Welch Allyn Traditional Instruments User manual

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Traditional Instruments

Service Manual

Traditional Instruments

PN 117081-1

Medical Division

4341 State Street Road, P.O. Box 220

Skaneateles Falls, NY 13153-0220

PN 117081-1

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Drawings and/or illustrations and/or part numbers contained in this document are for reference purposes only. For current revisions call Welch Allyn Customer Service 1-800-535-6663.

If during servicing these products, you require further technical assistance, call Welch Allyn.

Traditional Instruments Service Manual PN 117081-1

TABLE OF CONTENTS

Section 1 ................................................................ Ophthalmoscope

Section 2 ..................................................................Strabismoscope

Section3 ....................................................................... Retinoscopes

Section 4 ...........................................................................Otoscopes

Section 5 ................................ Illuminated Bivalve Nasal Speculum

Section 6 ............................................................ Larynx Illuminator

Nasopharynx Illuminator

Larynx Illuminator

Nasopharynx Illuminator

Section 7 ..............................................................Tongue Depressor

Section 8 ...................................................... Fiber Optic Anoscopes

Procto-Sigmoidoscopes

Fiber Optic Light Head

Standard Anoscopes

Rotating Anoscope

Section 9 ..........................................................................Headlights

Section 10 ...........................................................................Episcope

Section 11 .................................................... Laryngoscope Handles

Section 12 ....................................................................... Illuminator

Section 13 .......................................................Laryngoscope Blades

Section 14 ............................................................... Battery Handles

Section 15 .................................................................. Light Handles

Section 16 .......................................................................... Penlights

Pocket Lights

Section 17 ..............................Binocular Indirect Ophthalmoscoope

Section 18 ........................... Binocular Indirect Ophthlamoscope II

Section 19 .......................................................................CompacSet

Section 20 ...................................................CompacSet Ophthalmic

Section 21 ................................................... 767 Wall Transformner

Section 1

OPHTHALMOSCOPES

MODEL # SUB-SECTION PAGE

11110 A 1-2, 11400, 11411 B 3 11470, 11475, C 4 11500, 11511 D 5-6 11600 E 7 11605 F 8 11610 G 9 11620 H 10 11630 I 11-12 11650 J 12-13 11660, 11710 K, L 14 11720 M 15-16 11730 N 17-18 12810, 12813, 12814, 12830 0 19-20 APPENDIX 1 21 APPENDIX 2 22 APPENDIX 3 23 APPENDIX 4 24-26

OPHTHALMOSCOPES

Special Instructions Ophthalmoscope Service:

Clean all returned ophthalmoscopes by wiping with a solution of 10% Clorox / 90% water. Do not apply alcohol, chemicals or water to the mirror or lenses. Follow disassembly and assembly sequences as printed. Disassembly of the Optical Tube Base is not recommended or covered by this Service Manual. Always begin service work with a thorough understanding of the customer’s complaint and its cause. Avoid overtightening of fasteners by applying light tightening torque.

Notes: 1. “*SLP*” means “Small Loose Parts” and cautions you to disassemble carefully,

reducing the chances of losing small, possibly spring-loaded, parts.

2. Use T-10913 for loosening the lock ring.

3. Refer to corresponding diagrams in Welch Allyn Repair Parts Catalog PN

900299.

A. 11110 2.5 Volt Halogen Lite Set ™ Ophthalmoscope Disassembly:

A1 Lamp -- Pull lamp from bottom of optical tube.

A2 Bumper -- Pull corner, peel back.

A3 Cover Ass'y -- Loosen retaining ring.

(Doctor-side)

A4 2 Screws -- Un-screw 2 screws, (torx 05).

Remove cover assembly (doctor-side) *SLP*. Remove (from doctor-side cover): lens disc, lens dial index spring, magnifier lens.

A. 11110 2.5 V Halogen Lite Set™ Ophthalmoscope Cont'd: A5 Ophthalmoscope -- Remove: Horseshoe (PN111026)

Body Assembly Numeral Illuminator

Aperture Disc Assembly Index Spring 2 Screws (Holding the lens holder ass'y) Lens Holder Assembly Filter Housing and Filter * Optical Tube Base *Filter is easily scratched.

**** 11110 Reassembly ****

A6 Ophthalmoscope -- Insert optical tube base assembly into ophthalmoscope body.

Body Assembly Inspect filter over shiny metal surface and look through filter at

its own shadow. One side will show a ‘blue’ tint. Place tint side of the filter towards the inside of the scope during reassembly. When using new replacement filter, remove protective polyethylene films 2 sides. Insert filter into filter housing and place into ophthalmoscope body with filter housing finger tab towards top of the scope. Place lens holder assembly into position and fasten with 2 screws. Place index spring onto raised anchor. Rounded indexing spring end should face the hub. Place aperture disc assembly onto hub with apertures at bottom. Place numeral illuminator on top of the center of the aperture disc assembly with pivot in hole at base. Place horseshoe over numeral illuminator with open end of horseshoe at top as shown in parts diagram and notch directly over numeral illuminator.

A7 Cover Assembly -- Place lens dial index spring onto the raise anchor. (Rounded

(Doctor Side) end of indexing spring towards lens disc assembly hub).

A8 Lens Disc Assy. -- Clean disc. Place disc on hub. (Number side down) engage

with detent.

A9 Cover Ass'y -- Place cover onto ophthalmoscope body assembly. Place ring

(Doctor Side) onto base with numbers “128” right-side-up. Tighten ring,

screws. Install bumper.

A10 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 11110 Reassembly

B 11400 and 11411 2.5 Volt Ophthalmoscope Disassembly:

B1 Bumper -- Pull corner, peel back.

B2 Back Cover -- Loosen and remove retaining ring.

(Doctor-side)

B3 2 Screws -- Remove 2 screws, (torx .05) separate covers. *SLP*

Remove (from doctor-side cover):lens disc, center hub (metal) indexing spring, lens retainer, magnifying lens.

B4 Housing -- Separate housing from optical tube base assembly. (Patient-side)

B5 Lamp -- Pull lamp from bottom of optical tube.

**** 11400 and 11411 Reassembly ****

B6 Cover -- Insert optical tube base assembly.

(Patient-side)

B7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover. (Return bend on left side)

B8 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

B9 Lens Retainer -- Place lens retainer on top of lens.

B10 Lens Disc Ass'y. -- Clean disc. Place disc in cover. (Number side down, engaged

with detent) place hub in center of lens disc (small pivot side up).

B11 Cover -- Place cover onto patient-sidecover/optical tube base assembly.

Install and tighten ring (undercut knurl or smooth edge at bottom) screws. Install bumper.

B12 Lamp -- (Only halogen lamps are available for the 14000).

Align pin of lamp into groove of lamp socket and press lamp in. Test.

End 11400 and 11411

C 11470 and 11475 2.5 Volt Ophthalmoscope Disassembly:

C1 Bumper -- Pull corner, peel back.

C2 Back Cover -- Loosen and remove retaining ring.

(Doctor-side)

C3 2 Screws -- Remove 2 screws, (torx .05) separate halves.*SLP*. Remove

(from doctor-side cover): lens disc, indexing spring and button, lens retainer, magnifying lens.

C4 Housing -- Separate housing from optical tube base assembly.

(Patient-side)

C5 Lamp -- Pull lamp from bottom of optical tube.

**** 11470 and 11475 Reassembly ****

C6 Cover -- Insert un-printed plug (tabs pointing to top of instrument),

(Patient-Side) optical tube base assembly.

C7 Indexing spring -- Place spring into position below bumper cut-out of doctor-side

cover. (2 tabs on spring facing down).

C8 Indexing Button -- Place button, into guides beneath spring, flat side to spring.

C9 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

C10 Lens Retainer -- Place lens retainer on top of lens.

C11 Lens Disc Ass'y. -- Clean disc. Place disc in cover.

(Number side down, engaged with detent)

C12 Cover -- Place cover onto patient-side cover/optical tube base assembly.

(Doctor-Side) Install and tighten ring (undercut knurl or smooth edge at

bottom), screws. Install bumper.

C13 Lamp -- Align pin of lamp into groove of lamp socket and press in. Test.

End 11470 and 11475

D 11500 and 11511 2.5 Volt Ophthalmoscope Disassembly:

D1 Rubber Hood -- Pull corner, lift up.

D2 Light Carrier -- Pry/pull out light carrier assembly and remove condensing

Assembly lens and lamp.

D3 Back Cover --

(Doctor-Side) key). Remove light carrier retaining spring from ring nut if

D4 Ophthalmoscope -- Remove lens disc and small glass lens. Do not remove

Body aperture assembly disc now. Clean lens disc. Check tightness

D5 Aperture Ass'y -- Pull aperture assembly (disc) straight up. Remove small detent

Loosen/remove

damaged. Remove base. Remove cover. *SLP* (Glass lens PN106006)

of the three small brass screws in center of lens disc. (Do not disassemble lens disc) *SLP* clean in ultrasonic bath. Optional upgrade: Replace multi-lens disc with acrylic lens disc. Remove clear plastic washer (.76" or 19.4mm outside diameter / .45" or

11.58mm inside diameter, PN 106017) brass insert (disc) from hub. Remove lens disc indexing spring detent at top. Un-screw screws from mirror holder assembly, and remove mirror assembly.

spring, clear plastic spacer (.75" or 19.19 mm outside diameter / .223" or 5.67 mm inside diameter, PN 106019; not found on all 115 scopes)

set screw first and then ring nut. (Use .035" hex

**** 11500 and 11511 Reassembly ****

D6 Ophthalmoscope -- Insert both detent springs (top spring return bend to the left;

Body bottom spring return bend to the right). Place clear plastic

spacer (small hole) onto hub. Place aperture disc ass’y on hub (engage detent spring). Place mirror holder assembly over edge of aperture disc and fasten with 2 screws. Place clear plastic washer (large hole) and hub insert onto mirror holder assembly hub.

D 11500 and 11511 2.5 Volt Ophthalmoscope Reassembly:

D7 Lens Disc Ass'y -- Place lens disc assembly onto hub (number side up) and engage

in detent. Optional upgrade: Acrylic disc PN 116041-502.

D8 Magnifying Lens -- Place lens (flat side onto lens disc) onto horizontal lens disc and

position it over the bottom-most number. This will line up with opening in doctor-side cover. Gently engage and lower doctorside cover onto the ophthalmoscope body assembly and magnifying lens. Make sure the lens is still aligned to fit into the hole in the doctor-side cover. Do not chip or scratch the magnifying lens.

D9 Base -- Install base. Temporarily engage the base set screw into the hole

in bottom of scope casting. Install light carrier retaining spring onto base retaining ring nut, and screw the ring nut into the base (use Welch Allyn wrench T-11896). Do not thread ring nut into the base if the set screw extends into the thread area. This will damage set screw and ring nut. Make sure the set screw will not interfere with the ring nut by first partially unscrewing the set screw. Then tighten the ring nut. Tighten set screw and inspect for burrs on set screw head. Install rubber hood.

D10 Light Carrier -- Clean lamp, lens. Install lamp into light carrier. Engage alignment

pin of lamp into groove of lamp socket. Slide condensing lens assembly over lamp. Insert light carrier into base of scope. Test.

End 11500 and 11511

E 11600 3.5 Volt Halogen Ophthalmoscope Disassembly:

E1 Bumper -- Pull corner, peel back.

E2 Back Cover -- Loosen retaining ring.

(Doctor-Side)

E3 2 Screws -- Remove 2 screws, (torx .05) separate halves. *SLP*

From the doctor-side cover, remove: Lens disc, center hub (metal) indexing spring, magnifying lens. (Early11600 models have separate glass lenses (23) in lens disc, and a glass magnifying lens.) Do not disassemble lens disc for cleaning.*SLP* Clean in ultrasonic bath. Optional upgrade: replace glass lens assembly with acrylic lens disc, new cover acrylic magnifying lens.

E4 Housing -- Separate housing from optical tube base assembly. (Patient-side)

E5 Lamp -- Pull lamp from bottom of optical tube.

**** 11600 Reassembly ****

E6 Cover -- Insert optical tube base assembly.

(Patient-side)

E7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover. (Return bend on left side)

E8 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

E9 Lens Disc Ass'y -- Clean disc. Check tightness of 3 small brass screws on disc.

Do not unscrew these 3 screws. Place disc in cover with number side down and engaged with detent. Place hub in center of lens disc (small pivot side up)

E10 Cover -- Place cover onto patient-side cover/optical tube base assembly.

(Doctor-Side) Tighten ring, screws. Install bumper.

E11 Lamp -- Align pin if lamp into groove of lamp socket and press lamp in.

Test.

End 11600

F 11605 3.5 Volt Halogen Ophthalmoscope Disassembly:

F1 Bumper -- Pull corner, peel back.

F2 Back Cover -- Loosen retaining ring.

(Doctor-Side)

F3 2 Screws -- Un-screw 2 screws, (torx .05) separate halves. *SLP*

Remove (from doctor-side cover): lens disc, indexing spring, magnifying lens retainer & lens.

F4 Housing -- Separate housing from optical tube base.

(Patient-Side) Assembly

F5 Lamp -- Pull lamp from bottom of optical tube.

**** 11605 Reassembly ****

F6 Cover -- Insert optical tube base assembly.

(Patient-Side)

F7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover. (Return bend on left side).

F8 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

F9 Lens Retainer -- Place lens retainer on top of lens.

F10 Lens Disc Ass'y. -- Clean disc. Place disc in cover. (Number side down, engaged

with detent)

F11 Cover -- Place cover onto patient-side cover/optical tube base assembly.

(Doctor-side) Tighten ring, screws. Install bumper.

F12 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 11605

G 11610 3.5V Halogen Coaxial Sealed Ophthalmoscope Disassembly:

G1 Bumper -- Pull corner, peel back.

