observe how the front and the rear

Observe that each cam sleeve has a slot

Service Manual 488061 Rev. B Welch Allyn Exam Light III 9

Section 4 Disassembly and Repair

E. Slide the rear body over the main body
assembly.

NOTE: There are three tabs in the rear of the
rear body. The rear body tabs will need to fit
into the slots of the cam sleeves. You may
have to rotate the rear body to get the rear
body tabs to fit in the cam sleeve slots.

F. Slide the front body over the assembly. You
may have to rotate the front body. The front
body will snap in place.

10 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Repair Parts Appendix A

Bubble # Part # Description

1 236732 IEC CONNECTOR

2 488042 WIRE HARNESS,PWR MOD/GROUND S

3 488074-502 WIRE HARNESS, POWER MOD/SWITCH

4 488074-501 WIRE HARNESS,POWER MOD/SWITCH

5 236707-2 ILLUMINATED SWITCH-EXPORT 250VAC

6 488053 MOLEX HOUSING

7 106140-19 #6-32 X 1.375 PH,PN,ST,ZN

8 236733 FUSE DRAWER

9 236706-3114 FUSE 500MA USA

10 443071-1 TRANSFORMER, 35W

11 443093 SPARE WIRE CAPS

12 236706-3112 FUSE- 315 MA EUROPE, UK, Aus.

13 488307-4 FUSE-630 MA, JAPAN

14 761076-0 POWER CORD, DETACH.(DOM/JAPAN)

15 761076-2 POWER CORD-DETACH (EUROPEAN)

16 761076-4 POWER CORD-DETCHBL(U.K)

17 761076-6 POWER CORD DETACH. (AUSTRALIA)

18 106130-2 QUICK CONNECT RECEPTACLE

19 488082 MOLEX CONNECTOR

20 48200 FIBER OPTIC LITE PIPE ASSY

21 48605 FOCUSING SLEEVE ASSEMBLY

22 488106 INNER SLEEVE

23 488401-2 BODY-MAIN,MACHINED

24 488406 CAM SLEEVE

25 488403 REAR LEANS

26 488405 END WINDOW

27 488408 FRONT OUTER BODY

28 488404 FRONT LENS

29 488407 REAR BODY

30 488035 RETAINING COLLAR

31 488034 INSULATOR

32 488311 FILTER-HEAT

33 106101-2 RETAINING RING

34 488432 BRAKE

35 488312 GASKET-HEAT FILTER

36 106113-22 SET SCREW, 6-32 X .125 CUP

37 488001-502 PIPE CONNECTOR ASSEMBLY

38 236707-1 ILLUMINATED SWITCH-DOMESTIC 125VAC

39 488118-501 REAR HOUSING, ASSY COMPLETE

40 747187 #8-32 HEX NUT-CAD PLTD

41 483412 #8 EXTERNAL LOCKWASHER

42 106137-2 NUT,8-32 EXTLOCK

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Appendix A Repair Parts

Bubble # Part # Description

43 488110 KEYHOLE STANDOFF

44 488112 CAPTIVE PANEL SCREW

45 106140-3 4-40 X.25 W/EXT WASHER

46 488070 487 MODEL LABEL JAPAN

47 488069 487 MODEL LABEL (DOM)

48 488083 LAMP CHANGE LABEL

49 488071 487 MODEL LABEL EUROPE

50 488072 487 MODEL LABEL (AUST/UK)

51 455508 LABEL, PROTECTIVE EARTH GROUND

52 488089 CLIP REMOVAL LABEL

53 488116 WIRE TIE

54 443083 WIRE TIE W/MOUNTING HOLE

55 106100-4 PHPS 4-40 X .38 LG

56 488066 EMI SHIELD, 35W

57 488076-501 TRANSFORMER/WIRE HARNESS (DOM)

58 488043-503 FAN WITH WIRE HARNESS

59 488073-501 WIRE HARNESS LAMP/REC.BOARD

60 488058 LAMP HARNESS CONNECTOR

61 495073 LAMP HARNESS CONNECTOR

62 488077 LAMP CONNECTOR

63 106102-35 FHCS 4-40 X .75,NYLON BLACK

64 106109-13 NUT 4-40 SM,SM.HEX, STEEL ZINC

65 106140-18 3-48 X .250 PHP,ST.ZN W/WAS

66 488067-501 RECTIFIER BOARD

67 488063 MR16 LAMP HOLER

68 488084 35W BAFFLE

69 106137-1 NUT,4-40X.250 HEX,KEPS EXTLOCK

70 106102-40 FHPS #8-32 X .500

71 488023 BRACKET, WALL MOUNT

72 488206 MOUNTING PLATE 48780 ONLY

73 482205 RECEIVER BRACKET 48780 ONLY

74 488111 INSULATOR, TRANSFORMER

75 042000 HALOGEN LAMP-2 PIN

76 488011-2 FRONT COVER W/LOGO

77 488420-502 MOUNTING HARDWARE KIT

78 482200-501 FLEXIBLE FIBER OPTIC CABLE ASSY

79 106113-25 CUT PT.SET SCR,8-32X.25 STEEL

80 488082 Molex Connector

81 714160 Operation Instruction

82 488061 Service Manual

2 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

Appendix B Exploded View Drawings/Photos

57

74

Transformer
Insulator

2 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

59

60

62

61

66

65

64

63

58

Service Manual 488061 Rev. B Welch Allyn Exam Light III 3

Appendix B Exploded View Drawings/Photos

39

40

41 42

43

44

4 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

68

45

67

69

Service Manual 488061 Rev. B Welch Allyn Exam Light III 5

Appendix B Exploded View Drawings/Photos

6 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

21

22

23

25

26

24

27

28

24

24

29

75

Service Manual 488061 Rev. B Welch Allyn Exam Light III 7

Appendix B Exploded View Drawings/Photos

76

77

78

For the 48780

83

Neonate
Lite
Pipe

8 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

45

56

Service Manual 488061 Rev. B Welch Allyn Exam Light III 9

Appendix B Exploded View Drawings/Photos

37

79

Set Screw

30

31

36

35

34

33

32

10 Welch Allyn Exam Light III Service Manual 488061 Rev. B

Exploded View Drawings/Photos Appendix B

46

47

48

49

50

51

52

53

54

55

Service Manual 488061 Rev. B Welch Allyn Exam Light III 11

Appendix B Exploded View Drawings/Photos

70

71

72

73

12 Welch Allyn Exam Light III Service Manual 488061 Rev. B

TRANSFORMER PRIMARY
BLU - COMMON
WHT - 100V TAP
BLK - 120V TAP
BRN - 230V TAP
GRAY - 240V TAP

1

4

J4

RECTIFIER BD.

POWER

SWITCH

DPST

IEC

CONNECTOR

F1

F2

FUSE

LINE

NEUTRAL

GND

FAN

BLACK

RED

CHASSIS

TRANSFORMER

12VAC

BRN

BLU

BLU

WHT

RED

YEL

1

2

J1

LAMP

BRN

BRN

AC LINE

1

2

J5

­+

GRN/YEL

BLK

WHT

BRN

GRAY

Electrical Schematic Appendix C

Service Manual 488061 Rev. B Welch Allyn Exam Light III 1

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