JUPITER Operating Table
Service Manual
This is a class 1 medical product within the meaning of the European Medical Device Directive (MDD)
93/42/EEC, June 1993, Appendix 9, and the German Medizin Produkte Gesetz (MPG) (Law of Medical
Products), August 1994, Appendix 9.
The manufacturer declares that this product conforms to the essential requirement of the MPG, Appendix 7,
and this is documented by the CE sign.
TRUMPF Medizin Systeme GmbH
Postfach 1263
D-07303 Saalfeld
Germany
TRUMPF Medizin Systeme GmbH
Carl-Zeiss-Straße 5
D-07318 Saalfeld
Germany
Sales and
Distribution
Telephone +49 3671 586-0
Telefax
+49 3671 586 166
Service
Telephone +49 3671 586 172
+49 3671 586 176
Telefax
+49 3671 586 175
We are constantly working on further developments.
Therefore, please understand that we must reserve the right to change the scope of delivery in respect of the
form, equipment and technology at any time.
Reprinting, copying or translating this document, in whole or in part, is forbidden without the express written
permission of TRUMPF Medizin Systeme GmbH.
All rights under the copyright laws are expressly reserved by TRUMPF Medizin Systeme GmbH.
Within the framework of the legal requirements, the manufacturer is only responsible for the safety
characteristics of this device if the maintenance, repair and modifications performed on this device are carried
out by the manufacturer, or by a person authorised by the manufacturer and in accordance with the
manufacturer’s instructions.
© 03/03 TRUMPF Medizin Systeme GmbH
ATTENTION!
This Service Manual only applies to the following sale units/item numbers:
JUPITER SF column (permanently mounted column)
JUPITER SM column (mobile column)
GM Table top
RY Table top
Pelvis section, driven (PSA)
Cable remote control
IR remote control
Charging unit for remote control (table model)
Charging unit for remote control (wall model, 230 V)
Charging unit for remote control (wall model, 24 V)
SM column power pack (230 V)
SM column power pack (230 V)
SM column power pack (115 V)
SF column power pack (230 V)
SF column power pack (115 V)
Shuttle 1
Shuttle 2
Shuttle 3
Section control unit
Charging unit for Section control unit
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
544
544
544
544
544
544
544
544
544
544
544
144
144
145
145
544
544
544
544
544
112
113
100
130
102
119
120
122
123
139
121
892
897
564
565
115
116
117
148
149
NOTE!
Only perform those repairs which
• you are familiar with through your training, or have been agreed with
TRUMPF Medizin Systeme GmbH in advance,
• and are described in the Service Manual,
• only use original spare parts which provide complete functionality and
safety.
Service Manual JUPITER 4 900 361 - 03/03
Service Manual JUPITER 4 900 361 - 03/03
Contents
Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
Introduction
Notes for Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Protection against Infection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Instructions for Protecting the Environment . . . . . . . . . . . . . . . . . . . . . . . . . 10
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2
2.1
2.2
Preparations
Repair Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tools, Measuring Equipment, Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Electrical Components of the SM/SF Columns
Changing the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Circuit Boards in the Operating Computer. . . . . . . . . . . . . . .
Replacing the Adapter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test/Replace Fuses in the Operating Computer . . . . . . . . . . . . . . . . . . . . .
Replace Operating Computer EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Contact Plate/Circuit Board of the Column Head Cover . . . . . . . . .
Replacing the Connection Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Unit for External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . .
Hand Control Connection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wedge Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor Module on the Left-Hand Tilting Drive . . . . . . . . . . . . . . . . . . . . . . .
Sensor Module on the Right-Hand Tilting Drive . . . . . . . . . . . . . . . . . . . . . .
Sensor Module on the Trendelenburg Drive . . . . . . . . . . . . . . . . . . . . . . . .
Reference Sensor on the Vertical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Takeover Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Presence Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inclination Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the End Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In the Sensor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On the Vertical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Power Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trendelenburg Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilting Motor Right Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilting Motor Left Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Membrane Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Adjustment of Main Lift for Service Work . . . . . . . . . . . . . . . . . .
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
Service Manual JUPITER 4 900 361 - 03/03
15
18
20
21
23
25
27
27
29
31
33
33
35
39
43
48
49
50
51
53
53
57
59
61
63
63
65
65
65
66
67
1
Contents
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
2
Mechanical Components of the SM/SF Columns
Replacing the Cladding Components (without Membrane Keypad) . . . . . . . .69
Replacing the Cladding Component with the Membrane Keypad . . . . . . . . . .70
Replacing the Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Replacing the Rubber Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Replacing the Complete Base Plate and Seal . . . . . . . . . . . . . . . . . . . . . . . .74
Replacing the Rubber Seal for the Base Plate . . . . . . . . . . . . . . . . . . . . . . . .75
Replacing the Potential Contact under the Base Plate . . . . . . . . . . . . . . . . . .76
Replacing the Drives (Trendelenburg, Tilting/Left, Tilting/Right) . . . . . . . . . . .77
Trendelenburg Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Dismantling the Trendelenburg Drive Module. . . . . . . . . . . . . . . . . . . . . . . .81
Replacing the toothed belt of the Trendelenburg drive. . . . . . . . . . . . . . . . . .81
Replacing the spindle/stop nut of the Trendelenburg. . . . . . . . . . . . . . . . . . .81
Replacing the Trendelenburg drive motor. . . . . . . . . . . . . . . . . . . . . . . . . . .82
Tilting Drive/Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Dismantling the Tilting Module (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Replacing the toothed belt of the tilting drive/right . . . . . . . . . . . . . . . . . . . .87
Replacing the spindle/stop nut of the tilting drive/right . . . . . . . . . . . . . . . . .87
Replacing the tilting drive motor/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Tilting Drive/left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Dismantling the Tilting Module/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Replacing the toothed belt of the tilting drive/left . . . . . . . . . . . . . . . . . . . . .93
Replacing the spindle/stop nut of the tilting drive/left . . . . . . . . . . . . . . . . . .93
Replacing the tilting drive motor/left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Replacing the Main Spindle and Toothed Belt . . . . . . . . . . . . . . . . . . . . . . .96
Dismantling the bearing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Replacing the toothed belt of the bearing module. . . . . . . . . . . . . . . . . . . . .98
Setting the bearing module (only if necessary!) . . . . . . . . . . . . . . . . . . . . . . .98
Replacing the ball-bearing spindle in the bearing modules . . . . . . . . . . . . . .99
Repairing and setting the brake on the SF column . . . . . . . . . . . . . . . . . . .100
Removing the set of batteries from the SF column . . . . . . . . . . . . . . . . . . . .100
Electrical Components of the GM Table top
Contact Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Distributor Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Replacing the longitudinal displacement motor/toothed disc . . . . . . . . . . . .106
Removing the toothed disc (motor pinion) . . . . . . . . . . . . . . . . . . . . . . . . .107
Longitudinal Displacement Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Sensor for Detecting the OR Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Leg Section Presence Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Reference and End Sensors for the Leg Section Joints . . . . . . . . . . . . . . . . .114
Reference and End Sensors for the Back Station . . . . . . . . . . . . . . . . . . . . .116
Leg Section Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Back Section Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Connecting Socket for Additional Accessories . . . . . . . . . . . . . . . . . . . . . .122
Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Additional Accessory Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Contact Plate Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Longitudinal displacement reference sensor/OR adapter cable . . . . . . . . . .127
Leg section cable left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Back section cable left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Service Manual JUPITER 4 900 361 - 03/03
Contents
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
Mechanical Components of the GM Table top
Plastic Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Covering Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leg Section Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leg Section Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Section Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Section Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Section Spar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel Wheel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linear Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel Wheel Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft’s Toothed Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing of the Longitudinal Displacement Shaft . . . . . . . . . . . . . . . . .
Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Train Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
135
136
139
142
144
146
149
152
154
156
158
160
162
164
166
167
7
7.1
Additional Components
Remote Control with circuit board 4 144 709 (old version) . . . . . . . . . . . .
Removing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the foil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable remote control with circuit board 4 144 996 . . . . . . . . . . . . . . . . .
Infrared remote control with circuit board 4 144 995 . . . . . . . . . . . . . . . .
Power Pack for the SM Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Pack for the SF Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Unit for the Remote Control (Table Model). . . . . . . . . . . . . . . . .
Charging Unit for Remote Control (Wall Model) . . . . . . . . . . . . . . . . . . . .
169
169
170
170
171
172
173
175
176
177
178
Accessories
Section Control Unit and Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mains Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing/Replacing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing/Replacing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Connecting Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Membrane Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
179
179
179
180
181
181
182
182
183
183
184
7.2
7.3
7.4
7.5
7.6
7.7
8
8.1
8.2
Service Manual JUPITER 4 900 361 - 03/03
3
Contents
4
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7
PSA Electrical Components
Replacing the Connecting Cable/PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Replacing the Socket for the Section Control Unit . . . . . . . . . . . . . . . . . . . .186
Replacing the Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Replacing the Leg Section Presence Sensor . . . . . . . . . . . . . . . . . . . . . . . .188
Replacing the Reference/End Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Replacing the Connecting Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Replacing Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
10
10.1
10.2
10.3
10.4
PSA Mechanical Components
Replacing the Plastic Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Replacing the Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Replacing the Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Coupling Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
Electrical Components of the RY Table top
Contact Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Distributor Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Leg Section Presence Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Reference and End Sensors for the Leg Section Joints . . . . . . . . . . . . . . . . .208
Leg Section Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Connecting Socket for Additional Accessories . . . . . . . . . . . . . . . . . . . . . .212
Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Additional Accessory Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Cable Contact Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Leg Section Cable - Right/Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
12
12.1
12.2
12.3
12.4
12.5
Mechanical Components of the RY Table top
Plastic Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Covering Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Leg Section Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Leg Section Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Seat Section Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
Repair Instructions Shuttle 1, 2, 3
Fender and Initiator Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Changing the Adjustable Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Takeover Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Changing the Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Rear Wheel Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Replacing the Table top Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . .233
Table/Column Changeover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Replacing the Hydraulic Lifting Unit (Shuttle 3) . . . . . . . . . . . . . . . . . . . . . .235
Bowden Cable (Shuttles 2 and 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Drive (Shuttles 2 and 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Service Manual JUPITER 4 900 361 - 03/03
Contents
14
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Appendices
Operating Instructions in brief
Fault Tracing to the JUPITER Operating Table
Technical Support
Test Programs
PC Service Program
Circuit Diagrams
Overview of Fuses
Annual Maintenance Work: JUPITER System
Spare parts SM/SF column
Spare parts GM Table top
Spare parts Shuttle 1, Shuttle 2, Shuttle 3
Status and Error Messages: Operating Table Software
Operation and power supply
Second-hand parts
Service Manual JUPITER 4 900 361 - 03/03
5
Contents
6
Service Manual JUPITER 4 900 361 - 03/03
Introduction
1
Introduction
Please follow this manual exactly when performing repairs and keep to all the scheduled
repair steps.