G2 Back Cover -- Loosen retaining ring.

(Doctor-Side)

G3 2 Screws -- Remove 2 screws, (torx 05) separate halves. *SLP*

Remove: lens disc, indexing spring, magnifying lens retainer & lens from doctor-side cover.

G4 Optical Tube -- Remove optical tube base, filter retainer, filter assembly.

Base Assembly *SLP*

G5 Lamp -- Pull lamp from bottom of optical tube.

**** 11610 Reassembly ****

G6 Ophthalmoscope -- Inspect filter over shiny metal surface and look through filterat its

Body Assembly own shadow. One side will show a ‘blue’ tint.Place tint side of (Patient-side) the filter will be towards the inside of the scope during

reassembly. (When using replacement filter, remove protective polyethylene film 2 sides). Insert filter into filter housing and place into ophthalmoscope body with filter housing finger tab towards bottom outside of scope. Insert filter retainer, & optical tube base assembly.

G7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover. (Return bend on left side)

G8 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

G9 Lens Retainer -- Place lens retainer on top of lens.

G10 Lens Disc Ass'y. -- Clean disc. Place disc in cover.

(Number side down, engaged with detent)

G11 Cover -- Place cover onto patient-side cover/optical tube base assembly.

(Doctor-side) Tighten ring, screws. Install bumper.

G12 Lamp -- Align pin of lamp into groove of lamp socket and press in.

Test.

End 11610

H 11620 3.5V Halogen Coaxial Sealed Ophthalmoscope Disassembly:

H1 Bumper -- Pull corner, peel back.

H2 Back Cover -- Loosen retaining ring.

(Doctor-Side)

H3 2 Screws -- Remove 2 screws, (torx 05) separate halves. *SLP*

Remove (from doctor-side cover): lens disc, indexing spring, indexing button, magnifying lens retainer & lens.

H4 Optical Tube -- Remove optical tube base, filter retainer, filter assembly.

Base Assembly *SLP*

H5 Lamp -- Pull lamp from bottom of optical tube.

**** 11620 Reassembly ****

H6 Ophthalmoscope -- Inspect filter over shiny metal surface and look through filter at

Body Assembly its own shadow. One side will show a ‘blue’ tint. Place tint side (Patient-side) of the filter will be towards the inside of the scope during

H7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover.

H8 Indexing Button -- Place button into guides beneath spring. (Flat side to spring).

H9 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

H10 Lens Retainer -- Place lens retainer on top of lens.

H11 Lens Disc Ass'y. -- Clean disc. Place disc in cover.

(Number side down, engaged with detent)

H12 Cover -- Place cover onto patient-side cover/optical tube base assembly ,

(Doctor-Side) tighten rin g, screws. Install bumper.

H13 Lamp -- Align pin of lamp into groove of lamp socket and press

lamp in. Test.

End 11620

I 11630 3.5 Volt Halogen Coaxial™ Ophthalmoscope(With Multiplier) Disassembly:

I-1 Bumper -- Pull corner, peel back.

I-2 Back Cover -- Loosen retaining ring. (Doctor-side)

I-3 2 Screws -- Remove 2 screws, (tprx 05) separate halves. *SLP*

Remove: lens disc, cam, multiplier disc, plastic spring detent.

I-4 Optical Tube -- Remove optical tube base, filter retainer, filter assembly.

Base assembly *SLP*

I-5 Lamp -- Pull lamp from bottom of optical tube.

**** 11630 Reassembly ****

I-6 Ophthalmoscope -- Inspect filter over shiny metal surface and look through filter Body Assembly at its own shadow. One side will show a ‘blue’ tint. Place tint

(Patient-side) side of the filter will be towards the inside of the scope during

I-7 Multiplier Disc -- Install multiplier disc, baffle side up, lenses at top of doctor-side

cover.

I-8 Cam -- Install cam on top of multiplier disc, slotted side up, hole of

cam engaged over pivot molded into cover.

I-9 Lens Disc Ass'y. -- Install lens disc, number side down, onto hub, with metal pin

away from cam ramp.

I-10 Spring Detent -- Place plastic spring detent into position below bumper cut-out

of doctor-side cover, smooth side up, detent bumps to engage both multiplier and lens disc.

I 11630 Ophthalmoscope Reassembly Continued

I-11 Cover -- Place cover/disc assembly onto patient-side cover/optical

(Doctor-Side) tube base assembly. Tighten ring, screws. Install bumper.

I-12 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 11630

J1 Bumper -- Pull corner, peel back.

J2 Back Cover -- Loosen retaining ring.

J3 2 Screws -- Remove 2 screws, (torx 05) separate halves. *SLP*

J5 Lamp -- Pull lamp from bottom of optical tube.

J6 Ophthalmoscope -- Inspect filter over shiny metal surface and look through filter

11650 3.5 Volt Halogen Coaxial ™ Sealed Ophthalmoscope Disassembly:

(Doctor-side)

Remove (from doctor-side cover): lens disc, indexing spring, indexing button, magnifying lens retainer & lens.

Optical Tube Base -- Remove optical tube base, filter retainer, filter assembly.*SLP* Assembly

**** 11650 Reassembly ****

Body Assembly at its own shadow. One side will show a ‘blue’ tint. Place tint (Patient-side) side of the filter will be towards the inside of the scope during

reassembly. (When using replacement filter, remove protective polyethylene film 2 sides.) Insert filter into filter housing and place into ophthalmoscope body with filter housing finger tab towards bottom outside of scope. Insert filter retainer, & optical tube base assembly.

J7 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover.

J8 Indexing Button -- Place button, into guides beneath spring, flat side to spring.

J9 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

J10 Lens Retainer -- Place lens retainer on top of lens.

J 11650 Ophthalmoscope Reassembly Continued

J11 Lens Disc Assy. -- Clean disc. Place disc on hub.

(Number side down, engaged with detent)

J12 Cover -- Place cover onto patient-side cover/optical tube base assembly.

(Doctor-side) Tighten ring, screws. Install bumper.

J13 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End11650

K 11660 3.5 Volt Halogen Coaxial™ Autostep Sealed Ophthalmoscope with Multiplier:

Disassembly and reassembly for the 11660 are the same as for the 11630 (as explained earlier on pages 11 and 12). Follow the same procedure but use the correct parts for the 11660.

Basic differences between the 11660 and the 11630 are as follows:

K1 The tube base assembly on the 11660 has a covered aperture assembly and the 11630

does not.

K2 The doctor side cover peep hole on the 11660 does not have a window and the 11630

does have a window.

End 11660

L 11710 3.5 Volt Halogen Sealed Ophthalmoscope:

Disassembly and reassembly of the 11710 are the same as for the 11720 as explained below. Follow the same procedure but use the correct parts for the model you are working on.

Basic differences between the 11710 and the 11720 are as follows:

L1 The 11710 does not have the slide switch/rack and pinion gear mechanism. Instead it has

a small square Welch Allyn logo in the place made for the slide switch button.

L2 The 11710 does not have aperture windows on either side of the instrument.

End 11710

M 11720 3.5 Volt Coaxial Sealed Ophthalmoscope Disassembly:

M1 Bumper -- Pull corner, peel back.

M2 Back Cover -- Loosen retaining ring.

(Doctor-side)

M3 2 Screws -- Remove 2 screws, (torx 05) and separate halves. *SLP*

Remove (from doctor-side cover): lens disc, indexing spring, indexing button, magnifying lens retainer & lens.

M4 Housing -- Separate housing from optical tube base assembly. *SLP*

(Patient-side)

M5 Switch, Gear, -- Remove individual components. *SLP*

Ball and Spring, Rack Assembly

M6 Lamp -- Pull lamp from bottom of optical tube.

**** 11720 Reassembly ****

M7 Switch, Gear -- Place spring in hole on right side ( base towards you), place

ball on top of spring. Put rack into position and place gear into engagement with rack. Center rack in housing. Put switch in slot of tool T-8118 and place switch over spring and ball in a centered position. Slide patient-side cover onto T-8118 at the switch slot and lower patient-side cover onto optical tube base assembly. Check that ball detent is properly engaged when switch is moved left and right.

M8 Indexing Spring -- Place spring into position below bumper cut-out of doctor-side

cover.

M9 Indexing Button -- Place button, into guides beneath spring, flat side to spring.

M10 Magnifying Lens -- Place lens into opening of body cover, round side down, flat

side facing you.

M11 Lens Retainer -- Place lens retainer on top of lens.

M 11720 Reassembly Continued

M12 Lens Disc Assy. -- Clean disc. Place disc on hub.

(Number side down, engaged with detent)

M13 Cover -- Place cover onto patient-side cover/optical tube base

(Doctor-side) assembly. Tighten ring, screws. Install bumper.

M14 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 11720

N 11730 3.5 Volt Coaxial Autostep Sealed Ophthalmoscope (With Multiplier) Disassembly:

N1 Bumper -- Pull corner, peel back.

N2 Back Cover -- Loosen retaining ring.

(Doctor-Side)

N3 2 Screws -- Remove 2 screws, torx 05) and separate halves. *SLP*

Remove: lens disc, cam, multiplier disc, plastic spring detent.

N4 Housing -- Separate housing from optical tube base assembly. *SLP*

(Patient-side)

N5 Switch, Gear, -- Remove individual components. *SLP*

Ball and Spring, Rack Assembly

N6 Lamp -- Pull lamp from bottom of optical tube.

**** 11730 Reassembly ****

N7 Switch, G ear -- Place spring in hole on right side (base towards you), place

N8 Multiplier Disc -- Install multiplier disc, baffle side up, lenses at top of doctor-side

cover.

N9 Cam -- Place cam on top of multiplier disc, slotted side up, with the hole

of cam engaged over pivot molded into cover.

N10 Lens Disc Assy. -- Install the lens disc with the number side down, onto the hub,

with the metal pin facing away from the cam ramp.

N 11730 Reassembly Continued

N11 Spring Detent -- Place plastic spring detent into position below bumper cut-out

of doctor-side cover, smooth side up, detent bumps to engage both multiplier and lens disc.

N12 Cover -- Place cover/disc assembly onto patient-side cover/optical

(Doctor-Side) tube base assembly. Tighten ring, screws. Install bumper.

N13 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 11730

O1 Lamp -- Pull lamp from bottom of optical tube.

O2 Bumper -- Pull corner, peel back.

O3 Cover Ass’y -- Loosen retaining ring.

O4 2 Screws -- Remove 2 screws, (use .050" hex key) remove cover assembly

12810, 12813, 12814, 12830 2.5 Volt Pocket Scope Ophthalmoscope Disassembly:

SPECIAL NOTE: The12810, 12813, 12814, and 12830 Ophthalmoscopes are similar in repair procedures with the exception of : Aperture combinations for the 12810-12814, and base thread construction for the 12830 export model.

(Doctor-side)

(doctor-side) *SLP*. Remove (from doctor-side cover): Lens disc, indexing spring (PN128013), lever, multiplier and magnifier link. (These last two items will be installed into the doctor side cover during reassembly. During disassembly,however, they usually fall off their respective pivots and lay on top of the aperture dial assembly.)

O5 Ophthalmoscope -- Remove N.D.(number dial) filter assembly. (On newer models,

Body Assembly this part will not have the small filter on top). Remove

aperture disc assembly, detent ball and indexing (coil) spring (116119), indexing spring (128024). Remove 2 screws holding lens holder assembly. Remove lens holder assembly and filter assembly.

**** Reassembly ****

O6 Ophthalmoscope -- Insert optical tube base assembly into ophthalmoscope body.

Body Assembly Inspect filter over shiny metal surface and look through filter at

its own shadow. One side will show a‘blue’ tint. Place tint side of the filter towards the inside of the scope during reassembly. (When using new replacement filter, remove protective polyethylene films 2 sides) insert filter into filter housing and place into ophthalmoscope body with filter housing finger tab towards top of the scope. Place lens holder assembly into position and fasten with 2 screws. Place indexing spring (128024) onto raised anchor. Round end of indexing spring should face hub. Aperture disc assembly onto hub, hole in disc at top, apertures at bottom. Insert indexing spring (coil spring PN 116119) into hole and place ball bearing on top of it. Place N.D. filter assembly on top of the center of the aperture disc assembly with filter assembly pivot in hole at base.

O 12810, 12813, 12814, 12830 2.5 Volt Pocket Scope Ophthalmoscope Disassembly Cont'd

O7 Cover Assembly -- Place lever into position in the ( - ) negative with magnifier lens

(Doctor-Side) position, ( - ) side. Place indexing spring (128013) over lever and

onto the raised anchor. (Rounded end of indexing spring should face the lens disc assembly hub as shown in repair parts diagram).

O8 Lens Disc Assy. -- Clean disc. Place disc on hub.

(Number side down, engaged with detent)

O9 Multiplier -- Place multiplier on top of lens disc, engaged with hub, pivot

facing up, and lenses at the top of the assembly (as shown in the repair parts diagram). Connect multiplier to lever with magnifier link, thick end of link towards the magnifier, and with the curved side towards the hub as shown in the parts diagram.

O10 Cover Ass’y -- Place cover onto ophthalmoscope body assembly. Place ring

(Doctor-Side) onto base with numbers “128” right-side-up. Tighten ring,

screws.Install bumper.

O11 Lamp -- Align pin of lamp into groove of lamp socket and press lamp

in. Test.

End 12810, 12813, 12814, 12830

APPENDIX 1

TOOLS/MATERIALS/SUPPLIES

OPHTHALMOSCOPE: 11110, 11400, 11411, 11470, 11475, 11500, 11511, 11600, 11605,

11610, 11620, 11630, 11650, 11660, 11710, 11720, 11730, 12810, 12813, 12814, 12830.

Bayonet Pliers (For removing lamps) Welch Allyn T-10802 Strap Wrench Welch Allyn T-10913 Ring-Nut Wrench (‘TEE’Handle) Welch Allyn T-11896 Switch Tool Welch Allyn T-8118 T5 Torx Flag Style WHA #30-13 Torx ™ Bit # 440-TX-05 or Torx Screwdriver (Torx .05) Replaceable-Bit 1/4" Driver (APEX M-1505-P)For use with Torx .05 bit Tweezers ( Grobet Peer #7 Stainless Steel ) 12" X 12" (approximately) Foam Pad (Mouse Mar American Covers Inc.) Windex ™ Glass Cleaner or Vestal Glass Cleaner #8618-21 Lint Free Wipes / Swabs Jewelers Screwdriver With 1/16" Flat Blade Small Ultasonic Bath ie:* Pro-Craft Model 23.577-1 Ultra Sonic Bath Cleaning Solution Miller Stephenson Aero-Duster #MS-222 De-Ionized Water. Small Stainless Steel Tubs (1 QT. Capacity or less)

One each of the following items: Taps are used to clean up threads or open the hole up to the next size where permissible.

TAP/DRILL/KEY: TAP DRILL KEY

2-56 #50 (.0700") .035" 3-48 #47 (.0785") .050" 4-40 #43 (.0890") .050"

APPENDIX 2

Inspections for Repaired Ophthalmoscopes:

1. Operate all slide switches.

2. Rotate knobs and discs to determine whether or not detents are operating correctly and operating smoothly, positively, and through full stroke.

3. View through the scope to determine that the aperture, filter, or lens are correctly aligned through each detent position.

4. Inspect the cleanliness and condition of the lens dial. No scratches, dirt, glue, or any material should be visible.

5. Check the illuminated and non-illuminated numbers on the lens dial. They should be in the center of the aperture.

6. Check projected images for shadows, dirt, and filament images using the aperture dial and the slide switch if so equipped.

7. Check windows for cracks, streaks, spots or anything that would obscure the viewed image.

8. Check for any stray light that interferes with looking through the scope. Project a fixation spot into a darkened box. Look through the peephole with a lens setting of ‘0’. There should be no bright streaks in the image, or any light appearing in the dark area surrounding the projected spot.

9. Check the scope for scratches or physical damage before the repair as well as after.

10. Clean the repaired scope and wrap it in a plastic bag to protect it from dust and fingerprint contamination.

APPENDIX 3

Checklist for:

F inal Inspection of Ophthalmoscopes

Ophthalmoscope Checklist: Ref#: Model:

1. [] Bumper in place A02387 (V1)* all

2. [] Retaining ring up (body&cover) all

3. [] Lens disc turns freely A02121 all

4. [] Leave lens disc assy on ‘0’ all

5. [] Lever does not jump 12810

6. [] Lamp makes contact w/ handle all

7. [] Numbers readable on lens disc A02121 all

8. [] No cracks in cello when illuminated 116 & 115

9. [] No glare with filters A02387 (V8)** all w/filter

10.[] Filter window is secure A02787 (V8) 11720 & 30

11.[] Retainer secure in mirror assembly all

12.[] Filter assy. not catching on mirror all w/mirror

13.[] Lens clarity A02121 all

14.[] Aperture turns freely all

15.[] Aperture on large circle all

16.[] Filter window open all

* V1=visual measurement (repair operator judgement) ** V8=remove from fixture or handle and apply General Electric RTV #108 to adjustment hole.

(clear translucent silicone sealant, WA M#30313).

APPENDIX 4

Troubleshooting Ophthalmoscopes

Model #'s: 11400,11411, 11610, 11620,11630, 11650,11660

Problem

Dirty

Optics

Obstruction in viewing area

Apart

Glare ‘Reflection of extra light seen a) mirror through Oph. with filter down.”

VOTE: Plastic lenses [objective lens and filter) scratch easily. To clean, use a soft lens paper and or cotton swab.

Normal use

Heavy dirt or scratch on lens disc.

Filter Assembly:

discolored

scratched

fingerprinted

c) Mirror hood bent up

Insert pulled out from overtightning of screws.

User disassembled.

Dirt or scratches on:

b) filter

objective lens

Cause

Clean optics but do not use alcohol on 116 series.

Replace lens disc.

Replace filter assembly. Replace filter assembly. Clean

Replace mirror. Replace body set.

Replace missing or damaged parts and reassemble.

Clean parts if dirty. Replace if scratched.

Corrective Action

Shadows on light spot

Dirty Optics

Lamp filament asymmetrical.

Lamp envelope dirty.

Loose condensing lens or

retaining ring. Condensed lens

tipped.

Scratch or chip

Objective lens loose

Wrong lamp

Clean

Turn lamp around to opposite slot in sleeve or replace if this does not remove shadows.

Clean with soft cloth.

Check lens (tap with small needle and check for movement if loose). Press down to tighten. Lens should

be flat. center”.

Replace condensing lens on condensing lens.

Remove retaining ring from mirror mount and reset. (Refer to mirror assembly procedure).

Replace with correct lamp.

tilted it will project light “off

APPENDIX 4 continued....

Troubleshooting Ophthalmoscopes

MODEL #:

11400,11411,11610 11620,11630,11650,11660

Problem

Numbers ens assembly.

Broken mirror

Will not focus

Intermittent light output

not readable on

light

Cause

Alcohol damage (improper cleaning)

Lamp problem a) pin off-jammed in sleeve, not pinned correctly b) blown or gray c) shadow d) wrong

Dropped

Customer tampered with Ophth.

Mirror or hood unglued Alcohol damage (alcohol will discolor

mirror and lenses)

Objective lens loose.

Lens carrier out of position

Loose connection with power source

envelope will appear white

bent filament

lamp/

not Welch Allyn lamp

Corrective Action

Replace magnifier lens disc (clean with

Vestal cleaner or window cleaner)

Replace lamp

Turn lamp in sleeve or replace lamp. Replace with correct Welch Allyn lamp.

Replace mirror

Replace mirror, lenses

Remove from mirror and reset.

Adjust lens carrier (Refer to adjustable mirror assembly instructions)

Check base/handle. ( See problem

below)

Loose condensing or objective lens

Wrong lamp

Poor connection with power source.

Lens assembly sticks or drags (friction) a) rubs on body

NOTE:

When changing new style cover from the old style (index spring to new spring and

Optical tube base:

a) worn (loose fit)

b) bent (tight fit) c) misaligned optic sleeve or lamp

Aperture dial:

b) ball bearing rotation stiff

Lens disc assembly: a) warped

b) 11630 lens:

1) film warped or pin not engaging

in cam properly.

2) multiplier disc baffle warped

3) not cleaned properlly.

Inspect and secure

Replace with correct Welch Allyn lamp Replace base

(a)

(b)

Remove and realign

Shave cut out area in cover (body) slightly.

Ream bearing hole in base. Apply

small dot of molykote 33 grease.

Replace lens disc. b-l, b-2, b-3

multiplier, or cam. (Visually check for

warp. It is not easily detected).

button), be sure to exchange old style filter retainer ( different design

in stiff rotation of lens assembly.

..__

Replace lens disc,

)

Failure to do so will result

APPENDIX 4 continued. . .

Troubleshooting Ophthalmoscopes

MODEL #:

Problem

Mirror

unglued, broken

scratched

Glare

Lever sticks. Lever moves by itself when

ens assembly is rotated. Poor focus

12810 (PocketScope)

Mirror adheres to RTV during disassembly.

Cracked (Ophth dropped)

Cleaned improperly. Film on mirror filter or lenses caused

by improper cleaning.

Dirty optics. Cover Assy warped.

Multiplier catches edge of lens disc.

Dirty optics Objective lens

Cause

Corrective Action

Remove mirror from lens older and replace with new body/mirror assembly.

Replace body with mirror assemlby or filter.

Clean with window cleaner. Replace cover.

Replace disc or multiplier.

Clean lenses (no alcohol)

Place open aperture hole over lens area, adjust focus, re-seal with G.E. 108 RTV objective with RTV. Make flush so that turning aperture does not interfere).

M30313 (surround peg on

Intermittent or no light

Loose filter window or

polarized) filter catching.

NOTE: For “shadow in ‘light circle", be sure filter is completely open or closed. Check

that lamp is in sleeve

lightly.

Loose

film on numeral

lluminator

Bulb blown. Retainer not on tight.

Loose sleeve.

Minor unglued from body.

Poor connection with power source. Rubber tube worn.

Glue failure

Replace bulb.

Tighten retainer with strap wrench.

Tighten screw on back of optical base (be sure sleeves is aligned).

Replace body-withmirror assembly.

Check with known good handle.

Replace rubber tube.

Replace with new illuminator. (New style has no film).

Section 2

STRABISMOSCOPE

MODEL # PAGE

12400 1-6

STRABISMOSCOPE

12401 3.5V Strabismoscope (OCCLUDER) Disassembly:

1. Lamp — Pull lamp from base. (Use tweezers)

2. Beam Splitter —

3. Base — Remove base from cover.

4. Lamp Collar — Remove lamp collar from base.

**12400 Reassembly **

5. Beam Splitter — Clean beam splitter seating surfaces shown in FIG.1

Loosen retaining ring all the way towards base. (Use T-1413 rubber jaw ring pliers or T-10913 strap wrench to loosen retaining ring.) CAUTION: ON : Beam splitter may fall out. Carefully separate body halves by pivoting halves apart at top of instrument. Unhook halves at top. Use a fine point blade to separate RTV bond between beam splitter and physician side cover.

by shading and X's

PATIENT SIDE DOCTOR SIDE

FIG. 1

Posistion Doctor Side Cover (black) on flat surface and apply one .06" drop of clear RTV sealer to center of each of three circled locations in FIG. 2.

FIG. 2

12401 Reassembly Continued.....

5. Beam Splitter Reassembly cont'd Determine which side of beam splitter is coated by placing a pencil point onto the surface as in FIG. 3. Pencil point and reflected image meet on coated side / patient side. Image does not touch pencil point on uncoated side (doctor side).

FIG. 3

Clean beam splitter with lens cleaner and place it into RTV treated doctor side (black) cover. P a t i e n t s i d e u p. Apply .18" drop of clear RTV sealer to each of six places shown circled in FIG. 4. Drop should contact both beam splitter and the cover.

FIG. 4

Insert the light carrier base into the doctor side cover as shown in FIG. 5.

12401 Reassembly Continued.....

5. Beam Splitter

Reassembly Continued

FIG. 5

Assemble both cover halves together by first engaging the latch at the top of the instrument. See FIG. 6. Then close the covers together at the bottom. Screw the lock ring up to the covers and tighten. (Smooth ridge towards bottom of base.)

FIG. 6

6. Lamp Collar — Insert replacement lamp collar into base. (Use tweezers). Push in and turn to seat lamp collar.

7. Lamp — Clean lamp with alcohol and cotton ball. Align the rib in the lamp base with either of the two slots in the lamp collar. Gently press the lamp into the collar. Clean both sides of the beam splitter. Connect to battery handle and test.

End 12401 Reassembly

STRABISMOSCOPE

TOOLS/MATERIALS/SUPPLIES

Bayonet Pliers Welch Allyn T-10802

Only one of the next two T-tools is required: Rubber Jaw Ring Pliers Welch Allyn T-1413 Strap Wrench Welch Allyn T-10913

Tweezers (Stainless Steel or Plastic, must be

Non-Magnetic, Grobet Peer # 7 )

12"X 12" (Approximately) Foam Pad Mouse Mat ™,

American Covers Inc.

Windex™ Glass Cleaner or Vestal Glass Cleaner #8618-21

Lint Free Wipes / Swabs

Aero-Duster #MS-222

De-Ionized Water.

Small Stainless Steel Tubs (1 Qt. Capacity Or Less)

Silicone RTV Sealant M-30380 (Dow Medical Adhesive Silicone) or

(G.E. Translucent RTV 108 )

Inspections For Repaired Strabismoscopes:

1. Check locking ring for tightness.

2. Check to see that instrument fits on handle before repairing. Base rim may be bent if dropped

on hard surface.

3. Check beam splitter for cracks, chips or other defects. Check for any stray light that interferes

with the viewed image.

4. Check the scope for scratches, physical damage, rough surface before repairing.

5. Clean the repaired scope and wrap it in plastic to protect it from dust and fingerprint

contamination.

6. Check for function.

STRABISMOSCOPE TROUBLESHOOTING

MODEL #: 12401

Problem

Broken beam splitter (Mirror)

Apart

Scratched beam splitter

Lamp loose

Cause Corrective Action

Dropped

Loose retaining ring Beam splitter unglued

Dropped Not cleaned properly

Lamp collar worn or missing.

Replace beam splitter.

Tighten ring.

Reglue (RTV) Replace

Clean (Refer to cleaning instructions). Replace collar.

Section 3

RETINOSCOPES

MODEL # SUB-SECTION PAGE

18201 A 1-2 17201 B 2 18100 C 3-4 17710 D 4-5 17610 F 6 18000 F 6 18010 E 6 17600 G 7-8 17700 H 8-9

RETINOSCOPES

Retinoscope Disassembly: A. 18201 3.5 Volt Retinoscope Disassembly:

A1. Lamp — Pull lamp from bottom. (Use tweezers).

A2. Bumper — Pull corner, peel back. (Use fingers).

A3. Magnetic Overlay — Lift corner, peel off. (Use thin blade).

A4. Sleeve Grip — Pull bottom edge off by inserting tweezers under bottom edge

of grip and removing grip from circumference. Pull whole grip off. (Use tweezers carefully).

A5. Nameplate — Lift corner, peel off. (Use thin blade).

A6. Doctor-side — Remove 3 screws (.05 Torx) and separate covers. Remove

Cover doctor-side window retainer and window.

A7. Patient-side — Remove : Optics carrier subassembly, main sleeve assembly,

lens positional control device (small square).