We would be grateful to receive any corrections to this manual and also any tips for
performing repairs more efficiently than described here.
Please contact our Service Department in Saalfeld.
1.1
Notes for Service Personnel
This repair manual is intended for trained service and maintenance personnel.
Refer to the user manual for information about operating the device.
Please contact our Service Department if a problem occurs which cannot be remedied with
the assistance of this repair manual.
Repairs may only be performed by trained personnel.
We offer training for this purpose.
This service manual also serves as training documentation.
Repairs which are not covered by this service manual may only be performed after
consultation with TRUMPF Medizin Systeme GmbH or be performed by
TRUMPF Medizin Systeme GmbH in Saalfeld.
After all repairs or settings, a functional test or test must be performed in accordance with
the instructions in this service manual.
The device may only be handed over to the customer after being tested and in a fully
functional condition.
The handover must be made in writing and must be confirmed by the customer.
The device must be demonstrated to the customer at the handover.
TRUMPF Medizin Systeme GmbH
Service
Carl-Zeiss-Straße 5
D-07318 Saalfeld
Germany
Telephone: +49 3671 58 61 72
+49 3671 58 61 76
Telefax:
+49 3671 58 61 75
Service Manual JUPITER 4 900 361 - 03/03
7
Introduction
1.2
Important information
Important information in this service manual is marked as follows.
Please pay particular attention to these notes.
An additional symbol alongside the warning symbol illustrates the danger.
WARNING!
Danger to life and limb (for example electric shock)!
Risk of serious injuries and damage to property.
CAUTION!
Risk of injury and/or damage to property.
(The example shown here is the symbol for the risk of fingers being
crushed).
ATTENTION!
Risk of damage to property.
NOTE!
Useful additional information and tips.
TEST!
Performance of functional testing, measurements and tests.
ENVIRONMENT!
Instruction for protection of the environment.
8
Service Manual JUPITER 4 900 361 - 03/03
Introduction
1.3
General Safety Instructions
Please observe the following instructions:
• Only perform those repairs and settings for which you have been trained and which are
described in the Service Manual.
Please contact us if you have any doubts.
• Only use original spare parts provided by TRUMPF Medizin Systeme GmbH as spare
parts.
• Keep the areas around the device clean and tidy during and after maintenance.
• Do not perform any actions which could put people in danger or could make the device
a source of danger.
• Store dismounted casings and other parts of the device which have been removed in a
safe place while working. Always place tools and dismounted parts in a place where no
one can trip over or slip on them. If any nuts, bolts or other small parts fall into any of
the JUPITER modules they must be removed.
• Your clothing must be so arranged that it cannot get caught in the device. Button up the
sleeves of your shirt or jacket or roll them up. Long hair must be tied together or put up.
Tuck the ends of scarves, ties and shawls into your clothing or fasten them securely.
Loose items of clothing can be dangerous!
• Wear protective goggles for the following activities:
– hammering pins or similar parts in or out
– removing springs under tension and safety devices
– working with an electric drill
– using spring hooks or inserting springs
– soldering
– when using solvents, cleansers or other chemicals
– in general, when the working conditions present a possible risk to the eyes.
• After work has been completed, replace or renew all safety devices, such as:
– covers
– cable connectors, cable holders
– cable screens
– bonding and potential connections
– earthing connections.
potential equalisation/earth connections must be tested after assembly.
• When soldering, only limed resin may be used as flux.
• After completing the repair, check the electrical connections again with the circuit
diagram before performing a functional test.
• Bolts and screws with an M4 or larger thread must be fixed with Omnifit 100 (red).
• Replace all defective parts, which are not clearly in good working order, with original
spare parts, including those which go beyond the scope of the repair order.
• After repairs have been completed, all cables must be restored to their original positions,
and a final check must be made for any risk of shearing and crushing.
Check the cable positions again during and after the course of movements of the table
and its sections.
• Unauthorised or provisional repairs are not permitted, even if the customer requests
them.
Service Manual JUPITER 4 900 361 - 03/03
9
Introduction
1.4
Protection against Infection
Safety instructions for working in the operating theatre area:
CAUTION!
There is a risk of infection in the entire hospital.
Observe all safety measures.
As a service technician, also follow the requirements of the medical facility
concerning protection against infection.
• Only perform maintenance and repair work on operating tables which have been
disinfected.
• The disinfection of the interior parts of the operating table must be organised at the
proper time before the repair/maintenance work and is to be performed by the medical
facility.
• Observe all the medical facility’s hygiene requirements concerning clothing, cleaning
regulations and disinfection measures. Observe all rules on behaviour, especially in the
operating theatre area.
• Work may only be performed in the operating theatre area if the relevant authorisation
has been given.
• See a doctor immediately if symptoms of illness or disease occur.
Tell your doctor that you have worked in areas where there is risk of infection - even
months later.
Instructions for persons at risc:
NOTE!
Ask a doctor about the possible risks and possible measures to avoid them
in your work as a service technician.
• After consulting a doctor, get inoculated against hepatitis B.
A booster inoculation is required every 3 to 5 years.
• The incubation period for hepatitis B is 1 to 6 months.
1.5
Instructions for Protecting the Environment
• Follow the recycling regulations for components which have been removed, particularly
in the case of:
– batteries
– circuit boards
– cables.
10
Service Manual JUPITER 4 900 361 - 03/03
Introduction
1.6
Glossary
The following terms and abbreviations are used in this service manual:
Terms and Abbreviations
SM column
Column, mobile
SF column
Column, permanently installed
Operating table
Table top with column
Table top
Table top without column
Column
Column without table top
System
Column, Table top, Shuttle and functional accessories
Functional accessories
Head-/leg section, adapters, extensions etc.
Shuttle
Transporter for table top with/without column
(Shuttle variants 1, 2 or 3)
Remote control
Infrared remote control (no cable)
Hand control
Hand control with spiral cable
Membrane keypad
Column keypad, operating keypad on the column
Foot control
Foot control for Trendelenburg and height
Wall panel
Operating keypad on the wall
Standard rail
Fixing rail for accessories and fitments
Coupling point
Separable connecting point between the functional
accessories
Docking point
Wedge and wedge holder
Contact plate
Electrical connection between column head and
table top
AP area
Area which is subject to special conditions in accordance
with DIN VDE 0107
Zone M
Zone devision in accordance with DIN VDE 0107
AP-M
Designation of device protection type for devices which
may be used in the AP area of Zone M
Shift key
Key used in two-key operations for additional functions
Service Manual JUPITER 4 900 361 - 03/03
11
Introduction
12
Service Manual JUPITER 4 900 361 - 03/03
Preparations
2
Preparations
2.1
Repair Site
Ensure that conditions are hygienic at the working site, ask the doctor responsible if you are
in any doubt concerning protection against infection.
Do not perform the repairs until protection against infection has been ensured for you!
CAUTION!
There is a risk of infection in the entire hospital!
Follow all safety measures.
As a service technician, also follow the requirements of the medical facility
in respect of protection against infection.
Observe the following:
• Only perform maintenance and repairs on devices which have been disinfected.
• The disinfection of the interior parts of the operating table must be organised at the
proper time before the repair/maintenance work and is to be performed by the medical
facility.
• Observe all the medical facility’s hygiene requirements concerning clothing, cleaning
regulations and disinfection measures. Observe all rules on behaviour, especially in the
operating theatre area.
• Work may only be performed in the operating theatre area if the relevant authorisation
has been given.
2.2
Tools, Measuring Equipment, Materials
Tools
Basic equipment:
• Set of mechanic’s tools
• Hot air gun (hot air blower)
• Battery screwdriver
Special tools:
• Allen keys for emergency adjustment of the column stroke
• Pin remover
• Ejector tool (LEMO) for contacts on the table top socket
• Open-ended spanner 10 (ground)
• Lever for operating computer
• Special spanner for slotted nut
Service Manual JUPITER 4 900 361 - 03/03
13
Preparations
TRUMPF Medizin Systeme Measuring Equipment (specifically for JUPITER Service)
• Filling gauge 0.2 mm/small
• Gauges 1, 2, 3 (for end switch settings)
Materials
• Scotch Weld 110DP adhesive
• Instant adhesive
• Line connector
• Screw fixing lacquer OMNIFITT 100M
• Screw fixing lacquer OMNIFITT 200M
• Fixing lacquer for sensors
• Double sided adhesive tape
• Wooden spacer (replacing lifting motor)
• Wooden spacer (work beneath the base plate)
• Spirit (degreaser)
• Spindle grease (order from TRUMPF Medizin Systeme GmbH)
14
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3
Electrical Components of the SM/SF Columns
CAUTION!
Danger of infection!
Before beginning work, obtain confirmation from the medical facility that all
the necessary measures for protection against infection have been
performed.
3.1
Changing the Batteries
NOTE!
Always change the complete set of batteries.
Removal:
1. Transfer the table top onto a shuttle raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
1
2
Figure 1:
Sheet metal covering of the bottom of the column
1 Sheet metal covering
2
M3 screws
3. Screw 2 M3 screws [2] out of the lower part of the sheet metal covering [1].
Service Manual JUPITER 4 900 361 - 03/03
15
Electrical Components of the SM/SF Columns
3
4
5
Figure 2:
Securing the column covering
3 Sheet metal covering
4 M6 fixing screw
5
Trendelenburg drive
4. Open the bottom of the sheet metal covering [3], slide it upwards and fix it securely to
the Trendelenburg drive [5] with the M6 fixing screw [4].