NOTE: New spring style introduced early 1999. Coil spring 182047 and cap 182048 can be removed from patient-side cover 182020-4.

**** 18201 Reassembly ****

A8. Patient-side __ Replace small spring and spring cap into patient-side cover

Install small square lens positional control device and main sleeve assembly. Insert spring and ball under slide switch tab of optics carrier subassembly. Hold in place with T-

8118. Place optics carrier subassembly into cover.

18201 Retinoscope Reassembly Continued

A9. Doctor-side Cover __ Install doctor-side window and window retainer. Join doctor

side and patient side assemblies. Install 3 screws. Polarizing slide switch should operate with click detents at both ends of stroke.

A10. Sleeve grip — Push on and smooth out between top and bottom of edge of

adjustment barrel. (Use fingers).

A11. Magnetic Overlay — Position over center of overlay recess and press into place.

A12. Bumper — Press into slot.(Use fingers).

A13. Lamp — Align pin on lamp base with groove of lampsocket and

press into position. Clean lamp with alcohol and swab then turn on. (Use tweezers to position lamp, then press with fingers).

End 18201

—————————————————————————————————

B. 17201 2.5 Volt Retinoscope:

NOTE: The 17201 2.5 volt retinoscope is slightly different from its ‘look-alike’, the 18201 3.5 volt retinoscope. Disassembly and reassembly are similar. Differences are listed below:

* Lamp and power source voltage. * No polarizer in the 17201. * No windows (either side) in the 17201. * Mounting configuration (bases are not iterchangeable).

—————————————————————————————————

C. 18100 3.5. Volt Halogen Streak Retinoscope Disassembly:

C1. Lamp Carrier — Pull lamp carrier from bottom. (Use needle-nose pliers).

Inspect small spring near flange.

C2. Lamp — Unscrew lamp from lamp carrier.

C3. Bumper — Pull corner, peel back. (Use fingers).

C4. Eyepiece __ Unscrew eyepiece assembly. (Use fingernails to grip).

Assembly

C5. Head Assembly — Unscrew sleeve assembly from head. (Use strap wrench T-

10913 to hold head collar).

C6. Control Sleeve — Remove stop washer from top of control sleeve sub-assembly.

Subassembly Pull control sleeve sub-assembly from outer sleeve assembly.

**** 18100 Reassembly ****

C7. Control Sleeve — Insert control sleeve sub-assembly into outer sleeve assembly

Subassembly knurled end first. (Squeeze plastic split ring with fingers to

move it beyond:top Of outer sleeve and cutout of outer sleeve. Use fingers). Install stop washer onto top of control sleeve subassembly.

C8. Head assembly — Screw sleeve assembly into collar of head assembly. (Use

strap wrench to tighten). Align as per parts diagram.

C9. Eyepiece — Screw eyepiece assembly into head assembly. (Use fingernails

Assembly to tighten).

C10. Bumper — Press into slot. (Use fingers).

C11. Lamp — Screw lamp into light carrier assembly. (Use fingers to tighten

lamp). Clean lamp with alcohol and soft wipe.

18100 Retinoscope Reassembly Continued

C12. Lamp Carrier — Position lamp carrier into control sleeve with very light

pressure and slight rotation to align two tabs near lamp with grooves in the interior of the control sleeve. Do not force. When lamp carrier is lined up with grooves, insert lamp carrier into control sleeve. Test.

End 18100 Reassembly

—————————————————————————————————

D. 17710 2.5 Volt Halogen Streak Retinoscope Disassembly:

D1. Lamp carrier — Unscrew base assembly (collar) from outer sleeve.(Use strap

wrench T-10913). Remove lamp carrier. Inspect small spring near flange.

D2. Lamp — Unscrew lamp from lamp carrier.

D3. Bumper — Pull corner, peel back. (Use fingers).

D4. Eyepiece — Unscrew eyepiece assembly. (Use fingernails to grip).

Assembly

D5. Head Assembly — Unscrew sleeve assembly from head. (Use strap wrench to

hold head collar).

D6. Control Sleeve — Remove stop washer from top of control sleeve subassembly.

Subassembly Pull control sleeve subassembly from outer sleeve assembly.

**** 17710 Reassembly ****

D7. Control Sleeve — Insert control sleeve subassembly into outer sleeve assembly

Subassembly knurled end first. (Squeeze plastic split ring with fingers to

get it beyond: top of outer sleeve and cutout of outer sleeve). Install stop washer onto top of control sleeve subassembly.

17710 Retinoscope Reassembly Continued

D8. Head Assembly — Screw sleeve assembly into collar of head assembly. (Use

strap wrench to tighten). Align as per parts diagram.

D9. Eyepiece Assembly — Screw eyepiece assembly into head assembly. (Use fingernails

to tighten).

D10. Bumper — Press into slot. (Use fingers).

D11. Lamp — Screw lamp into light carrier assembly. (Use fingers to

tighten lamp). Clean lamp with alcohol and soft wipe.

D12. Lamp Carrier — Position lamp carrier into control sleeve with very light

End 17710 Reassembly

E. 18010 3.5. Volt Halogen Spot Retinoscope Disassembly:

E1. Lamp — Pull 3.5 v. Lamp from base. (Use needle nose pliers).

E2. Bumper — Pull corner, peel back. (Use fingers).

E3. Eyepiece — Unscrew eyepiece assembly. (Use fingernails to grip).

Assembly

E4. Head Assembly — Unscrew optical base subassembly from head. (Use strap

wrench T-10913 to hold head collar).

**** 18010 Reassembly ****

E5. Head Assembly — Screw optical base subassembly into collar of head assembly.

(Use strap wrench to tighten).

E6. Eyepiece — Screw eyepiece assembly into head assembly. (Use fingernails

Assembly to tighten).

E7. Bumper — Press into slot.(Use fingers).

E8. Lamp — Clean lamp with alcohol and soft wipe. Press lamp into base.

End 18010 Reassembly

—————————————————————————————————

F. 17610 2.5 Volt and 18000 3.5 Volt Spot Retinoscopes:

Note: The 17610 and 18000 spot retinoscopes differ slightly from the 18010 as listed below. Disassembly and reassembly are similar however.

* Lamp voltage * Base configuration * Length of optical base assembly

G. 17600 Spot Retinoscope Disassembly:

G1. Lamp Carrier — Unscrew light carrier from body subassembly.

G2. Lamp — Remove diaphragm assembly. Unscrew lamp from light carrier.

G3. Bumper — Unscrew 3 screws and remove cover.

G4. Eyepiece — Unscrew eyepiece assembly (use fingernails to grip).

G5. Mirror Assembly — Unscrew 1 screw. Remove assembly from body subassembly.

G6. Lens Mount — Remove lens mount assembly.

Assembly

G7. Contact and — Unscrew and remove contact and bayonet assembly from base.

Bayonet Assy Use bayonet pliers T-10802.

**** 17600 Reassembly ****

G8. Contact and __ Replace contact and bayonet assembly into base. Install and

Bayonet Assy tighten with bayonet pliers T-10802.

G9. Lens mount — Insert lens mount assembly into body subassembly. Align hole in

Assembly assembly with hole in body subassembly.

G10. Mirror Assembly — Install assembly into body subassembly and secure with screw.

G11. Bumper — Position bumper over top of cover and attach cover to body sub-

assembly with 3 screws. (Insert the 2 short screws at the top). The long screw must engage hole in lens mount assembly.

G12. Eyepiece — Screw eyepiece assembly into cover. (Use fingernails to tighten).

G13. Lamp — Screw lamp into light carrier assembly. (Use fingers to tighten

lamp).

Clean lamp with alcohol and soft wipe.

17600 Reassembly Continued

G14. Lamp Carrier — Screw light carrier to body subassembly.

Test.

End 17600 Reassembly

—————————————————————————————————

H. 17700 Streak Retinoscope Disassembly:

H1. Lamp Control — Unscrew lamp control assembly from body subassembly.

Assembly

H2. Lamp — Unscrew lamp from lamp control subassembly.

H3. Bumper — Unscrew 3 screws and remove cover. Remove bumper from

cover.

H4. Eyepiece — Unscrew eyepiece assembly from cover. (Use fingernails to

grip).

H5. Mirror Assembly — Unscrew 1 screw. Remove assembly from body subassembly.

H6. Lens Mount — Remove lens mount assembly.

Assembly

H7. Contact and — Unscrew and remove contact and bayonet assembly from

Bayonet Assy base. Use bayonet pliers T-10802

**** 17700 Reassembly ****

H8. Contact and — Replace contact and bayonet assembly into base. Use bayonet

Bayonet Assy pliers T-10802

H9. Lens Mount — Insert lens mount assembly into body subassembly. Align

hole in assembly with hole in body sub-assembly.

H10. Mirror Assembly — Install assembly into body sub-assembly and secure with

screw.

17700 Reassembly Continued

H11. Bumper — Position bumper over top of cover and attach cover to body

sub-assembly with 3 screws (2 short screws at top). Long screw must engage hole in lens mount assembly.

H12. Eyepiece — Screw eyepiece assembly into cover. (Use fingernails to

Assembly tighten).

H13. Lamp — Screw lamp into light carrier assembly. (Use fingers to tighten

lamp). Clean lamp with alcohol and soft wipe.

H14. Lamp Carrier — Screw light carrier to body sub-assembly.

Test.

End 17700 Reassembly

APPENDIX

RETINOSCOPES TOOLS/MATERIALS/SUPPLIES

Needle Nose Pliers .028 Hex Key Torx .05 Screwdriver Strap Wrench Welch Allyn T-10913 Slide Switch Holding Tool Welch Allyn T-8118-30 Tweezers (Grobet Peer #7 Stainless Steel) 12"X 12" (Approximately) Foam Pad Windex™ Glass Cleaner or Vestal Glass Cleaner #8618-21 Lint Free Wipes / Swabs Jewelers Screwdriver with 1/16" Flat Blade Small Ultrasonic Bath Ultra Sonic Bath Cleaning Solution Ie: Micro™ Liquid Laboratory Cleaner. Miller Stephenson Aero-Duster #MS-222 De-Ionized Water. Small Stainless Steel Tubs (1 Qt. Capacity Or Less)

Inspections For Repaired Retinoscopes

1. Check streak focus and out of focus uniformity.

2. Check polarizer switch for positive detent and smooth operation.

3. Check control sleeve for both rotational and vertical smooth operation.

4. Check optics for cleanliness and clarity.

5. Clean and seal retinoscope in plastic bag to protect from dust and fingerprint contamination.

TROUBLESHOOTING RETINOSCOPES

Instrument: Retinoscopes (Streak) Model #:

18100

Problem Cause

Control sleeve

Does not fit in handle properly Tight or no fit (dropped) bent.

Poor focus

Intermittent light

operation difficult

Light carrier inserted incorrectly.

worn

Tension spring Outer sleeve bent. Chemical build up (residue) inside of sleeve

from improper cleaning.

Loose. Worn.

Lamp filament not aligned properly.

Dirty optics.

Contact between light carrier and inner

ledge of outer sleeve.

on control sleeve.

Corrective Action

Remove and align groove in control sleeve with 2 slots on band at top of light carrier.

Replace control sleeve. Replace outer sleeve. Use window cleaner.

Replace outer sleeve at base of outer

sleeve.

Replace outer sleeve. Replace lamp

Clean mirror, eyepiece and control sleeve lens with glass cleaner. Clean lamp. Remove eyepiece to clean back side of mirror and eyepiece lens.

Remove light carrier and apply small amount of conductive grease to ledge.

carrier

Put in light position repeatedly to test.

and rotate in down

Replace light carrier contact on light carrier.

lighten down lamp so that it makes proper contact

Replace head assembly. If loose, push ring down with screwdriver.

If still

loose, replace retaining ring.

Install washer.

Broken mirror Loose head assembly

Worn or loose wire.

Lamp not inserted properly.

Dropped Worn or loose retaining ring on collar.

Washer missing.

Note: Damage to the head assembly, other than eyepiece, requires replacement of the head since it does not disassemble.

Note: The head assembly of the 17610 (2.5 v), 17710 (2.5 v), and the 18010 (3.5 v) spot retinoscopes are the same as the 18100 streak retinoscope. However, they have a different sleeve assembly. The problems are the same as the 18100 streak retinoscope with the following exceptions: 17710, the light carrier looks much like the 18 100 light carrier. They are not interchangeable as they have a different lamp (see parts catalog) and control sleeve operation would be affected.

TROUBLESHOOTING RETINOSCOPES

Instrument: Model #:

Film on window (difficult to see

image)

Not focusing properly

Control sleeve too loose Control sleeve too tight

Magnetic overlay missing

No light

Windows scratched or loose

Retinoscopes

18200 streak and 18300 spot

Problem

Cause

Fingerprints scratches Incomplete cleaning

Lamp filament not aligned. Lens positional control device.

Lens positional control device out of position.

Self adhesive is not sticking. Replace with new magnetic overlay. Lamp problem

a) lamp blown b) lamp not seated

Cleaned improperly Window unglued Replace cover assembly.

Clean lenses with alcohol and soft cloth. Use cotton covered toothpick to clean small peephole.

Replace lamp. Replace PN 182025, (black rubber part).

Reposition or replace with

Replace lamp

Align pin on lamp with groove in socket.

Replace cover assembly.

Corrective Action

new

part.

Scope rattles

Lens has fallen out of scope. Uses old

style retaining

ring.

Replace control sleeve.

NOTE: Do not take cover assembly apart more than twice. Repeated insertion and removal of self tapping screws in plastic screw holes in patient side cover reduces the gripping power of plastic holes.

Section 4

OTOSCOPES

MODEL # SUB-SECTION PAGE

20000 A 1 23520 A 1 24020 B 2 23510 B 2 23570 B 2 24033 B 2 24031 B 2 25020 B 2 21110 C 2-3 21130 D 3 20100 E 4-6 20150 E 4-6 20200 F 6 20250 F 6 20202 G 7-8 20262 G 7-8 21600 H 8-10 21700 I 11

APPENDIX SECTION

Tools and Material 12 Inspections 13 Troubleshooting 14-16 Otoscope Pneumatic Tests 18 Schematic 19

OTOSCOPES

SPECIAL INSTRUCTIONS:

Refer to corresponding diagrams in Welch Allyn Repair Parts Catalog PN 900299. Clean all returned scopes by wiping with a solution of 10% Clorox / 90% Water. Use special tools, lens cleaner, and lens tissue as listed in Appendix. Do not apply alcohol, chemicals or water to the mirror or lenses. Follow disassembly and assembly sequences as printed. Begin with a thorough inspection to understand the customer complaint and its cause. Perform tests as specified in the Appendix. ————————————————————————————————— A. 20000 (20002 without Speculum) 3.5V Otoscope Disassembly:

23520 (stamped 20000A) Screw-on 3.5V Otoscope Disassembly:

23520 (stamped 20000R) Snap-on 3.5V Otoscope Disassembly: A1. Lens Holder — Slide lens holder assembly out of otoscope body assembly.

Assembly Inspect lens and seal.

A2. Base Assembly — 20000R, pull the base assembly from the 20000 otoscope body.

23520, unscrew (counter-clockwise) the base assembly from the 23520 otoscope body.

A3. Lamp — Pull lamp straight out of bottom of base assembly.

A4. Lamp Collar — Remove lamp collar from bottom end base assembly. (Use

tweezers).

**** 20000 / 23520 Reassembly ****

A5. Lamp Collar — Insert replacement lamp collar into base assembly through

bottom. (Points of collar should face up).

A6. Lamp — Clean replacement lamp and carefully insert into bottom of

base assembly.

A7. Base Assembly — 20000R, press the base assembly onto the 20000 otoscope body.

23520, screw (clockwise) the base assembly onto the 23520 otoscope body.

A8. Lens Holder — Clean lens and slide lens holder assembly into otoscope body

Assembly assembly. Inspect. Perform Otoscope Pneumatic Test A00181.

End 20000R / 23520

B. 24020 (24033 without Speculum) 2.5V Ototscope Disassembly:

24033 (24031 without Speculum) 2.5V Otoscope Disassembly:

25020 (25022 without Speculum) 3.5V Otoscope Disassembly:

23510 (stamped-25020A) 3.5V Otoscope Disassembly

23570 (stamped-240A) International 2.5V Otoscope Disassembly B1. Lens Holder — Slide lens holder assembly out of otoscope body assembly.

Assembly Inspect lens and seal. B2. Lamp — Pull lamp straight out of bottom of base.

**** 24020 / 24033 / 25020 / 23510 / 23570 Reassembly ****

B3. Lamp — Select appropriate replacement lamp. Clean lamp and

carefully insert into bottom of base.

B4. Lens Holder — Clean lens and slide lens holder assembly into otoscope body

Assembly assembly. Inspect. Perform Otoscope Pneumatic Test A00181.

End 24020 / 24033 / 25020 / 23510 / 23570

————————————————————————————————— C. 21110 2.5v Otoscope Disassembly:

C1. Otoscope Body — Unscrew otoscope body from battery handle. Check tightness of

threaded ring.

C2. Otoscope — Unscrew illuminator assembly from battery handle.

Illuminator

Assembly

C3. Lamp — Pull lamp straight out of bottom of otoscope illuminator

assembly.

C4. Lamp Collar — Remove lamp collar from bottom end of otoscope illuminator

assembly. (Use tweezers).

C5. Lens — Slide lens out of otoscope body. Inspect lens and seal.

**** 21110 Reassembly ****

C6. Lens — Clean lens and slide lens into otoscope body assembly.

C7. Lamp Collar — Insert replacement lamp collar into otoscope illuminator

assembly through bottom. (Points of collar should face up.)

C8. Lamp — Clean lamp and carefully insert into bottom of otoscope

illuminator assembly. 2

C. 21110 Otoscope Disassembly Continued

C9. Otoscope — Screw illuminator assembly onto battery handle.

Illuminator

Assembly

C10. Otoscope Body — Screw otoscope body onto battery handle.

Inspect.

End 21110

—————————————————————————————————

D. 21130 2.5. Otoscope Disassembly:

D1. Otoscope Body — Unscrew otoscope body from battery handle. Check tightness of

threaded ring.

D2. Lamp — Pull lamp straight out of bottom of otoscope body assembly.

D3. Lamp Collar — Remove lamp collar from bottom end of otoscope body assembly.

(Use fine tweezers).

D4. Lens — Slide lens out of otoscope body. Inspect lens and seal.

**** 21130 Reassembly ****

D5. Lens — Clean lens and slide lens into otoscope body assembly.

D6. Lamp Collar — Insert replacement lamp collar into otoscope body assembly.

(Points of collar should face up).

D7. Lamp — Clean lamp and carefully insert into bottom of otoscope body

assembly.

D8. Otoscope Body — Screw otoscope body onto battery handle.

Inspect.

End 21130

E. 20100 (20101without Speculum) 2.5V Otoscope Disassembly:

20150 2.5V OotoscopeDisassembly:

(Above otoscopes are WIRED and not fiber-optic.)

E1. Lamp — Pull lamp hood off. Unscrew lamp.

E2. Window Assembly — Unscrew spring cup screw. Remove spring cup, spring, and wear

plate. Remove window assembly.

E3. Lens — Unscrew lens retainer. (Use lens window wrench tool #T-847)

remove lens. Remove and discard gasket.

E4. Contact Assembly __ Remove bayonet contact. Unscrew bayonet assembly and pull

off of wire. (Wire is sealed into the bayonet assembly with RTV silicone sealant. Therefore do not remove bayonet contact and assembly unless you are planning to replace the contact assembly). Unscrew flat screw. Push out old contact assembly and pull out wire. Clean out RTV from both the bayonet and the otoscope light guide wire channel.

**** 20100, 20150 Reassembly ****

E5. Contact Assembly __ See FIG. 1 through 3. Position replacement contact assembly

on doctor-side of otoscope light guide. With wire down, insert contact assembly into hole as shown in FIG. 1 below. Push contact assembly into hole slightly beyond wire channel as shown in FIG. 2. Insert the end of the wire into the wire channel and push through the wire channel so that it comes out of the bottom of the scope as shown in FIG. 3. Reposition the contact assembly slightly rearward so that the wire goes directly down into the wire channel hole. Screw flat screw flush with light guide.

20100, 20150 Otoscope Reassembly Continued

FIG. 1 FIG. 2 FIG. 3

E6. Bayonet Assembly __ Insert wire through the bayonet assy. Fill with medical grade

RTV sealant. Screw bayonet assy into scope while carefully applying slight tension on the wire to remove excess wire from the scope.

E7. Bayonet Contact — Remove insulation from the wire that protrudes from the end of

the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has good electrical contact with the wire. Remove excess wire as in FIG 4.

FIG. 4

20100, 20150 Otoscope Reassembly Continued

E8. Lens — Install lens in window assembly and secure with lens retainer.

Screw and tighten lens retainer with tool T-847. Install new gasket seal on lens window assembly.

E9. Window Assembly — Assemble spring cup screw through washer, spring and spring

cup. Attach lens window assembly to otoscope.

E10. Lamp — Screw lamp into light carrier. Slide lamp hood over lamp. Clean

lamp. Inspect. Perform Pneumatic Test A01303.

End 20100, 21050 Reassembly

—————————————————————————————————

F. 20200 (20201 without Speculum) 3.5v Otoscope Disassembly:

20250 (20251 without Speculum) 3.5v Otoscope Disassembly:

F1. Lamp — Pull lamp out of base of scope.

F2. Window Assembly — Unscrew spring cup screw. Remove spring cup, spring, and wear

plate. Remove window assembly.

F3. Lens — Unscrew lens retainer. (Use lens window wrench tool T-847)

remove lens. Remove and discard gasket.

**** 20200, 20250 Reassembly ****

F4. Lens — Install lens in window assembly and secure with lens retainer.

Screw and tighten lens retainer with tool T-847. Install new

gasket seal on lens window assembly.

F5. Window Assembly — Assemble spring cup screw through washer, spring and spring

cup. Attach lens window assembly to otoscope.

F6. Lamp — Clean lamp and press lamp into base of scope. Inpect.

Perform Pneumatic Test A01303.

End 20200, 20250 Reassembly

G. 20202 (20203 without Speculum) 3.5V Otoscope Disassembly:

20262 (20263 without Speculum) 3.5V Otoscope Disassembly:

G1. Lamp — Pull lamp out of base of scope.

G2. Double Viewer — Loosen knurled ring and remove double viewer assembly.

Assembly Remove ‘o’ ring from body & light pipe assembly.

G3. Lenses — Unscrew both lens retainers and remove both lenses.

G4. Liner Blank — Pull liner blank out with finger tip.

G5. Beam Splitter — Unscrew 2-56 x 3/32' set screw. Pull beam splitter subassembly

Subassembly out.

G6. Window — (For broken or scratched windows only) remove window

retaining ring and window from double viewer assembly. Remove RTV from window area.

**** 20202, 20262 Reassembly ****

G7. Window — Clean window and apply RTV sealant and install new window.

Secure with window retaining ring.

G8. Beam Slpitter — Clean mirror carefully on both sides. Insert beam splitter sub-

Subassembly assembly into long end of double viewer subassembly and

align to create view for side view port. Secure with 2-56 x 3/32' set screw.

G9. Liner Blank — Insert liner blank into side view port.

G10. Lenses — Clean lens and place lens on double viewer subassembly with

convex surface out / flat side in. Determine that lens is centered over port and then screw on lens retainer and fingertighten. Repeat for other lens.

20202, 20262 Reassembly Continued

G11. Double Viewer — Install new ‘o’ ring on body & light pipe assembly. Attach

Assembly double viewer subassembly to body & light pipe assembly.

Fingertighten knurled ring.

G12. Lamp — Clean lamp and press lamp into base of scope. Inspect. Perform

Pnuematic Test A01303.

End 20202, 20262 Reassembly

—————————————————————————————————

H. 21600 (21601 without Speculum) 2.5v Otoscope Disassembly:

(Above otoscope is WIRED and not fiber-optic).

H1. Lamp — Unscrew lamp.

H2. Lens Holder — Unscrew lens holder screw. Remove lens holder spring washer,

Assembly 2 lens holder washers, and lens holder.

H3. Speculum — Unscrew lock nut clockwise from patient side perspective.

Holder Remove prism screw (set screw). Remove speculum holder.

H4. Lock Nut — Remove 2 lock ring halves. Remove lock nut.

H5. Contact Assembly __ Remove bayonet contact. Unscrew bayonet assembly and pull

off of wire. (Wire is sealed into the bayonet assembly with RTV silicone sealant. Therefore, do not remove bayonet contact and assembly unless you are planning to replace the contact assembly). Pull out old contact assembly and wire. Clean out RTV from both the bayonet and the body assembly.

**** 21600 Reassembly ****

H6. Contact Assembly — See FIG. 5. Position the wire downwards relative to the

replacement contact assembly. Insert the wire into the threaded hole (lamp socket) and guide it down into the small hole in the bottom of the lamp socket. See FIG.6. It will come out of the bottom of base as you push it in. Insert the contact assembly while gently pulling on the end of the wire.

FIG. 5 FIG.6

H7. Bayonet Assembly __ Insert wire through the bayonet assy. Fill with medical grade

RTV sealant. Screw bayonet assy into scope while carefully applying slight tension on the wire to remove excess wire from the scope.

H8. Bayonet Contact — Remove insulation from the wire that protrudes from the end

of the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has a good electrical connection to the wire ends. Remove excess wire as in FIG. 7.

21600 Reassembly Continued

FIG. 7

H9. Lock Nut — Place lock nut over body assembly stem. Insert speculum holder

into stem of body assembly in ‘up’ position. Insert prism screw and tighten. Place 2 lock ring halves in groove of stem and slide lock ring toward speculum holder and finger tighten.

H10. Lens Holder — Place lens holder spring washer onto body assembly. Place lens

Assembly holder assembly over washer (with lens recess towards doctor

side). Fasten it with lens holder screw and 2 lens holder washers.

H11. Lamp — Screw lamp into light guide. Clean lamp. Inspect.

End 21600 Reassembly

I. 21700 (21701) 3.5V Otoscope:

I1. Lamp — Pull lamp out of base.

I2. Lens Holder — Unscrew lens holder screw. Remove lens holder spring washer,

Assembly 2 lens holder washers, and lens holder.

I3. Speculum — Unscrew lock nut clockwise from patient side perspective.

Holder Remove prism screw (set screw). Remove speculum holder.

I4. Lock Nut — Remove 2 lock ring halves. Remove lock nut.

I5. Lamp Collar — Remove lamp collar. (Use tweezers)

**** 21700 Reassembly ****

I6. Lamp Collar — Insert replacement lamp collar into body subassembly base

(points up).

I7. Lock Nut — Place lock nut over body assembly stem. Insert speculum holder

into stem of body assembly in ‘up’ position. Insert prism screw and tighten. Place 2 lock ring halves in groove of stem and slide lock ring toward speculum holder and finger tighten.

I8. Lens Holder — Place lens holder spring washer onto body assembly. Place lens

Assembly holder assembly (with recess towards doctor-side) over washer

and fasten it with lens holder screw and 2 lens holder washers.

I9. Lamp — Clean lamp and insert into base. Inspect.