+
1 2
1 3
1 4
+
-
6
7
9
8
-
1 0
+
1 1
Figure 3:
5.
Removing the batteries
6 Holding plate for holding band
7 Holding band
8 Plug shoe/battery connectors
9 Plug
10 Cable holder
11
12
13
14
Screw for cable holder
Bridge, sw (black)
Negative output voltage, bn (brown)
Positive output voltage, ws (white)
Pull the 6 battery connections [8] off the 3 batteries.
6. Remove 2 screws of the holding band [7] and screws of the holding plate [6].
16
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
7. Screw out the screws [11] on the cable holder [10] and remove the cable holder [10].
8. Mark plugs [9] and pull them out.
Plugs from top to bottom:
- Presence sensor
- Takeover sensor 1 (upper)
- Takeover sensor 2 (lower)
Reassembly:
ATTENTION!
Danger of a short circuit!
Connect the batteries correctly! Connecting the battery terminals incorrectly
causes damage. The batteries are connected in series!
1. Insert 3 new batteries.
2. Screw the holding band [7] and holding plate [6] up tightly.
3. Plug in bridges [12] and battery connections [13], [14].
The voltage between brown (bn) and white (ws) is 36 V DC.
4. Screw the cable holder [10] up with screws [11] and fix the cables.
5. Remount column.
6. Check the charge in the batteries (charge with power pack if necessary).
TEST!
Test the column functions.
Service Manual JUPITER 4 900 361 - 03/03
17
Electrical Components of the SM/SF Columns
3.2
Replacing the Circuit Boards in the Operating Computer
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug [4] out of the circuit board of the operating computer.
7. Pull the socket connections off and cut the cable binders.
8. Remove the screws from the cooling plates.
9. Starting from one side, press the snap-in lugs of the circuit board holder together
(5 per circuit board) and carefully pull the circuit boards out in an upward direction.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Treat the cooling plates with heat-conducting paste and mount them.
4
1
2
3
Figure 4:
IR Code
1 Coding switch for IR Code
2 Coding switch for IR Code
3
4
Coding switch for IR Code
Battery plug
• Take the IR code and set it for the new operating computer. Set with the coding switches
[1], [2] and [3] starting from the inside.
• Set the date and time with the PC (delete error memory and operating hours).
18
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
• Relay the cables as they were before and secure with new cable binders (see Cable
Layout Plan).
• Balance the inclination sensors.
• Check the charging end voltage (43.2 V).
• If necessary plug-in the jumper for permanent installation (see „Circuit Diagrams”).
• Plug contact plate plugs of the head cover into circuit board. Cable connection to circuit
board of the head cover must point to hand control connection unit.
TEST!
Test the column functions.
Service Manual JUPITER 4 900 361 - 03/03
19
Electrical Components of the SM/SF Columns
3.3
Replacing the Adapter Circuit Board
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 6 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the rest of the cladding downwards.
5. Pull off either the positive or negative battery connection.
6.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding!
Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
7. Slide the rubber bellows upwards at the adapter circuit board corner and fix it.
1
1
2
2
3
3
4
5
Figure 5:
Membrane keypad
1 Clamp terminal
2
3
Membrane-flat ribbon cable
Snap-in lug (circuit board holder)
4
5
Holding plate for the adapter-circuit
board
Membrane keypad of the column
8. Remove the flat ribbon cable [2] from terminal [1] (slide clip contact back and then pull
the flat ribbon cable out).
9. Starting from one side, press the snap-in lugs [3] of the circuit board holder together
and carefully remove the circuit board in an upward direction.
10. Unclamp the circuit board and replace it with a new one (see „Circuit Diagrams”).
Reassembly:
Reassemble in the reverse order.
TEST!
Test the column functions.
20
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.4
Test/Replace Fuses in the Operating Computer
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows. Lever the head cover off
carefully. Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
NOTE!
Refer to the overview of all the fuses in the appendix.
Item no. 4 144 703
Item no. 4 144 991
1
1
F 3
F 4
F 3
F 4
F 1
F 1
F 5
F 6
Figure 6:
Changing the fuses
1 Battery plug
F1 10 A delay-action fuse
F2 400 mA delay-action fuse
F3 2.5 A delay-action fuse
F 2
F4 630 mA fuse
F5 630 mA delay-action fuse
F6 400 mA delay-action fuse
6. Pull the battery plug [1] out of the circuit board of the operating computer.
7. Test the fuses which have been removed and replace where necessary.
Service Manual JUPITER 4 900 361 - 03/03
21
Electrical Components of the SM/SF Columns
Reassembly:
1. Test the fuses and replace where necessary (see „Overview of Fuses”).
2. Reinsert in the reverse order.
3. Plug the contact plate plugs of the head cover into the circuit board. The cable
connection to the circuit board of the head cover must show the hand control as the
connection unit.
4. Remount column.
TEST!
Test the column functions.
22
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.5
Replace Operating Computer EPROMs
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
4
1
2
3
Figure 7:
EPROM Replacement
1 Motor EPROM
2 Operating EPROM
3
4
Lug on EPROM
Battery plug
6. Pull the battery plug [4] out of the circuit board of the operating computer.
7. Pull EPROM [1] and/or [2] carefully up out of the socket(s).
Service Manual JUPITER 4 900 361 - 03/03
23
Electrical Components of the SM/SF Columns
Reassembly:
1. Reinsert in the reverse order.
2. Carefully insert the new EPROM into the socket on the relevant circuit board.
NOTE!
Pay attention to the following during insertion:
- polarity
- EPROM lug must point towards the right-hand wedge
- avoid electrostatic charges.
3. Check whether all the pins are lying correctly on the socket guides.
4. Press the EPROM in carefully. Ensure that none of the pins gets bent while doing so.
5. Plug the contact plate plugs of the head cover into the circuit board.
The cable connection to the circuit board of the head cover must point to the hand
control connection unit.
6. Remount column.
TEST!
Test the column functions.
24
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.6
Replace Contact Plate/Circuit Board of the Column Head Cover
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
1
2
3
4
6
Figure 8:
Replacing the contact plate
1 M4 screws
2 M3 nut
3 Contact plate
5
4
5
6
Head cover
Circuit board
Contact plate plug
3. Remove 8 M4 screws from the head cover [4].
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the plug [6] of the contact plate out of the operating computer.
5. Lay the cover down.
6. Unscrew 5 M3 nuts [2] on the contact plate [3] and remove the plate.
7. Unscrew 5 M4 screws [1] on the circuit board [5] and exchange the circuit board.
Service Manual JUPITER 4 900 361 - 03/03
25
Electrical Components of the SM/SF Columns
Reassembly:
1. Reassemble in the reverse order.
2. Insert the new element and ensure that it is in the proper position.
(The cable connection is made opposite to the information on the label on the potential
equalisation connection.)
3. Reseal with silicone when the contact plate has been replaced.
4. Plug the contact plate [6] plug of the head cover [4] into the operating computer.
The cable connection to the circuit board of the head cover must point to the hand
control connection unit.
5. Remount column.
TEST!
Test the column functions.
26
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.7
Replacing the Connection Units
Connection Unit for External Power Supply
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7
8
1
9
2
3
4
8
9
1 0
5
6
Figure 9:
External power supply connection unit
1 Plug
2 Cable screw connection charging
socket
3 Cable screw connection IR
4 Plug
5 External connection unit power supply
6
7
M5 nuts
sw (black)
8 ws (white)
9 gn (green)
10 bn (brown)
7. Unscrew 2 M5 nuts [6] and loosen 2 cable screw connections [2], [3].
8. Unclip the cable leads to the plugs [1], [4].
9. Pull the connection unit external power supply [5] together with the cables carefully off
the column head and renew.
Service Manual JUPITER 4 900 361 - 03/03
27
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Plug the contact plate plugs of the head cover into the circuit board. The cable
connection to the circuit board of the head cover must point to the hand control
connection unit.
• Remount column.
TEST!
Test the column functions.
28
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Hand Control Connection Unit
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
6
1
7
2
9
8
3
1 0
1 1
1 2
1 3
7
1 4
8
9
4
5
Figure 10: Hand control connection unit
1 Hand control connection unit
2 Plug
3 Cable screw connection IR
4 Plug
5 Hand control cable screw connection
6 M5 nuts
7 ws (white)
8
9
10
11
12
13
14
gn (green)
br (brown)
free
bl (blue)
gr (gray)
rs (pink)
ge (yellow)
7. Unscrew 2 M5 nuts [6] and disconnect 2 cable screw connections [3], [5].
8. Unclip cable leads to the plugs [2], [4].
9. Carefully pull the hand control connection unit [1] together with the cables off the
column head and renew it.
Service Manual JUPITER 4 900 361 - 03/03
29
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Plug the contact plate plugs of the head cover into the circuit board. The cable
connection to the circuit board of the head cover must point to he hand control
connection unit.
• Remount column.
TEST!
Test the column functions.
30
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.8
Replacing the Motor Control
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the rest of the cladding downwards.
5. Pull off either the positive or negative battery connection.
2
3
1
4
5
6
7
8
Figure 11: Motor control
1 M4 screws
2 Cable binder
3
4
6.
Plug
Screen for lifting motor cable
5
6
7
8
Stain relief clamp
Clamp block (left brown/right white)
cable to operating computer
Nuts
Clamp block (left brown/right white)
cable from lifting motor
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
Screw 6 M4 screws [1] out of the motor control cover.
7. Remove the motor control cover.
8. Loosen the strain relief clamps [5] from the cables (3 nuts).
9. Remove 2 cable binders [2].
10. Unscrew 3 nuts [7] and remove the distance plate.
11. Mark all ten plugs [3] and remove them.
12. Unclip cables from terminal blocks [6], [8].
13. Remove an M5 machine screw from the right-hand side.
14. In addition, remove 2 M5 machine screws and 2 M4 hexagon head cap screws on the
left-hand side of the cover in order to be able to remove the motor control.
15. Remove the motor control and replace with a new one.
Service Manual JUPITER 4 900 361 - 03/03
31
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order with the following instructions:
• Replace the cables exactly as they were before, renew cable binders.
• Clamp the shield/cable [4] under the lifting motor cover.
TEST!
Test the column functions.
32
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.9
Replace Sensors
Wedge Sensor
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
1
2
Figure 12: Wedge sensor
1 M10 Allen screw
2
Wedge holder
7. Lever the metal covers [2] off both wedges (they are fixed with double-sided adhesive
tape).
8. Unclip the wedge sensor connections (3 items).
9. Screw out 2 M10 Allen screws [1] and remove wedge [2].
10. Bore out the wedge sensor and glue in a new one or change the wedge [2].
Service Manual JUPITER 4 900 361 - 03/03
33
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Plug the contact plate plugs of the head cover into the circuit board. The cable
connection to the circuit board of the head cover must point to the hand control
connection unit.
• Remount column.
ATTENTION!
Danger of property damage!
Do not crush the cables during reassembly.
TEST!
Test the column functions.
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Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Sensor Module on the Left-Hand Tilting Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the rest of the cladding downwards.
12.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
13. Slide the rubber bellows upwards.
14. Unscrew (6 M5) the left-hand part of the fastening frame.
Service Manual JUPITER 4 900 361 - 03/03
35
Electrical Components of the SM/SF Columns
2
3
1
4
5
6
7
8
Figure 13:
Motor control
1 M4 screws
2 Cable binder
5
6
3
4
7
8
Plug
Screen for lifting motor cable
Stain relief clamp
Clamp block (left brown/right white)
cable to operating computer
Nuts
Clamp block (left brown/right white)
cable from lifting motor
15. Remove 6 M4 screws [1] from the motor control cover.
16. Remove the motor control cover.
17. Loosen the cable strain relief clamps [4] (3 nuts) and remove the cable binders [2].
18. Unplug the sensor module plug connector [3] on the motor control.
9
1 0
1 1
A
1 2
1 3
1 4
B
1 5
Figure 14:
Sensor module tilting drive left
9 Cardan
10 Setting screw
11 Reference sensor
12 Sensor module tilting left
13 Screw
14 End switch tilting left
15 Stop nut
19. The sensor module can be taken out after removing 2 M4 Allen screws [13].
20. Put in a new sensor module.
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Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Reassembly:
1. Reassemble in the reverse order.
2. Screw the new sensor module [12] down so that the switching point of the end
switch [14] lies in the upper third (B) of the stop nut [15] (only tighten the screws [13]
slightly).
NOTE!
Listen for the switching sound!
The end switch makes an audible click when the switching point is
reached.
3. Plug the sensor module [12] back into the motor control.
4. Plug the battery plug in and switch the column on.
5. In service mode, move all the spindle drives individually into the upper end position with
the remote control or with the PC.
1 6
1 7
1 8
1 9
Figure 15: End switch - Test left tilting drive switching point
16 Head
18 Cardan
17 Gauge 2
19 Suspension plate
6. Adjust the end switch of the left-hand tilting drive [14] by sliding the sensor module [12]
so that the gauge 2 [17], held as close as possible to the cardanic suspension [18], fits
tightly between the head [16] and the suspension plate [19] of the drive.
7. To set the reference sensor move all the spindles together into the lower end position.
2 0
2 1
2 1
2 2
A
2 3
Figure 16: Test reference sensor switching point tilting left
20 Cardan
22 Reference sensor
21 M4 setting screw
23 Sensor module
Service Manual JUPITER 4 900 361 - 03/03
37
Electrical Components of the SM/SF Columns
8.
ATTENTION!
Danger of property damage!
Ensure that the M4 setting screw [21] on the cardan [20] does not hit the
sensor [22]. The setting screw [21] must travel past the reference
sensor [22] with a clearance (A) of < 0.3 mm.
To correct the clearance (A) between the setting screw [21] and reference sensor [22]
press the sensor module [23] left or right and then check the clearance (A) with a feeler
gauge.
9. Tighten the sensor module [23] screws [13] tightly.
2 4
2 5
2 6
2 7
Figure 17:
Test reference sensor tilting drive left
24 Head
25 Gauge 1
26 Cardan
27 Suspension plate
10. Adjust the setting screw M4 [21] on the cardan [26] so that, after the spindle drive has
been switched off, gauge 1 [25] fits tightly between head [24] and suspension plate [27]
when held close against the drive cardan [26].
If gauge 1 [25] does not fit against the cardan [26], the cardan’s [26] setting screw [21]
must be readjusted.
11. Move the spindle drives upwards to some extent.
12. Travel to the lower end position again and check all drives with gauge 1 again.
13. Move the drives together almost to the upper end position.
14. Move the drives individually into the upper end position in service mode or with the PC.
15. Check the settings of the end switches for the tilting drives with gauge 2 and for the
Trendelenburg drive with gauge 3 again.
ATTENTION!
The settings are not finished until the gauges fit tightly between head
and suspension plate of the drives.
16. Reseal the screws.
17. Remount column.
TEST!
Test the column functions.
38
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Sensor Module on the Right-Hand Tilting Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the rest of the cladding downwards.
12.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
13. Slide the rubber bellows upwards.
1
1
2
2
3
3
4
5
Figure 18: Membrane keypad
1 Clamp terminal
2 Membrane flat ribbon cable
3 Snap-in lug (circuit board holder)
4
5
Holding plate of adapter circuit board
Column membrane keypad
14. Detach the flat ribbon cable [2] from the terminal [1] (slide the clip contact back and
then pull the flat ribbon cable out).
Service Manual JUPITER 4 900 361 - 03/03
39
Electrical Components of the SM/SF Columns
15. Push the flat ribbon cable down and through.
16. Dismount the cover part with the membrane key pad (3 M3 screws).
7
8
6
9
1 0
1 1
1 2
1 3
Figure 19:
Motor control
6 M4 screws
7 Cable binder
8
9
10 Stain relief clamp
11 Clamp block (left brown/right white)
cable to operating computer
12 Nuts
13 Clamp block (left brown/right white)
cable from lifting motor
Plug
Screen for lifting motor cable
17. Remove 6 M4 screws [6] on the motor control cover.
18. Remove the motor control cover.
19. Loosen the cable strain relief clamps [10] (3 nuts) and remove the cable binders [7].
20. Unplug the sensor module connector [8] to the motor control.
21. Undo the cable straps.
1 4
1 5
1 6
1 7
A
1 8
1 9
2 0
B
2 1
Figure 20:
Sensor module tilting drive right
14 Cardan
15 Setting screw
16 Reference sensor
17 Sensor module tilting right
18 Flat ribbon cable connection for
membrane keypad
19 M4 screw
20 End switch tilting right
21 Stop nut
22. The sensor module [17] can be taken out after removing 2 M4 screws [19].
40
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Reassembly:
1. Reassemble in the reverse order.
2. Screw on the new sensor module [17] so that the switching point of the end switch [20]
lies in the upper third (B) of the stop nut [21] (only tighten the screws [19] slightly).
NOTE!
Listen for the switching sound!
The end switch makes an audible click when the switching point is
reached.
3. Plug the sensor module [17] back into the motor control.
4. Plug the battery plug in and switch the column on.
5. In service mode, move all the spindle drives individually into the upper end position with
the remote control or with the PC.
2 2
2 3
2 4
2 5
Figure 21: End switch - Test right tilting drive switching point
22 Head
24 Cardan
23 Gauge 2
25 Suspension plate
6. Adjust the end switch of the right-hand tilting drive [20] by sliding the sensor
module [17] so that the gauge 2 [23], held as close as possible to the cardanic
suspension [24], fits tightly between the head [22] and the suspension plate [25]
of the drive.
7. To set the reference sensor, move all the spindles together into the lower end position.
2 6
2 7
2 7
2 8
A
2 9
Figure 22: Test switching point of reference sensor tilting right
26 Cardan
28 Reference sensor
27 Setting screw
29 Sensor module
8.
ATTENTION!
Danger of property damage!
Ensure that the M4 setting screw [22] on the cardan [26] does not hit the
sensor [28]. The setting screw [27] must travel past the reference
sensor [28] with a clearance (A) of < 0.3 mm.
To correct the clearance (A) between the setting screw [27] and reference sensor [28]
press the sensor module [29] left or right and then check the clearance (A) with a feeler
gauge.
Service Manual JUPITER 4 900 361 - 03/03
41
Electrical Components of the SM/SF Columns
9. Tighten the sensor module [29] screws [19] tightly.
3 0
3 1
3 2
3 3
Figure 23:
Test reference sensor tilting drive right
30 Head
31 Gauge 1
32 Cardan
33 Suspension plate
10. Adjust the setting screw M4 [27] on the cardan [32] so that, after the spindle drive has
been switched off, gauge 1 [31] fits tightly between head [30] and suspension plate [33]
when held close against the drive cardan [32].
If gauge 1 [31] does not fit against the cardan [32], the cardan’s [32] setting screw [27]
must be readjusted.
11. Move the spindle drives upwards to some extent.
12. Travel to the lower end position again and check all drives with gauge 1 again.
13. Move the drives together almost to the upper end position.
14. Move the drives individually into the upper end position in service mode or with the PC.
15. Check the settings of the end switches for the tilting drives with gauge 2 and for the
Trendelenburg drive with gauge 3 again.
ATTENTION!
The settings are not finished until the gauges fit tightly between head
and suspension plate of the drives.
16. Reseal the screws.
17. Remount column.
TEST!
Test the column functions.
42
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Sensor Module on the Trendelenburg Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the rest of the cladding downwards.
12.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
13. Slide the rubber bellows upwards.
Service Manual JUPITER 4 900 361 - 03/03
43
Electrical Components of the SM/SF Columns
1
1
2
2
3
3
4
5
Figure 24:
Membrane keypad
1 Clamp terminal
2 Membrane flat ribbon cable
3 Snap-in lug (circuit board holder)
4
5
Holding plate of adapter circuit board
Column membrane keypad
14. Detach the flat ribbon cable [2] from the terminal [1] (slide the clip contact back and
then pull the flat ribbon cable out).