End 21700 Reassembly

APPENDIX

TOOLS/MATERIALS/SUPPLIES

OTOSCOPE

Bayonet Pliers (Welch Allyn T-10802) Lens Window Wrench (Welch Allyn T-847) Strap Wrench (Welch Allyn T-10913) Flat Blade Screwdriver ie. Xcelite # P-181 Long Nose Pliers ie. Xcelite # 52cg 152mm Tweezers (Stainless Steel or Plastic, must be Non-Magnetic, Grobet Peer # 7) 12"X 12" (Approximately) Foam Pad Windex™ Glass Cleaner or Vestal Glass Cleaner #8618-21 Lint Free Wipes / Swabs Jewelers Screwdriver with 1/16" Flat Blade ie. General #3 (.055") Small Ultrasonic Bath ie: * Pro-Craft Model 23.577-1 * Ultra Sonic Bath Cleaning Solution ie: Micro™ Liquid Laboratory Cleaner. Miller Stephenson Aero-Duster #MS-222 De-Ionized Water. Small Stainless Steel Tubs (1 Qt. Capacity or Less) Silicone RTV Sealant (Dow Medical Adhesive Silicone Welch Allyn M-30380) or (G.E. Translucent RTV 108) Insufflator/Tube/Tip (Welch Allyn # 21504) Glass Beaker (Approx. 1 Qt. Capacity) Wire Stripper For 22-30AWG Wire ** (Ideal #45-217) **

Tap/Drill/Key: Tap Drill Key

2-56 #50 (.070") .035 3-48 #47 (.0785") .050 4-40 #43 (.0890") .050

* Pro-Craft/GFC Co., Carlstadt, New Jersey, 07072 U.S.A. ** Ideal Industries Inc., Sycamore, Ill. Model #45-217 ‘T’-stripper. From catalog:

Contact-East Inc., 335 Wilow St., North Andover, Ma, 01845. Ph. (508) 682-2000.

APPENDIX

Inspections for Repaired Otoscopes:

1. Check fit of disposable and re-useable speculums.

2. Check to see that instrument fits on handle before repairing. Base rim may be bent if dropped

on hard surface.

3. If applicable, perform Otoscope Pneumatic Test appropriate for this Otoscope. See

Appendix.

4. Check windows and lenses for cracks, chips or other defects. Check for any stray light that

interferes with the viewed image.

5. Check the scope for scratches, physical damage, rough surface before repairing.

6. Clean the repaired scope and wrap it in plastic to protect it from dust and fingerprint

contamination.

TROUBLESHOOTING OTOSCOPES

Instrument:

Otoscope

Model #: 20000, 24020, 25020, (211

Problem

Low

or no light

Shadows

Not air tight

Blown lamp Wrong lamp Worn fibers Dirt on tip, lens

Lamp filament Bent at tip (dropped) Worn fibers

Entry worn Window frame worn Body insulator worn

10, 21

Cause

130 Pocket)

Corrective Action

Replace lamp Replace with correct lamp Replace body Clean (See cleaning instructions)

Replace lamp Replace body Replace body

Replace body Replace window lens Replace body

(For leaking 21110

Replace gasket)

Body apart

Spec

is loose

Illuminator or base loose

Lamp falls out

Retaining ring is loose on 240, 250

Nose ring detached (dropped or worn)

Cracked (dropped) Worn spec

Tip

bent

Worn

Set screws missing, loose (old

style) Lamp collar is loose or missing

Turn ring counter clockwise to tighten (Replace head if ring is still loose)

Replace body (new style eliminated nose ring)

Replace body Try new

body. Replace body

Test connection on base with a ‘known good’ handle and body assembly. Replace the worn part (base, body, or handle).

Tighten or replace screws.

Replace lamp collar

spec,

if still too loose, replace

TROUBLESHOOTING OTOSCOPES

Instrument: Model

No light

Not

air tight

Window apart

Otoscope (Pneumatic) 20100 (2.5 Volt), 20200 (3.5 Volt)

Problem

Blown lamp

Wrong lamp

For 20100 a) worn contact b) short in wire

Window assembly a) worn gasket b) lens is loose c) body is bent

For 20200 a) light pipe loose b) speculum worn c) valve stem loose (unsoldered)

Set screw stripped

Lens broken

Crack in window subassembly

Cause

Corrective Action

Replace lamp

Replace with correct lamp

Rewire

Replace gasket Tighten retainer Replace body

Tightens set screw Replace speculum Replace body Retest

Replace screw assembly

Replace lens

Replace window subassembly

Low light output

Poor connection

Out of spec. lamp filament alignment

Defective power handle

20200 Light pipe

a) worn fibers

b) incorrect light pipe alignment

Bent (dropped)

Lamp not inserted

Lamp is loose

Replace lamp

Check otoscope on a known good handle

Replace body assembly

Replace body assembly with power source. Worn base (loose)

Push lamp in until it fully snaps into place.

Change lamp collar.

NOTE: When changing from ‘old style’ metal frame window assembly to new style, replace screw asssembly with new. (The old assembly strips easily).

TROUBLESHOOTING OTOSCOPES

Instrument: Model #:

Low or no light Light flickers

Speculum loose Speculum holder loose

Light not centered

Otoscope 21600, 217OO

Problem Cause

Blown lamp

Wrong lamp

Worn contact (216) Worn fibers (217)

Speculum or holder is worn Threads of speculum or lock nut

worn Lock nut loose

Speculum cracked Lite pipe (217) bent or loose

Corrective Action

Replace lamp

Replace with correct lamp Re-wire

Replace body

spec -

Test with new Replace

Tighten lock nut (allow speculum to move left to right and hold position). Test by repeat movement to see if holder has loosened.

Replace speculum Replace body subassy

replace worn part

spec

Replace holder (Use test pattern). Replace lamp (Use test pattern).

Replace screw and washers

Replace body Replace body

Replace body (Test with ‘known good’ handle, or if available, the customer’s handle).

Lens holder assy is loose/apart

Poor connection source

power

Spec

holder bent (old style metal)

Lamp filament not centered Lens holder screw is stripped or

worn.

Posts damaged or unsoldered/bent Base bent (dropped)

Base worn (loose)

NOTE: Check top cover of lite pipe for cracks. If cracks are found, replace body.

Otoscope Pressure Testing form A02800

Otoscope Pneumatic Test (Using Fixture T7503)

- Connect specula tip to otoscope.

- Connect surgical tubing to insufflator fitting.

- Ensure Validyne M odel PS309 is “ON”.

- Ensure slide plunger is pushed in all the way.

- Push reset valve button to release any built up pressure. Pressure Test

- Before & during testing tighten ring on window assembly with T847 as

needed.

- Pull actuate lever out all the way. Meter must read a minimum of 22.

- Make sure lever remains all the way out while reading is taken.

- Push reset button in until meter reads O.

- Rotate window 2 full revolutions and repeat air test.

Suction (Vacuum) Test

- Push actuate lever in all the way. Meter must read a minimum of 22.

- Make sure lever remains all the way in while reading is taken.

Equipment:

1. Low volume air pump (Aquarium style or equal)

2. Bleeder valve

3. Flow control

4. ”U” tube 12" min. Manometer filled with water and Meriam 1000 green

5. Various hoses, tees, and connectors. See T1217 for details

Procedure:

Otoscope Pressure Testing from A00181

fluid concentrate or equivalent. Fill to line (“0”)

1 A Energize pump

B Set input flow control to .3-.5SCFH (Dwyer RMA-1-SSV)

2 Put insufflation tip (attached to hose) into block. Adjust Bleeder valve until liquid

level reaches CAL (calibrate) line. This is equivalent to 0.4PSI on a pressure gage (11.08" h2o on manometer). Reference check for flow rate: from 0 to “CAL” line 34 seconds should elapse.

3 Insert metal tip of otoscope into an adapter block and plug taper fitting into

insufflation port.

- All scopes must be AT or ABOVE Min (Minimum) line of 3.45" h2o read on manometer to be acceptable for air seal.

- (The requirement is approximately .25PSI which equates to a total displacement of 6.9" h2o.)

- Conversion reference 1 PSI = 27.7" h2o @ 62EF (For this spec no compensation necessary for temp)

Section 5

ILLUMINATED BIVALVE NASAL SPECULUM

MODEL # PAGE

26000 1-3

Illuminated BiValve Nasal Speculum

Special Instructions:

Refer to corresponding diagrams in Welch Allyn Repair Parts Catalog 900299. Clean all

returned Nasal Speculums by wiping with a solution of 10% Clorox / 90% Water. Begin with a thorough inspection to understand the customer complaint and its cause. —————————————————————————————————

26000 Disassembly: 2.5 Volt

1. Lamp — Unscrew lamp.

2. Light C arrier — Pull bivalve nasal spec assembly off of base. Base Assembly

3. Handle Speculum — Unscrew hinge pin. Remove hinge spring, and handle speculum.

4. Contact Assembly — Pull bayonet contact out of bottom of bayonet assembly.

Unscrew and remove bayonet assembly from light carrier base subassembly. Remove old contact assembly and small contact spring ( underneath contact assembly ) from lamp socket of light carrier base subassembly. Use thin needle-point awl and tweezers. Pull old contact assembly and wire from light carrier base subassembly and inspect to make sure there is no debris left in wire channel or lamp socket.

**** 26000 Reassembly ****

5. Contact Assembly __ Put contact assembly wire through contact assembly spring

(PN 383065) and position spring under contact assembly. Insert contact assembly wire into lamp socket and push wire through bottom of light carrier base assembly. Grab end of wire with tweezers when it is visible in the base. Pull it up with tweezers so that the contact assembly goes to the bottom of the lamp socket.

26000 Reassembly Continued.....

6. Bayonet Assembly — Insert wire through the bayonet assembly. Screw the bayonet

assembly into the base while carefully applying slight tension on the wire to remove excess wire (slack).

7. Bayonet Contact — Remove insulation from the wire that protrudes from the end

of the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has good electrical contact with the wire. Remove excess wire strands with X-acto knife.

8. Handle Speculum — Assemble spring into the hinge slot of the handle speculum.

Position the ends of the spring downwards in the direction towards the base. The spring does not stay in the slot, slightly bend the walls of the slot together so the spring is retained. Assemble the handle speculum to the base speculum and insert hinge pin into clearance hole (unthreaded hole), and through spring. Tighten hinge pin.

9. Light Carrier — Press bivalve nasal spec ass’y onto base. Base Assembly

10. Lamp — Screw lamp into lamp socket. Clean lamp.

Perform tests.

End 26000 Reassembly

APPENDIX

TOOLS/MATERIALS/SUPPLIES

Nasal Specs 26000

Bayonet Pliers (Welch Allyn T-10802) Needle Point Awl Flat Blade Screwdriver ie. Xcelite # P-181 Needle Nose Pliers ie. Xcelite # 52cg 152mm Tweezers (Grobet Peer # 7) 12"X 12" (Approximately) Foam Pad (Mouse Mat™ American Covers Inc.) Windex™ Glass Cleaner Or Vestal Glass Cleaner #8618-21 Lint Free Wipes Wire Stripper (Ideal Industries*, Model #45-217 ‘T-stripper’) X-acto Knife W/#11 Blade

* Ideal Industries, Sycamore, Ill. avaliable through catalog of Contact East Inc., 335 Willow St.,North Andover, MA, 01845 ph. (508) 682-2000

Section 6

LARYNX ILLUMINATOR

NASOPHARYNX ILLUMINATOR

MODEL # PAGE

27000 1-2 27050 1-2 27200 1-2 27250 1-2

Illuminator

Special Instructions:

Refer to corresponding diagrams in Welch Allyn Repair Parts Catalog 900299. Clean all

returned instruments by wiping with a solution of 10% Clorox / 90% Water. Begin by thoroughly inspecting to determine the cause and effect of the malfunction and how it relates to the customer complaint.

—————————————————————————————————

27000, 3.5Volt Larynx Illuminator, 27050, 3.5Volt Nasopharynx Illuminator, 27200, 2.5Volt Larynx Illuminator, 27250, 2.5Volt Nasopharynx Illuminator Disassembly:

1. Lamp — Pull lamp from base.

2. Lamp Collar — Remove lamp collar. ( Use tweezers )

3. Mirror Section — Unscrew knurled ring. Remove mirrorsection from

transilluminator assembly. Inspect mirror for defects.

**** 26000, 27050, 27200, 27250 Reassembly ****

4. Mirror Section __ S lide mirror section on to transilluminator assembly. Thread

knurled ring finger-tight.

5. Lamp Collar — Insert lamp collar into lamp socket. Position collar with points

towards top of instrument.

6. Lamp — Clean lamp. Press lamp into lamp socket perform tests.

End 26000, 27050, 27200, 27250 Reassembly

TOOLS

Tweezers ( Grobet Peer

Instrument: Model #:

Problem

Broken, bent or scratched mirror

Poor connection with handle

Lamp falls out

Image is not centered

Larynx Illuminator

27000,27200

#7 )

TROUBLESHOOTING ILLUMINATORS

Nasopharynx

27050,27250

Cause

Dropped Improperly stored

Dropped (bent base) Worn base (loose)

Loose lamp collar Lamp collar missing

Defective lamp (filament is off center)

Replace mirror section.

Replace illuminator section.

Replace lamp collar. Install lamp collar.

Replace lamp.

Corrective Action

Mirror stem bent

Not properly aligned

Bend stem slightly to the correct angle (see diagram).

Position light spot to project through aperture in mirror. Bend carefully to avoid breaking the solder connection. NOTE: Do not remove mirror screw assembly. Mirror could fall off.

Section 7

TONGUE DEPRESSOR

MODEL # SUB-SECTION PAGE

28000 A 1-2 28100 B 2-3

TONGUE DEPRESSOR

Special Instructions:

Refer to corresponding diagrams in Welch Allyn Repair Parts Catalog 900299. Clean all

returned instruments by wiping with a solution of 10% Clorox /90% Water. Begin by thoroughly inspecting to determine the cause and effect of the malfunction and how it relates to the customer complaint.