15. Push the flat ribbon cable down and through.
16. Dismount the cover part with the membrane key pad (3 M3 screws).
17. Unscrew the holding plate [4] of the adapter circuit board from the fastening frame of
the rubber bellows (2 M4 screws).
NOTE!
Protect the adapter circuit board from mechanical damage and do not
let it hang by the cables.
18. Unscrew 10 M5 screws from the fastening frame of the rubber bellows.
19. Remove the frame and lay it down.
20. Lay the holding plate [4] with the adapter circuit board carefully and protected (pads if
necessary) between the column head and the suspension plate.
7
8
6
9
1 0
1 1
1 2
1 3
Figure 25:
Motor Control
6 M4 screws
7 Cable binder
8
9
Plug
Screen for lifting motor cable
10 Strain relief clamp
11 Clamp block (left brown/right white)
cable to operating computer
12 Nuts
13 Clamp block (left brown/right white)
cable from lifting computer
21. Remove 6 M4 screws [6] from the motor control cover.
44
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
22. Remove the motor control cover.
23. Remove the cable strain relief clamps [10] (3 nuts) and remove the cable binders [7].
24. Unplug the sensor module connector [8] to the motor control.
1 4
1 5
1 6
1 7
A
1 8
1 9
2 0
B
2 1
Figure 26: Trendelenburg drive sensor module
14 Cardan
15 Setting screw
16 Reference sensor
17 Flat ribbon cable connection for
membrane keypad
18
19
20
21
Trendelenburg sensor module
M4 screw
Trendelenburg end switch
Stop nut
25. The sensor module [17] can be taken out after removing 2 M4 Allen screws [19].
Reassembly:
1. Reassemble in the revers order.
2. Screw on the new sensor module [17] so that the switching point of the end switch [20]
lies in the upper third (B) of the stop nut [21] (only tighten the screws [19] lightly).
NOTE!
Listen for the switching sound!
The end switch makes an audible click when the switching point is
reached.
3. Plug the sensor module [19] back into the motor control.
4. Plug the battery plug in and switch the column on.
5. In service mode, move all the spindle drives individually into the upper end position with
the remote control or with the PC.
Service Manual JUPITER 4 900 361 - 03/03
45
Electrical Components of the SM/SF Columns
2 2
2 3
2 4
2 5
Figure 27:
6.
Test Trendelenburg drive reference sensor
22 Head
23 Cardan
24 Gauge 3
25 Suspension plate
Adjust the end switch of the Trendelenburg drive [20] by sliding the sensor module [17]
so that the gauge 3 [24], held as close as possible to the cardanic suspension [23] fits
tightly between the head [22] and the suspension plate [25] of the drive.
7. To set the reference sensor move all the spindles together into the lower end position.
2 6
2 7
2 7
2 8
2 9
A
Figure 28:
8.
Trendelenburg reference sensor switching point
26 Cardan
28 Reference sensor
27 Setting screw
29 Sensor module
ATTENTION!
Danger of property damage!
Ensure that the M4 setting screw [27] on the cardan [26] cannot hit the
sensor [28]. The setting screw [27] must travel past the reference
sensor [28] with a clearance (A) of < 0.3 mm.
To correct the clearance (A) between the setting screw [27] and reference sensor [28]
press the sensor module [29] left or right and then check the clearance (A) with a feeler
gauge.
9. Tighten the sensor module [29] screws [19] tightly.
46
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3 0
3 1
3 2
3 3
Figure 29: Test Trendelenburg drive reference sensor
30 Head
31 Cardan
32 Gauge 1
33 Suspension plate
10. Adjust the setting screw M4 [27] on the cardan [31] so that, after the spindle drive has
been switched off, gauge 1 [32] fits tightly between head [30] and suspension plate [33]
when held close against the drive cardan [31].
If gauge 1 [32] does not fit against the cardan [31], the cardan’s [31] setting screw [27]
must be readjusted.
11. Move the spindle drives upwards to some extent.
12. Travel to the lower end position again and check all drives with gauge 1 again
13. Move the drives together almost to the upper end position.
14. Move the drives individually into the upper end position in service mode or with the PC.
15. Check the settings of the end switches for the tilting drives with gauge 2 and for the
Trendelenburg drive with gauge 3 again.
ATTENTION!
The head adjustment must always be correct!
The settings are not finished until the gauges fit tightly between head
and suspension plate of the drives.
16. Reseal the screws.
17. Remount column.
TEST!
Test the column functions.
Service Manual JUPITER 4 900 361 - 03/03
47
Electrical Components of the SM/SF Columns
Reference Sensor on the Vertical Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the rest of the cladding downwards.
5. Pull off either the positive or negative battery connection.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
5
C
2
6
1
7
2
8
3
9
A
4
Figure 30:
Reference sensor on the vertical drive
1 End switch upper lift position
2 Reference sensor
3 End switch lower lift position
4 Actuating diagonal
5 Switch plate
6
7
8
9
A
Nut
Holding plate screw
End switch screw
Locking screw for connections
Switch gap 0.2 mm ± 0.1 mm
6. Measure the reach (C) of the reference sensor [2].
7. Unsolder the cable lead from the end switch [3] and cut the other one.
8. Carefully screw the reference sensor [2] out and screw the new reference sensor in.
(Note the reach (C) and measure the switch gap (A) of 0.2 mm ± 0.1 mm).
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Reconnect the cables.
• Reseal the screws.
• Remount column.
TEST!
Test the column functions.
48
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Takeover Sensors
NOTE!
Please call TRUMPF Medizin Systeme Service in Saalfeld if a takeover sensor
is defective on the column lifter side.
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
1
2
3
Figure 31: Takeover sensors
1 Sheet metal covering
2 M3 screws
3
Takeover sensor
3. Screw 2 M3 screws [2] out of the lower part of the sheet metal covering [1].
4. Open the sheet metal covering [1] at the bottom, slide it upwards and fix it securely to
the Trendelenburg drive with the M6 fixing screw.
5. Pull off either the positive or negative battery connection.
6. Remove the batteries if necessary.
7. Expose the cables to the takeover sensor [3] and unclip at the plug.
8. Knock the defective takeover sensor [3] inwards out of the sheet metal covering [1].
9. Clean the borehole from adhesive and degrease it.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Only use Scotch Weld DP 110 to glue in the new takeover sensor and hold it in position
until the adhesive has set.
• Restore the cable connections.
• Remount column.
TEST!
Test the column functions.
Service Manual JUPITER 4 900 361 - 03/03
49
Electrical Components of the SM/SF Columns
Presence Sensor
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
1
2
3
Figure 32:
Presence sensors
1 Sheet metal covering
2 M3 screws
3
Presence sensor
3. Screw 2 M3 screws [2] out of the lower part of the sheet metal covering [1].
4. Open the sheet metal covering [1] at the bottom, slide it upwards and fix it securely to
the Trendelenburg drive with the M6 fixing screw.
5. Pull off either the positive or negative battery connection.
6. Remove the batteries.
7. Expose the cables to the presence sensor [3] and unclip at the plug.
8. Knock the defective presence sensor [3] inwards out of the sheet metal covering [1].
9. Clean the borehole from adhesive and degrease it.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Only use Scotch Weld DP 110 to glue in the new presence sensor and fix it in position
until the adhesive has set.
• Restore the cable connections.
• Remount column.
TEST!
Test the column functions.
50
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Inclination Sensor
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
3
4
6
5
6
5
4
3
1
2
Item no.
Operating
computer
4 144 703
Figure 33: Circuit board inclination sensors
1 Battery plug
2 Circuit board inclination sensor
3 Zero position x direction
(Trendelenburg)
4
5
6
Item no.
Operating
computer
4 144 991
Amplification x direction
Zero position y direction (Tilting)
Amplification y direction
6. Pull the battery plug [1] out of the circuit board of the operating computer.
7. Screw 2 M4 screws out of the sensor circuit board [2].
8. Carefully lift the circuit board [2] up and out and insert the new circuit board together
with the inclination sensor [2].
Service Manual JUPITER 4 900 361 - 03/03
51
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Restore the cable connections.
• Remount column.
• Test the horizontal position in the Trendelenburg and tilting direction with service mode
sub-item 4.
TEST!
Test the column functions.
52
Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.10
Replacing the End Switch
In the Sensor Modules
I
II
III
Tilting right
Tilting left
Trendelenburg
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
In the case of tilting to the right, the membrane keypad also has to be unclipped from
the adapter circuit board, and the screws on the topmost cover component are to be
removed together with the membrane keypad.
11. Remove the freed cover component and guide the rest of the cladding downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
Do not raise column through the additional lift to avoid activating the
end switch.
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53
Electrical Components of the SM/SF Columns
1
2
3
4
5
I / II
Figure 34:
III
End switch
I
Tilting right
II Tilting left
III Trendelenburg
1
2
3
4
5
Cable leads
End switch
End switch screws
Stop nut
Trendelenburg spindle casing
12. Note the assignment of each of the 3 cable leads [1] to the soldering position of each
corresponding end switch [2].
13. Unsolder the cable leads [1], remove the screws [3] and exchange the end switch [2].
Reassembly:
1. Reassemble in the reverse order.
6
7
8
B
9
I / II
Figure 35:
B
1 0
End switch assembly
I
Tilting right
II Tilting left
III Trendelenburg
III
6
7
8
9
10
Cable leads
End switch
End switch screws
Stop nut
Trendelenburg spindle casing
2. Screw the new end switch [7] in with 2 screws [8].
3. Solder the cable leads [6] on. Use resin as the flux when soldering.
4. Adjust the end switch [7], so that the switching process takes place in the upper third (B)
of the stop nut [9].
5. Test the switching point several times.
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Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
6. Move all the spindle drives individually in service mode into the upper end position with
the remote control or with the PC.
1 1
1 2
1 3
1 4
Figure 36: Test end switch - right tilting switching point
11 Head
12 Gauge 2
13 Cardan
14 Suspension plate
7. Adjust the end switch of the right-hand tilting drive so that gauge 2 [12], when held as
near as possible to the cardanic suspension [13], fits tightly between the head [11] and
the suspension plate [14] of the drive.
1 5
1 6
1 7
1 8
Figure 37: Test end switch - left tilting drive switching point
15 Head
17 Cardan
16 Gauge 2
18 Suspension plate
8. Adjust the end switch of the left-hand tilting drive so that gauge 2 [16], when held as
near as possible to the cardanic suspension [17], fits tightly between the head [15] and
the suspension plate [18] of the drive.
Service Manual JUPITER 4 900 361 - 03/03
55
Electrical Components of the SM/SF Columns
1 9
2 0
2 1
2 2
Figure 38:
Test end switch - Trendelenburg drive switching point
19 Head
21 Gauge 3
20 Cardan
22 Suspension plate
9. Adjust the end switch Trendelenburg drive so that gauge 3 [21], when held as near as
possible to the cardanic suspension [20], fits tightly between the head [19] and the
suspension plate [22] of the drive.
ATTENTION!
Possible adjustment errors.
The settings are not finished until the gauges fit tightly between head
and suspension plate of the drives.
10. Reseal the screws.
11. Remount column.
TEST!
Test the column functions.
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Electrical Components of the SM/SF Columns
On the Vertical Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the rest of the cladding downwards
5. Pull off either the positive or negative battery connection.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
5
C
2
6
1
7
2
8
3
9
A
4
Figure 39: Vertical end switch
1 End switch upper lift position
2 Reference sensor
3 End switch lower position
4 Switch plate with actuating diagonal
5
6
7
8
Nut
Holding plate screw
End switch screw
Locking screw for connections
6. Remove the locking screws [8] on end switch [1] and/or [3].
7. Separate the cables from the end switch [1], [3].
8. Screw out 2 M2.5 screws on the end switch [1], [3].
9. Unsolder the cable leads.
10. Carefully dismount end switches [1], [3] and mount new ones.
11. Solder cable leads on. Use limed resin as the flux when soldering.
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Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
NOTE!
In the case of the upper end switch of the vertical drive [1], the switching
point must lie in the first third of the actuating diagonal of the switch
plate [4].
• Reseal the screws.
• Remount column.
TEST!
Test the column functions.
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Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
3.11
Cables
Preparing the Column:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the rest of the cladding downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
12. Unclip the batteries.
13. If necessary, remove the operating computer-circuit board on the relevant side.
14. Remove defective cable and replace with the same type of cable.
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59
Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Always replace defective cables with cables of the same type.
(see „Spare parts SM/SF column”).
• New cables must be laid in the same positions as those they replace.
• Make a final check for places where cables could be cut or crushed.
• Check the position of the cables again after moving the column.
• Keep to the cable layout plan!!!
• Only use limed resin as the flux for soldered joints.
• All cable binders and cable straps which have been removed must be renewed.
• Pay attention to the polarity!!!
• Assemble the cable screw connections in the correct sequence.
- motor control cable Ub
- motor control cable Data
- lifting motor cable, through power train
- battery connection cable, through power train
- cable to distributor 1, through power train
- cable to the membrane keypad
- upper column lift sensor connector cable, through power train
- column lift sensor connector cable
- only for the SF column: power supply cable, through power train
• Reseal the screws.
• Remount column.
TEST!
Test the column functions.
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Electrical Components of the SM/SF Columns
3.12
Replace Power Train
Removal:
1. Transfer the table top onto a shuttle raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Screw 2 M3 screws out of the bottom of the sheet metal covering.
4. Open the sheet metal covering at the bottom, slide it upwards and fix it securely to the
Trendelenburg drive with the M6 fixing screw.
5. Pull off either the positive or negative battery connection.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
6. Unclip the following cables:
- Unclip the lifting motor cable on the lifting motor
- Pull the battery connection cable off the batteries
- Unclip the cable to distributor 1 at the socket connector
- Unclip the upper lift position sensor connector cable to the lifting motor
- Only for the SF: unclip the power supply cable in the head, to do this, remove the
operating computer circuit board (side with cooling plates) and pull back the cable.
7. Remove 6 M4 screws from the motor control cover.
8. Remove the motor control cover.
9. Remove the cable holding plate on the lower holder of the power train.
10. Pull the cables out of the power train.
11. Remove the power train and replace it with a new one.
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Electrical Components of the SM/SF Columns
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• New cables must be laid in the same positions as those they replace.
• Make a final check for places where cables could be cut or crushed.
• Check the position of the cables again after moving the column.
• Keep to the cable layout plan!!!
• All cable binders and cable straps which have been removed must be renewed.
• Pay attention to the polarity!!!
• Assemble the cable screw connections in the correct sequence.
- clip the lifting motor cable onto the lifting motor
- plug the battery connection cable into the batteries
- clip the cable to distributor 1 onto the socket connector
- clip the upper lift position sensor connector cable onto the lifting motor
- only for the SF: clip the power supply cable into the head, insert the operating
computer-circuit board (side with cooling plates) and slide the cable in.
• Remount column.
TEST!
Test the column functions.
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Electrical Components of the SM/SF Columns
3.13
Motors
Lifting Motor
Removal:
1. Transfer the table top onto a shuttle raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Screw 2 M3 screws [2] out of the lower part of the sheet metal covering.
4. Open the bottom of the sheet metal covering [3], slide it upwards and fix it securely to
the Trendelenburg drive [5] with the M6 fixing screw [4].
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
5. Pull off either the positive or negative battery connection.
6.
CAUTION!
Danger of proper damages and injuries!
Support the Trendelenburg holder with a suitable wooden support!
Support the Trendelenburg holder with a suitable wooden support!!!
7. Cut the cable binders.
5
2
6
3
1
2
7
1
H o
2
1
2
8
9
1 0
3
1
1 1
1
H u
2
3
4
R
2
H
Figure 40: Connections to lifting motor (Extract from circuit diagram)
1 green
7 (line), brown
2 brown
8 GND, black
3 white
9 Upper end switch (grey)
4 blue
10 Reference (yellow)
5 GND (blue/violet/red-blue)
11 Lower end switch (green)
6 +36 V (red/pink/pink-grey)
R
H
Reference
Lifting motor
Service Manual JUPITER 4 900 361 - 03/03
Ho Upper lift position
Hu Lower lift position
63
Electrical Components of the SM/SF Columns
8. Note the assignments of the cable connections to the motor and then separate them
from the motor (see „Circuit Diagrams”).
1 2
1 3
1 4
1 5
1 6
Figure 41:
Lifting motor
12 Lifting motor
13 Screws
14 Motor holder
15 Toothed belt
16 Casing
9. Screw screws [13] out of the motor holder [14].
10. Carefully take the lifting motor [12] out of the toothed belt [15].
Reassembly:
1. Glue spacing sleeves with instant adhesive over the clean tapped holes.
2. Carefully insert the lifting motor [12] into the toothed belt [15] and lightly tighten
screws [13].
NOTE!
Ensure that the lifting motor is in the correct position!
3. Press the lifting motor [12] into the corner of the casing [16] to tighten the toothed
belt [15].
4. Tighten screws [13] tightly.
5. Further assembly in the reverse sequence with the following instructions:
- put the new cables in the same positions as those they replace
- make a final check for places where cables could be cut or crushed
- check the position of the cables again after moving the column
- keep to the cable layout plan!!!
- all cable binders and cable straps which have been removed must be renewed
- pay attention to the polarity!!!
6. Remount column.
TEST!
Test the column functions.
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Service Manual JUPITER 4 900 361 - 03/03
Electrical Components of the SM/SF Columns
Trendelenburg Motor
• See Replace Trendelenburg Drive Unit
Tilting Motor Right Drive Unit
• See Replace Tilting Right Drive Unit
Tilting Motor Left Drive Unit
• See Replace Tilting Left Drive Unit
Service Manual JUPITER 4 900 361 - 03/03
65
Electrical Components of the SM/SF Columns
3.14
Replacing the Membrane Keypad
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the rest of the cladding downwards.
5. Pull off either the positive or negative battery connection.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding!
6. Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
7. Slide the rubber bellows upwards at the adapter circuit board corner and fix it.
1
1
2
2
3
3
4
5
Figure 42:
Membrane keypad
1 Clamp terminal
2 Membrane flat ribbon cable
3 Snap-in lug (circuit board holder)
4
5
Holding plate for adapter circuit board
Column membrane keypad
8. Detach the flat ribbon cable [2] from the terminal [1] (slide the clip contact back and
then pull the flat ribbon cable out).
9. Remove 3 M3 screws together with membrane keypad on the upper cover segment and
remove the cover segment.
10. Exchange the membrane keypad [5].
Reassembly:
Reassemble in the reverse order.
TEST!
Test the column functions.
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Electrical Components of the SM/SF Columns
3.15
Emergency Adjustment of Main Lift for Service Work
1. Release wedge holders.
2. Lift the table top by hand from the column and place it on a shuttle.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the operating computer.
7. Pull off the round cover of the main lift emergency adjustment aperture in the middle
of the head.
8. Enable access to the lifting motor.
Depending upon the position of the main lift:
- by removing the cladding or
- by sliding the cladding upwards.
1
2
X
3
Figure 43: Feeding 36 V to the brake cables
1 Lifting motor
2 Cable
3
X
X
Brake cables (green leads)
36 V feed
9. Cut both cables to the brake [3] in the middle, strip the insulation and supply 36 V at (X).
ATTENTION!
Danger of damaging the motor and brake!
Do not apply the 36 V for longer than is necessary.
10. Fix an extended Allen key into the battery screwdriver.
11. Stick the Allen key through the emergency adjustment aperture in the head into the lifter
spindle.
12. Move the column upwards with the battery screwdriver.
13. Separate the brake from the 36 V supply.
ATTENTION!
Restore the electrical connections and the proper insulation on the lifting
motor after the emergency adjustment has been completed.