—————————————————————————————————

A. 28000 2.5Volt Disassembly:

A1. Lamp Hood — Pull lamp hood from lamp.

A2. Lamp — Unscrew lamp.

A3. Thumb Screw — Unscrew thumbscrew.

A4. Contact Assembly __ Remove bayonet contact. Unscrew bayonet assembly

and pull off of wire. Unscrew retaining screw with tool T11282. Remove pipe assembly. Remove retaining screw, contact assembly, small rubber tube.

**** 28000 Reassembly ****

A5. Contact Assembly __ Assemble rubber tube onto wire of contact assembly

and insert contact assembly into retaining screw. Insert new contact assembly/retaining screw into chrome barrel of body assembly. Insert contact assembly wire into threaded hole of pipe assembly and push all the way through the curved pipe. (If the wire kinks while trying to push it through, use a tweezers to push the wire. Insert the wire into the base hole of the body assembly and pull it out of the base with a straight tweezers.

28000 Reassembly Continued

A6. Pipe Assembly — Position the pipe assembly up to the back of the chrome

barrel and secure it by tightening the retaining screw with tool T-11282.

A7. Bayonet Assembly __ Insert wire through the bayonet assembly. Screw bayonet

into scope while carefully applying slight tension on the wire to remove slack.

A8. Bayonet Contact — Remove insulation from the wire that protrudes from

the end of the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has good electrical contact with the wire. Remove excess wire.

A9. Thumbscrew — Screw thumbscrew into threaded hole.

A10. Lamp — Screw lamp into light carrier. Slide lamp hood over

lamp. Clean lamp.

End 28000 Reassembly

—————————————————————————————————

B. 28100 3.5Volt Disassembly:

B1. Lamp Hood — Unscrew lamp hood. Lamp will come off with lamp

hood.

B2. Lamp — Remove lamp from lamp hood.

B3. Thumb Screw — Unscrew thumbscrew.

B4. Contact Assembly __ Remove bayonet contact. Unscrew bayonet assembly

and pull off of wire. Unscrew set screw ( 0-80 x 1/8" long ). (Use 028" hex key ). Unscrew retaining screw with tool T-2187 (double ‘tee’ wrench). Remove pipe assembly. Remove contact assembly, small rubber tube.

**** 28100 Reassembly ****

B5. Contact Assembly __ Assemble rubber tube onto wire of contact assembly and

insert contact assembly into retaining screw.Insert new contact assembly/retaining screw into chrome barrel of body assembly. Insert contact assembly wire into threaded hole of pipe assembly and push all the way through the curved pipe. (If the wire kinks while trying to push it through, use a tweezers to push the wire.Insert the wire into the base hole of the body assembly and pull it out of the base with a straight tweezers.

B6. Pipe Assembly — Position the pipe assembly up to the back of the chrome

barrel and secure it by tightening the retaining screw with tool T-2187. Insert and tighten set screw to secure the retaining screw.

B7. Bayonet Assembly __ Insert wire through the bayonet assembly. Screw bayonet

into scope while carefully applying slight tension on the wire to remove slack.

B8. Bayonet Contact — Remove insulation from the wire that protrudes from

the end of the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has good electrical contact with the wire. Remove excess wire.

B9. Thumbscrew — Screw thumbscrew into threaded hole.

B10. Lamp — Clean lamp. Place lamp in lamp holder. Screw lamp

holder onto body assembly.

End 28100 Reassembly

Tongue Depressors

APPENDIX

TOOLS/MATERIALS/SUPPLIES

Bayonet Pliers T-10802 Ring Nut Wrench For 28000. (Single’TEE’ “Wiring Tool” Drawing #23500877) T-11282 Ring Nut Wrench For 28100. (Double’TEE’ “Stud Setting Tool” Drawing #23500373) T-2187 Needle Nose Pliers ie. Xcelite # 52CG 152mm Tweezers (Stainless Steel or Plastic, Must Be Non-Magnetic, Grobet Peer # 7) Tweezers (Stainless Steel) Offset 4 1/4" Long (Model A-5ASA)** 12"X 12" (Approximately) Foam Pad (Mouse Mat™ American Covers Inc.) Windex™ Glass Cleaner or Vestal Glass Cleaner #8618-21 Lint Free Wipes / Swabs Wire Stripper For 22-30AWG Wire **( Ideal #45-217 )**

Tap/Drill/Hex Key: Tap; Tap Drill; Key; Thumbscrew 6-32 36 (.1065 ) Na Set Screw (PN 281019) 0-80 X 1/8" 0-80 3/64"(.0469) .028"

Pin Vise for .028 Allen Key Above. (L.S. Starrett Model 166 A )

** Ideal Industries Inc., Sycamore, Ill. Model #45-217 ‘T’- Stripper. From Catalog: Contact-East Inc., 335 Willow St., North Andover, Ma, 01845. Ph.(508) 682-2000.

Section 8

PROCTO-SIGMOIDOSCOPES:

FIBER OPTIC ANOSCOPES

PROCTO-SIGMOIDOSCOPES

FIBER OPTIC LIGHT HEAD

STANDARD ANOSCOPES

ROTATING ANOSCOPES

MODEL # SUB-SECTION PAGE

PROCTO-SIGMOIDOSCOPES: A 1

32010 32020 32410 32420 32810 32820 32830 33020 33220 33620 33830

FIBER OPTIC LIGHT HEAD: B 2

36019

FIBER OPTIC ANOSCOPE SERIES: C 2

37000

STANDARD ANOSCOPES D 3

38108 38114 38119 38122

ROTATING ANOSCOPE: E 3-4

38800

Tools Appendix 5

Troubleshooting Appendix 6 Model 38800

Fiber Optic Anoscopes

Procto-Sigmoidoscopes

Fiber Optic Light Head

Standard Anoscopes

Rotating Anoscope

Special Instructions:

Refer to diagrams in Welch Allyn Repair Parts Catalog 900299. Clean returned instruments

with a solution of 10% Clorox / 90% water. Begin by thoroughly inspecting to determine the cause and effect of the malfunction and how it relates to the customer complaint. ————————————————————————————————— A. Hinged Window Fiber Optic Procto-Sigmoidoscopes:

32010, 32020, 32410, 32420, 32810, 32820, 32830, 33020, 33220, 33620, 33830 Disassembly: Use T-5319 for 324044 window sub-assembly.

Use T-5320 for 328115-505 “ “ “

A1. Window Assembly — Remove spirol pin (1/16" x 1/2 “ ).(Use .060" drift

punch and hammer) springs you slowly remove window from hinge.

Collect 2 plungers and 2 plunger

A2. Window Screw — Remove retaining spring and remove window screw.

A3. Window Lens — 324044, 328115-505: Unscrew window retaining screw

with tool. 328115-502, 3, 4 & 332025: Remove snap ring and RTV. Remove window and window gasket.

**** Reassembly ****

A5. Window —

A6. Window Screw — Insert window screw into hole and secure with retaining

A7. Window Assembly — I

Assemble rubber gasket into window door. Insert window lens into recess in gasket seal with convex side on the doctor-side. Secure with window retaining screw. Tighten lightly with tool T-5320.

spring.

nsert plunger springs into speculum subassembly.Insert plungers on top of springs. Position window assembly hinge into speculum subassembly hinge. Insert spirol pin into hinge.

End Reassembly

B. 36019 Fiber Optic Light Head Disassembly:

B1. Window Assembly — Remove spirol pin. Collect 2 plungers and 2 plunger

springs as you slowly remove window from hinge.

B2. Window Screw — Remove retaining spring and remove window screw.

B3. Window Lens — Unscrew window retaining screw with tool T-5320.

Remove window and window gasket.

**** 36019 Reassembly ****

B5. Window — Assemble rubber gasket into window door. Insert window

lens into recess in gasket seal with convex side on the doctor-side. Secure with window retaining screw. Tighten lightly with tool T-5320.

B6. Window Screw — Insert window screw into hole and secure with retaining

spring.

B7. Window Assembly —

End 36019 Reassembly

—————————————————————————————————

C. 370 Series Fiber Optic Anoscopes Disassembly:

C1. Obturator Assembly — Remove obturator assembly.

C2. End Piece — Unscrew end piece from anoscope subassembly.

** 370 Series Reassembly **

C3. End Piece — Screw end piece onto anoscope subassembly.

C4. Obturator Assembly — Insert obturator into anoscope subassembly.

Insert plunger springs into speculum subassembly. Insert plungers on top of springs. Position window assembly hinge into speculum subassembly hinge. Insert spirol pin into hinge. Inspect/test.

End 370 Series Reassembly

D. 38108, 38114, 38119, 38122 Standard Anoscopes Disassembly: D1. Obturator Assembly — Pull obturator out of funnel assembly reassembly.

D2. Obturator Assembly — Insert obturator assembly into funnel assembly from

the doctor-side.

———————————————————————————————————————

E. 38800 Rotating Anoscope Disassembly:

E1. Obturator Assy. — Remove obturator assembly.

E2. Light Carrier — Pull light carrier assembly down and out of ring

Assembly assembly.

E3. Speculum —

Assembly pulling the speculum assembly from the ring assembly.

E4. Lamp — Unscrew lamp.

E5. Contact Ass’y — Pull bayonet contact out of bottom of bayonet assembly.

E6. Pinion Gear — Unscrew knob set screw ( 3-48 screw, use .050" key)

Pull knurled rotation knob upwards and hold it there while

Unscrew and remove bayonet assembly from light carrier base subassembly. Remove old contact assembly and small contact spring (underneath contact assembly) from lamp socket of light carrier base subassembly. Use thin needle-point awl and tweezers. Pull old contact assembly and wire from light carrier base subassembly and inspect to make sure there is no debris left in wire channel or lamp socket.

and remove knob. Pull pinion gear shaft down. Remove spring and guide.

**** 38800 Reassembly ****

E7. Pinion Gear —

Put guide PN 388009 onto pinion gear shaft with bevel against gear. Place spring over shaft and guide. Insert into shaft housing of ring assembly. Attach knurled knob and tighten the set screw (3-48 screw, use .050" key).

38800 Rotating Anoscope Reassembly Continued

E8. Contact Assembly __ Put contact assembly wire through contact assembly

spring (PN 383065) and position spring under contact assembly. Insert contact assembly wire into lamp socket and push wire through bottom of light carrier base assembly. Grab end of wire with tweezers when it is visible in the base. Pull it up with tweezers so that the contact assembly goes to the bottom of the lamp socket.

E9. Bayonet Assembly — Insert wire through the bayonet assembly. Screw the

bayonet assembly into the base while carefully applying slight tension on the wire to remove excess wire (slack).

E10. Bayonet Contact — Remove insulation from the wire that protrudes from

the end of the bayonet assembly. Press bayonet contact into the small hole in the end-insulation of the bayonet assembly so that it has good electrical contact with the wire. Remove excess wire strands with X-acto knife.

E11. Speculum — Pull knurled knob up and insert speculum assembly

Assembly into ring assembly. Release knob slowly. Turn knob to

rotate speculum.

E12. Lamp — Screw lamp into lamp socket. Clean lamp.

E13. Light Carrier — Press ring ass’y onto base.

Assembly

E14. Obturator Assy — Insert obturator assembly.

End 38800 Reassembly

Procto Sigmoidoscopes/Anoscopes

APPENDIX

TOOLS/MATERIALS/SUPPLIES

Window Screw Wrench Large (Undercut) ( Welch Allyn T-5320 ) Window Screw Wrench Small (Undercut) ( Welch Allyn T-5319 ) Bayonet Pliers ( Welch Allyn T-10802 ) Drift Pin Punch .060" Diam. Jewelers Hammer 6 Oz.. Needle Point Awl Flat Blade Screwdriver ie. Xcelite # P-181 Needle Nose Pliers ie. Xcelite # 52cg 152mm 12"X 12" (Approximately) Foam Pad (Mouse Mat™ , American Covers Inc.) Windex™ Glass Cleaner Or Vestal Glass Cleaner #8618-21 Lint Free Wipes Wire Stripper ( Ideal Industries*, Model #45-217 ‘T-stripper’) X-acto Knife W/#11 Blade Tweezers (Grobet Peer # 7) Tweezers (Model A-5ASA From Ideal Catalog)** Insufflation Bulb, Tube ( Welch Allyn 30200 ) Beaker 500 ML.

Tap/Drill/Key: Tap Drill Key

3-48 #47 (.0785") .050" 4-40 #43 (.0890") .050"

Pin Vises for Allen Keys above. (L.S. Starrett Model 166 A )

* Pro-Craft/GFC Co. Carlstadt, New Jersey, 07072 U.s.a.

** Ideal Industries Inc., Sycamore, Ill. Model #45-217 ‘T’-stripper. From catalog: Contact-East Inc., 335 Willow St., North Andover, MA, 01845. PH.(508) 682-2000.

TROUBLESHOOTING PROCTO SIGMOIDOSCOPES/ANOSCOPE

Instrument: Rotating Anoscope With 38300 Light Carrier Model #:

38800

Problem

Ring assembly sticks and Teeth worn/broken on ring or won’t rotate

Obturator won’t fit properly Obturator scratched Replace if it is sharp

Intermittent or no light Defective lamp

Low light

Anoscope is tight on light Light carrier is: Replace ring assembly carrier (It is difficult to separate).

speculum assembly

Handle bent Replace obturator Plating worn Speculum bent Replace speculum

For the 38300 Light Carrier

Worn contact Rewire Lamp out of alignment Replace lamp

Stem bent

a) bent (dropped) Replace carrier b) ball bearing is stuck Clean base of ring assembly (or (corrosion between ball and replace). base from improper cleaning)

Cause Corrective Action

Replace ring or

Replace obturator

Replace lamp

Bend to correct shape

spec.