Service Manual JUPITER 4 900 361 - 03/03
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Electrical Components of the SM/SF Columns
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Mechanical Components of the SM/SF Columns
4
Mechanical Components of the SM/SF Columns
CAUTION!
Danger of infection!
Before beginning work, obtain conformation from the medical facility, that
all the necessary measures for protection against infection have been
performed.
4.1
Replacing the Cladding Components (without Membrane Keypad)
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the remainder of the cladding
downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding!
5. Starting at the top, unscrew the cladding segment by segment (4 M3 screws per
segment) and renew the components.
Reassembly:
Reassemble in the reverse order.
Service Manual JUPITER 4 900 361 - 03/03
69
Mechanical Components of the SM/SF Columns
4.2
Replacing the Cladding Component with the Membrane Keypad
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the remainder of the cladding
downwards.
5. Pull off either the positive or negative battery connection.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. Cladding components would be damaged.
6. Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
7. Slide the rubber bellows upwards at the adapter circuit board corner and fix it.
1
1
2
2
3
3
4
5
Figure 44:
Loosen wedges, connection units and bellows
1 Clamp terminal
2
3
Membrane flat ribbon cable
Snap-in lugs (circuit board holder)
4
5
Holding plate of the adapter circuit
board
Membrane keypad of column
8. Detach the flat ribbon cable [2] from the connector [1] (slide clip contact back and then
pull the flat ribbon cable out).
9. Dismount the cover part with the membrane key pad (3 M3 screws).
Reassembly:
Reassemble in the reverse order.
TEST!
Test the column functions with new keypad.
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Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
4.3
Replacing the Head Cover
Removal:
1. Transfer the table top onto a shuttle.
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
Reassembly:
Reassemble in the reverse order.
TEST!
Test the column functions with the tabletop using the new membrane
keypad.
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71
Mechanical Components of the SM/SF Columns
4.4
Replacing the Rubber Bellows
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 6 M3 screws from the topmost cover component (without membrane keypad).
4. Remove the freed cover component and guide the remainder of the cladding
downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding!
5. Remove 8 screws from the head cover.
6. Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
7. Lay the cover down.
8. Pull the battery plug out of the circuit board of the operating computer.
9. In order to be able to dismount the cladding component with the membrane keypad,
the rubber bellows must be removed from the column head as follows:
1
2
Figure 45:
Removing the rubber bellows
1 Wedge fastening screws
2
Section which is glued to the sheed
metal cover
10. Lever the metal covers [2] off both wedges (they are fixed with double-sided adhesive
tape and loosen 2 screws [1] from the wedge on the membrane keypad side
(ca. 5 turns).
11. Dismount the wedge which lies opposite the membrane keypad. To do this, remove
2 screws from the wedge fastening [1] and remove the wedge (if the wedge sticks, lever
it up slightly).
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Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
3
3
4
6
5
4
6
7
Figure 46: Removing the rubber bellows
3 Hand control connection unit
4 Plug 1
5 Cable screw connection 1
6
7
Plug 2
Cable screw connection 2
12. Unscrew 2 M5 nuts from the fastening of the connection unit [3] and 2 cable screw
connections [5], [7].
13. Remove plugs [4], [6] from the circuit board of the operating computer.
14. Carefully pull the connection unit [3] outwards away from the column head until the
plugs [4], [6] touch the cable screw connections [5], [7].
15. Loosen 2 M5 nuts on the connection unit external power supply.
16. Unscrew 12 nuts M4 from the lower fastening frame of the rubber bellows.
17. Cut the defective rubber bellows with a knife in the right-hand corner next to the
membrane keypad and remove it.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Insert the fastening frame of the rubber bellows fully and ensure that the edge of the
bellows is in the correct position.
• Pull the rubber bellows carefully over the column head.
• The rubber bellows must be cut in the area of the wedges (see Old Bellows).
• Carefully cut off the excess rubber projecting at the top of the rubber bellows in the area
of the groove (outer) with a knife (otherwise the head cover will not fit exactly and form
a seal at the upper edge of the bellows).
• Mount the wedge loosely without the sensor.
• Make holes in the rubber bellows over the tapped holes and insert it into the groove.
• Screw wedges and connection units up tightly.
• Screw the fastening frame of the rubber bellows down with 12 M4 nuts.
• Remount column.
TEST!
Test the column functions.
Service Manual JUPITER 4 900 361 - 03/03
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Mechanical Components of the SM/SF Columns
4.5
Replacing the Complete Base Plate and Seal
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
1
2
3
4
Figure 47:
Laying the column on its side - base plate
1 M8 screw (7 items)
2 Pot
3.
3
4
Wooden spacer (70 mm x 300 mm)
Base plate
CAUTION!
Risk of injuries and damage to the column.
The column weighs 200 kg. Use two persons to lay it on its side.
Tip the column sideways and carefully lay it down with a wooden spacer [3] under the
pot [2]. The edge of the base plate [4] must be clear of the floor.
4. Screw 7 M8 screws [1] out of the base plate [4].
5. Remove the base plate [4] and replace it with a new one.
ATTENTION!
Risk of losing column adjustment.
On no account loosen the 3 screws under the base plate.
The adjustment of the column holder to the wedges will be lost.
Reassembly:
Reassemble in the reverse order.
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Mechanical Components of the SM/SF Columns
4.6
Replacing the Rubber Seal for the Base Plate
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
4
1
5
2
6
3
Figure 48: Laying the column on its side - rubber seal
1 Pot
2 Wooden spacer (70 mm x 300 mm)
3 Base plate
3.
4
5
6
Rubber seal
Holding plate
M4 screw (20 items)
CAUTION!
Risk of injuries and damage to the column.
The column weighs 200 kg. Use two persons to lay it on its side.
Tip the column sideways and carefully lay it down with a wooden spacer [2] under the
pot [1]. The edge of the base plate [3] must be clear of the floor.
4. On the base plate [3], screw 20 M4 screws [6] out of the 2 holding plates [5].
5. Remove the holding plates [5] and pull the rubber seal [4] out.
6. Insert a new rubber seal. The seal can be fixed with instant adhesive to make the
assembly of the holding plates [5] easier.
Reassembly:
Reassemble in the reverse order.
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Mechanical Components of the SM/SF Columns
4.7
Replacing the Potential Contact under the Base Plate
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
4
1
5
2
6
3
Figure 49:
Laying the column on its side - potential contact
1 Pot
4
2 Wooden spacer (70 mm x 300 mm)
5
3 Base plate
6
3.
M4 screw (2 items)
Contact with spring
Potential contact
CAUTION!
Risk of injuries and damage to the column.
The column weighs 200 kg. Use two persons to lay it on its side.
Tip the column sideways and carefully lay it down with a wooden spacer [2] under the
pot [1]. The edge of the base plate [3] must be clear of the floor.
4. To replace the potential contact, screw [6] 2 M4 screws [4] out of the base plate [3].
5. Remove the potential contact [6] together with the spring and renew the potential
contact or the spring. Check whether the potential contact springs easily.
Reassembly:
Reassemble in the reverse order.
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Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
4.8
Replacing the Drives (Trendelenburg, Tilting/Left, Tilting/Right)
Trendelenburg Drive
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the remainder of the cladding
downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
12. Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
13. Slide the rubber bellows upwards.
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Mechanical Components of the SM/SF Columns
1
1
2
2
3
3
4
5
Figure 50:
Disassembling the membrane contact behind the rubber bellows
1 Clamp terminal
4 Holding plate of the adapter circuit
board
2 Membrane flat ribbon cable
5 Membrane keypad of the column
3 Snap-in lugs (circuit board holder)
14. Detach the flat ribbon cable [2] from the terminal [1] (slide the clip contact back and
then pull the flat ribbon cable out).
15. Push the flat ribbon cable down and through.
16. Dismount the cover part with the membrane key pad (3 M3 screws).
17. Screw the holding plate [4] for the adapter circuit board off the fastening frame of the
rubber bellows (2 M4 screws).
NOTE!
Protect the adapter circuit board from mechanical damage and do not
let it hang by the cables.
18. Lay the holding plate [4] with the adapter circuit board carefully and with protection
(pads if necessary) between the column head and the suspension plate.
19. Unscrew 10 M5 screws from the fastening frame of the rubber bellows.
20. Remove the frame and lay it down.
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Mechanical Components of the SM/SF Columns
6
9
7
1 0
8
1 1
1 2
1 3
1 4
1 5
Figure 51: Loosen wedges, connection units and rubber bellows
6 Wedge fastening screws
11 Cable screw connection 1
7 Section with sheet metal cover
12 Plug 2
8 Cardan fastening screws
13 Cable screw connection 2
9 Hand control connection unit
14 2 nuts fixing power pack connection
10 Plug 1
15 Power pack connection unit
21. Unscrew 2 M5 nuts from the hand control connection unit [9] and 2 cable screw
connections [11], [13].
22. Pull the plugs [10], [12] out of the circuit board of the operating computer.
23. Carefully pull the hand control connection unit [9], together with the cables, off the
column head, so that the fastening screws of the upper cardan of the Trendelenburg
spindle [8] can be screwed out.
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Mechanical Components of the SM/SF Columns
1 7
1 8
1 6
1 9
2 0
2 1
Figure 52:
Motor control
16 M4 screws
17 Cable binder
18 Plug
19 Strain relief clamp
20 Screen for lifting motor cable
21 Nuts
24. Remove 4 screws [16] from the motor control cover.
25. Remove the motor control cover.
26. Loosen the strain relief clamp [19] from the cables (3 nuts) and cut the cable
binders [17].
27. Pull the relevant sensor module plug connector of the Trendelenburg unit out of the
motor control.
28.
CAUTION!
Danger of property damage and injuries!
Support the Trendelenburg drive module with a suitable wooden
support.
Unscrew the 6 M8 screws (Figure 51: [8]) which fasten the upper cardan of the
Trendelenburg module in the column head.
29. Remove the screw on the underside of the Trendelenburg module on the Trendelenburg
motor control suspension.