Section 9

HEADLIGHTS

AND TRANSFORMER

MODEL # SUB-SECTION PAGE

46003 A 1-2 46023 A 1-2 46050 A 1-2 49003 B 3-4 49022 B 3-4 49030 B 3-4 49034 B 3-4 49035 B 3-4 49036 B 3-4 790030-501 C 5-6 790030-502 C 5-6 470305 D 7-8 470225 D 7-8 470245 D 7-8 470285 D 7-8

Headlights

and Transformer

The terms POWER SUPPLY, TRANSFORMER, and AC ADAPTOR, are used interchangeably.

Special Instructions:

Clean returned headlights by wiping with a solution of 10% Clorox and 90% water. Do not apply alcohol, chemicals or water to the lens. Use approved lens cleaner only. Perform incoming evaluation to understand cause of the customer complaint.

A. Direct Focusing Headlight NOS. 46003, 46023, 46050.

Disassembly: Transformers PN791003-502, 791054, 791100 are non-serviceable items.

Female switch is replaceable.

A1. Lens Assembly — Pull lens assembly from lamp base assembly. Wipe lens with

soft cloth and lens cleaning solution. Inspect lens for: secure fit, no scratches or smudges.

A2. Lamp — Old lamps may be shattered, weakened, or break while

unscrewing, therefore, use glove or cloth to protect fingers while unscrewing lamp from lamp base assembly. Inspect socket contacts for corrosion and or wear.

A3. Lamp Base

Assembly — Unscrew two small screws on the back of the male switch

assembly (the switch that is mounted on the headband). Remove the plastic back plate and the male switch assembly. Unclip the connecting wire from under the headband wire clip. Unscrew the small wing nut on the headlight support. Remove the lamp base from the headband assembly.

A. Direct Focusing Headlight NOS: 46003 (120Volt), 46023 (220Volt), 46050 (250Volt)

Disassembly Continued:

A4. Male Switch — Un-solder two wires from back of male switch assembly and

Assembly clean wires. Refit the lamp base assembly with a new male

switch assembly by re-soldering the long wire to the ‘G’ terminal and the short wire to the ‘W’ terminal on the back of the male switch assembly. Use rosin core solder. Do not use acid core solder.

A5. Pad/Post Assembly — Grip ball of post in a vise and cut the (if headband is stem of

the post between its flange and in good condition) the aluminum disc. Use a hacksaw. Discard aluminum disc, post, and rubber pad.

A6. Install Pad/Post — Position new post through new aluminum disc and then

headband. Put a drop of Loctite 495 on fluted end of post. Press post into new rubber pad. Use smooth jaw vise to press parts together.

A7. Replace Lamp Base

Assembly — Position the male switch assembly against the headband with

the beveled edge facing up. Secure male switch to the headband assembly with two slotted head screws and plastic back plate. The screw heads should have no sharp edges or burrs after assembly. Lay the wire flat with no twists and secure it under the plastic clip on the headband. Clamp the lamp base assembly by tightening the wing nut.

A8. Replace Lamp — Install clean lamp in lamp base assembly. Push lens assembly

onto lamp base assembly. Plug transformer into mains turn it on to see that it works properly.

—End 46003, 46023, 46050 Reassembly—

Halogen Headlight: 49003 (110-130V) & 790030-501*Power Supply

49022 (220-250V) & 790030-502 Power Supply 49030 & 470305 IEC AC Adaptor* 49034 & 470225 IEC AC Adaptor 49035 & 470245 IEC AC Adaptor 49036 & 470285 IEC AC Adaptor

*The terms POWER SUPPLY, TRANSFORMER, and AC ADAPTOR, are used interchangeably.

B. Halogen Headlight: 49003 (110-130 Volt) 49034, 49035, 49036

Disassembly: (Transformers for the 490 series are serviceable items, refer to Section C.)

B1. Lens Assembly — Unscrew main housing assembly from reflector socket

assembly. Wipe lens with soft cloth and lens cleaning solution. Inspect lens for: Secure fit, no scratches or smudges. (Do not disassemble the main housing assembly.)

B2. Lamp — Old lamps may be shattered, weakened, or break while

removing, therefore, use glove or cloth to protect fingers while twisting lamp from socket. Inspect socket contacts for corrosion and or wear. They should have about 1/8" of spring to them.

B3. Reflector Socket

Assembly — Unscrew two small screws on the back of the male switch

B4. Male Switch

Assembly — Un-solder two wires from back of male switch assembly and

clean wires. Refit the reflector socket assembly with a new male switch assembly by re-soldering the long wire to the ‘R’ terminal and the short wire to the ‘W’ terminal on the back of the male switch assembly. Use rosin core solder.

B. Halogen Headlight/IEC AC adaptors: 49003, 49034, 49035, 49036

Disassembly: (Transformers for the 490 series are serviceable items, refer to Section C.)

B5. Pad/Post Assembly — Grip ball of post in a vise and cut the (if headband is stem of

the post between its flange and in good condition) the aluminum disc. Use a hacksaw. Discard aluminum disc, post, and rubber pad.

B6. Install Pad/Post — Position new post through new aluminum disc and then

headband. Put a drop of Loctite 495 on fluted end of post. Press post into new rubber pad. Use smooth jaw vise to press parts together.

B7. Replace Reflector

Socket Assembly. — Position the male switch assembly against the headband with

the beveled edge facing up. Secure male switch to the headband assembly with two slotted head screws and plastic back plate. The screw heads howled have no sharp edges or burrs after assembly. Lay the wire flat with no twists and secure it under the plastic clip on the headband. Clamp the reflector socket assembly by tightening the wing nut.

B8. Replace Lamp — Align pin with slot in socket, and insert lamp and twist

clockwise. Clean the lamp with a swab dipped in alcohol. Screw the lens assembly onto the reflector socket assembly. Plug transformer into mains, connect secondary to headband switch and turn transformer on. Inspect shutter for smooth operation.

—End 49030, 49034, 49035, 49036 Halogen Headlight Reassembly—

790030-501 (110-130Volt) & 790030-502 (220-250Volt) Power Supplies for 49003 & 49022 Headlight Respectively

C Disassembly

C1. Rocker Switch — Disconnect power supply from mains. Insert small flat blade

screwdriver between black spring retainer and chrome clip on the side of the switch (center of the end of the switch). See Figure 1. Then twist screwdriver slightly and lift the switch up by its wires as far as it will go on that side. Do the same on the other end of the switch to lift it completely out. Do not remove the black clip as this will be reused for the replacement switch. Cut wires from switch on the switch side of the crimp connectors.

Figure 1

Back of Switch

Note: this diagram is for position reference only. The terminals are not labeled on the Carling Switch.

C2. Restore Wiring

(For switch) — Install replacement switch in the housing prior to crimping

wires. Position the power switch in the cutout of the case with the ‘Off’ label towards the Welch Allyn name. Use the same screwdriver as before to spread the black clip to accept the switch as far as it will go. Crimp wires of replacement switch to: Both transformer primary winding leads, line neutral (white line cord wire), and the thermal interrupt safety switch, as per Figure 1 above. Use klein crimper pliers (Klein #1005 or equivalent).

C3. Transformer — Pull transformer from case. Cut crimp connectors from the

transformer leads. Unscrew the grounding wire ring terminal from the grounding post. Lift transformer out of case. Note in detail the position and arrangement of all components and wiring.

790030-501 (110-130Volt) & 790030-502 (220-250Volt) Power Supplies for 49003 & 49022 Headlight respectively

C Disassembly Continued

C3. Transformer

Continued — The early production versions had the transformer positioned

as shown in drawing #790030. Replace components and wiring for your transformer in the same position as it was prior to disassembly. Use klein crimper pliers (Klein #1005 or equivalent). Attach the foam pad from the old transformer to the same position on the replacement transformer (opposite the label). Make sure that wires do not get pinched between the transformer and the case, or between the case and the aluminum cover. See assembly drawing.

C5. Female Switch — Unscrew cover of female switch. Un-solder black and white

wires from the switch. Solder wires to replacement switch. Secure cover of female switch with screw. Perform full functional check. Use rosin core solder.

C6. Secondary Cord — Remove Heyco strain relief. Cut old secondary cord near

crimp connectors. Remove old cord. Insert replacement cord to case and secure with strain relief. Restore connections by crimping transformer secondary wires to secondary cord. Attach cover of power supply.

—End 790030-501 & 790030-502 Reassembly—

470305, 470225, 470245, 470285 IEC AC ADAPTORS for 49030, 49034, 49035, 49036 Headlights respectively

D Disassembly D1. Rocker Switch — Disconnect IEC AC adaptor from mains. Remove four

phillips head machine screws from back of the base. Pull spade connectors from switch and move wires out of the way. Press tabs on rocker switch to remove switch from cover assembly. See Figure 2. Do not cut wires from switch.

Figure 2

Back of Marquardt Switch

D2. Restore Wiring — Install replacement switch in cover assy. Prior to connecting

wires. Position the power switch in the cutout of the cover with the ‘O’ symbol ‘UP’. Attach wires to replacement switch per Fig 2.

D3. PC Board Assembly — Disconnect the two power cord (line voltage) wires from PC

board wire terminal block locations 1 and 2. Unscrew four phillips head screws from PC board. Turn PC board over and unsolder the two secondary wires (black and blue) from the trace side of the board. Note: It is not necessary to remove the gray fiber insulation from the base assembly.

D4. Replace PC Board — Solder* the secondary black and white wires onto the PC

board at locations marked ‘output’ with the white wire nearer the transformer. Make sure there is an insulation board in the base assembly. Attach line cord wires: Blue to #1 and brown to #2. Attach board with 4 phillips head screws and star washers. *Use rosin core solder.

470305, 470225, 470245, 470285 IEC AC Adaptors for 49030, 49034, 49035, 49036 Headlights respectively

D Disassembly Continued

D5. Female Switch — Unscrew cover of female switch. Un-solder black and white

wires from the switch. Solder wires to replacement switch with rosin core solder. Secure cover of female switch with screw. Perform full functional check. Use rosin core solder.

D6. Secondary Cord — Remove cover assembly and loosen PC board. Loosen the

strain relief screw nearest the transformer. Unsolder old secondary cord at the board. Remove old cord. Insert replacement cord through strain relief and secure with strain relief screw. Attach cover assembly.

D7. Power Cord — Remove cover assembly and loosen power cord strain relief

screw. Loosen two terminal screws and remove brown and blue wires from the terminal block. Prepare the end of the replacement power cord by removing outer insulation from approximately two inches of the cord. Strip 1/4 inch of the two wires. Attach line cord wires: Blue to #1 and brown to #2. Before tightening the strain relief screw, make sure there is a little slack (approximately 1/2 inch to 3/4 inch) in the base. Secure power cord with strain relief set screw. Perform full functional check.

D8. Fuse — Check the PC board fuse prior to replacing the board. Replace

fuse with original equipment type according to parts list. Only use IEC 5 x 20 mm time delay fuses. See printed chart in cover assembly.

TOOLS / MATERIALS / SUPPLIES

Tweezers (Grobet Peer #7 Stainless Steel or Equivalent) Miller Stephenson Aero-Duster #MS-222 (or Equivalent) Soldering Iron, 80W Unger #3180 (or Equivalent) Screwdriver, 1/8" Flat Blade Screwdriver, #0 and #2 Phillips Terminal Crimpers, (Klein #1005 or Equivalent) Wire Cutter, (Xcelite 107cg or Eqivalent) Heyco #29 Tool For Nos. 6P3-4 and #2M-4 Strain Reliefs. Wire Stripper, (Xcelite 105scg or Equivalent) Windex™ Glass Cleaner or Vestal Glass Cleaner #8618-21 Lint Free Wipes / Swabs Solder. (Rosin Flux Core)

INSPECTIONS FOR REPAIRED HEADLIGHTS

1. Operate:switches, adjust the headlight positioning wing nut, focus mechanism. These should

operate smoothly. Headlight should stay in position once adjusted and tightened.

2. Lenses and bulb should be free of smudges, scratches, dirt.

3. Check projected images for shadows, dirt, and filament images. The light beam should focus

to an even white spot.

4. Switch (on headband) should operate smoothly and provide positive on/off operation.

Switch on the 79003 transformer operates properly, including pilot light in rocker.

5. Lamp should not flicker when cord is flexed along its entire length.

6. The wing nut, and plastic back plate retaining screws (2) should be free of burrs or sharp

points.

7. The pad and headband should be free of sharp edges.

8. The brass contact(s) and/or screw threads of the lamp socket should be free of corrosion and

copper oxide.

9. (For the 49030, 49034, 49035, 49036) The two brass screws in the reflector socket assembly

are tight and making good contact with the ring terminals and contacts. ON/OFF switch

operates correctly.

Welch Allyn Traditional Instruments User manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Section 1

OPHTHALMOSCOPES

TOOLS/MATERIALS/SUPPLIES

Inspections for Repaired Ophthalmoscopes:

F inal Inspection of Ophthalmoscopes

Troubleshooting Ophthalmoscopes

Section 2

TOOLS/MATERIALS/SUPPLIES

Section 3

RETINOSCOPES

Inspections For Repaired Retinoscopes

18100

Section 4

OTOSCOPES

SPECIAL INSTRUCTIONS:

TOOLS/MATERIALS/SUPPLIES

Inspections for Repaired Otoscopes:

Section 5

Illuminated BiValve Nasal Speculum

Special Instructions:

TOOLS/MATERIALS/SUPPLIES

Section 6

Illuminator

TOOLS

Section 7

TONGUE DEPRESSOR

Special Instructions:

TOOLS/MATERIALS/SUPPLIES

Section 8

Special Instructions:

TOOLS/MATERIALS/SUPPLIES

38800

Section 9

Headlights

Special Instructions:

TOOLS / MATERIALS / SUPPLIES