30. Remove 4 M10 screws from the Trendelenburg suspension.
31. Pull the Trendelenburg drive module carefully forwards and out.
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Mechanical Components of the SM/SF Columns
Dismantling the Trendelenburg Drive Module
1
9
2
6
4
7
5
8
1 0
3
Figure 53: Trendelenburg drive module
1 Toothed belt
2 M4 screw
3
4
5
6
Flanged disk
M5 screws (4 items)
Motor toothed belt
Spindle toothed belt wheel
1 1
7
8
M6 screws (6 items)
M5 countersunk screws (4 items),
motor fixing
9 M4 screw
10 Stop nut (brass)
11 Spindle
Replacing the toothed belt of the Trendelenburg drive
1. The Trendelenburg drive module can remain in the belt (leave 6 M8 screws screwed in
on the lower cardan).
2. Loosen 4 M5 screws [4] on the spindle toothed belt wheel (do not screw them out!).
3. Slacken the toothed belt [1] and pull it off.
4. Insert a new toothed belt and tension it by hand.
Reassemble observing the following instruction: set toothed belt tension.
Replacing the spindle/stop nut of the Trendelenburg
1. Screw out 6 M6 screws [7] while holding the wheel against the toothed belt [1].
2. Loosen the toothed belt [1], by slightly loosening 4 M5 screws [4].
3. Pull the toothed belt [1] off.
4. Loosen screw [9] on the stop nut [10] on the spindle [11].
5. Screw the spindle [11] out of the stop nut [10] and pull out in an upward direction.
6. Renew the spindle or stop nut.
Reassemble observing the following instruction: set toothed belt tension.
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Mechanical Components of the SM/SF Columns
Replacing the Trendelenburg drive motor
1. Screw the central M4 screw [2] out of the flanged disk [3] on the motor toothed belt
wheel [5].
2. Loosen 4 M5 screws [4] of the spindle toothed belt wheel [6] (do not screw them out!).
3. Slacken the toothed belt [1] and pull it off. Pull the toothed belt wheel off.
4. Screw 4 M5 countersunk screws [8] out of the motor fixing device (under [6]).
5. Replace the motor.
Reassemble in the reverse order observing the following instructions:
• Fit the lower cardan in parallel! Check with a caliper gauge.
• Lay and fix the cables in the same places as they were before.
• Renew cable binders, set toothed belt tension.
ATTENTION!
Assembling the cardan incorrectly will cause bearing wear!
Make sure the cardan is fitted in a parallel position.
Check the parallelism with a caliper gauge (depth indicator).
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Mechanical Components of the SM/SF Columns
Reassembly (fitting the Trendelenburg drive unit):
Reassemble in the reverse order observing the following instructions:
• Turn the spindle of the new module by hand and position it at the same height as the old
spindle had been at.
• Screw the Trendelenburg drive module in with 4 M10 screws. Ensure that the tapped hole
for the sensor screw is in the correct position (screw facing outwards).
•
ATTENTION!
Danger of property damage!
The cardan must be aligned parallel to the column head.
The distance between the outer edge of the cardan and the outer edge
of the column head must be equal. Check with a caliper gauge.
Screw the upper cardan to the column head with 6 M8 screws.
TEST!
Check the parallelism of the cardan suspension.
• Remove the Trendelenburg drive sensor module from the old module and screw it to the
new one.
• Restore the cables to their previous positions.
• Connect the cables to the motor control and fasten the strain relief clamp.
• Renew cable binders.
• Screw the motor control cover on (6 M4 screws).
• Adjust the end switches and check the column head settings with gauges 1, 2 and 3
(see „Replacing the End Switch”).
TEST!
Check the end switch adjustments and column head settings.
• Screw on the fastening frame for the rubber bellows with 10 M5 screws. Note that there
are short and long screws. The short screws go in the blind holes.
• Screw on the fixing plate with adapter circuit board for the membrane keypad connection
to the fastening frame for the rubber bellows.
• Mount the rubber bellows, wedges and connection units carefully.
• Mount the cladding and restore the connections.
• Mount the head cover.
TEST!
Check the column functions.
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Mechanical Components of the SM/SF Columns
Tilting Drive/Right
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the customers alternately from below, lift it up slightly
and pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the remainder of the cladding
downwards.
ATTENTION!
Danger of damaging the cladding.
Do not lower the column. This would damage the cladding.
12. Unscrew the nuts (12 nuts) from the rubber bellows fixing home.
13. Slide the rubber bellows upwards.
1
1
2
2
3
3
4
5
Figure 54:
84
Disassembling the membrane connection behind the rubber bellows
1 Clamp terminal
4 Holding plate of the adapter circuit
board
2 Membrane flat ribbon cable
5 Membrane keypad of the column
3 Snap-in lugs (circuit board holder)
Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
14. Detach the flat ribbon cable [2] from the terminal [1] (slide the slip contact back and
then pull the flat ribbon cable out).
15. Push the flat ribbon cable down and through.
16. Dismount the cover part with the membrane key pad (3 M3 screws).
17. Unscrew the holding plate [4] for the adapter circuit board from the fastening frame of
the rubber bellows (2 M4 screws).
NOTE!
Protect the adapter circuit board from mechanical damage and do not
let it hang by the cables.
18. Lay the holding plate [4] with the adapter circuit board carefully, and with protection
(pads if necessary), between the column head and the suspension plate.
19. Unscrew 10 M5 screws from the fastening frame of the rubber bellows.
20. Remove the frame and lay it down.
7
8
6
9
1 0
1 1
1 2
1 3
Figure 55: Motor control
6 M4 screw
7 Cable binder
8
9
Plug
Screen for lifting motor cable
10 Strain relief clamp
11 Terminal block (left brown/right white)
cable to operation computer
12 Nuts
13 Terminal block (left brown/right white)
cable from lifting motor
21. Remove 6 M4 screws [6] from the motor control cover.
22. Remove the motor control cover.
23. Loosen the cable strain relief clamp [10] (3 nuts) and cut the cable binders [7].
24. Pull out the relevant plug connection of the tilting unit sensor module (right) to the motor
control.
25. Pull out the connecting cable to the circuit board operating computer on the membrane
keypad side.
26. Beginning on one side, press together the 5 snap-in lugs of the circuit board holder of
this circuit board and carefully pull the circuit board out in an upward direction.
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Mechanical Components of the SM/SF Columns
1 4
Figure 56:
Cardan fixing device of the tilting/right module
14 M8 screws (6 items)
27. Remove the 6 M8 screws [14] holding the upper cardan of the tilting drive/right.
28. Screw out the 4 M10 screws on the drive suspension.
29. Pull the drive module out carefully in a downward direction.
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Mechanical Components of the SM/SF Columns
Dismantling the Tilting Module (Right)
1
9
2
6
4
7
5
8
1 0
3
Figure 57: Tilting drive module/right
1 Toothed belt
2 M4 screw
3 Flanged disk
4
5
M5 screws (4 items)
Motor toothed belt wheel
6
7
8
Spindle toothed belt wheel
M6 screws (6 items)
M5 countersunk screws (4 items),
motor fixing
9 Spindle
10 Stop nut
Replacing the toothed belt of the tilting drive/right
1. Loosen the 4 M5 screws [4] of the spindle toothed belt wheel (do not screw them out!).
2. Slacken the toothed belt [1] and pull it off.
3. Insert a new toothed belt and tension it by hand.
Reassemble observing the following instruction: set toothed belt tension.
Replacing the spindle/stop nut of the tilting drive/right
1. Screw out 6 M6 screws [7] while holding the wheel against the toothed belt [1].
2. Loosen the toothed belt [1] by slightly loosening the 4 M5 screws (4].
3. Pull the toothed belt [1] off.
4. Loosen the M4 screw on the stop nut on the spindle [9].
5. Screw the stop nut [10] off the spindle [9].
6. Renew the spindle or stop nut.
Reassemble observing the following instruction: set toothed belt tension.
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Mechanical Components of the SM/SF Columns
Replacing the tilting drive motor/right
1. Screw out the central M4 screw [2] on the flanged disk [3] on the motor toothed belt
wheel [5].
2. Loosen 4 M5 screws [8] of the spindle toothed belt wheel [6] (do not screw them out!).
3. Slacken the toothed belt [1] and pull it off.
4. Screw 4 M5 countersunk screws [4] out of the motor fixing device.
5. Replace the motor.
Reassemble in the reverse order observing the following instructions:
• Fit the lower cardan in parallel! Check with a caliper gauge.
• Lay and fix the cables in the same places as they were before.
• Renew cable binders, set toothed belt tension.
ATTENTION!
Assembling the cardan incorrectly will cause the bearings to wear!
Make sure the cardan is fitted in a parallel position.
Check the parallelism with a caliper gauge (depth indicator).
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Mechanical Components of the SM/SF Columns
Reassembly (fitting the tilting drive unit/right):
Reassemble in the reverse order observing the following instructions:
• Turn the spindle of the new module by hand and position it at the same height as the old
spindle had been at.
• Screw the tilting module (right) in with 4 M10 screws. Ensure that the tapped hole is in
the correct position for the sensor screw (screw facing outwards).
•
ATTENTION!
Danger of property damage!
The cardan must be aligned parallel to the column head.
The distance between the outer edge of the cardan and the outer edge
of the column head must be equal. Check with a caliper gauge.
Screw the upper cardan onto the column head with 6 M8 screws. Ensure that it
is parallel.
TEST!
Check the parallelism of the cardan suspension.
• Remove sensor module of the tilting drive (right) from the old module and screw it onto
the new one.
• Restore the cables to their previous positions.
• Connect the cables to the motor control and fasten the strain relief clamp.
• Renew cable binders.
• Screw the motor control cover on (6 M4 screws).
• Adjust the end switches and check the column head settings with gauges 1, 2 and 3
(see „Replacing the End Switch”).
TEST!
Check the end switch adjustments and column head settings.
• Screw on the fastening frame for the rubber bellows with 10 M5 screws. Note that there
are short and long screws. The short screws go in the blind holes.
• Screw the holding plate with the adapter circuit board for the membrane keypad
connection onto the fastening frame for the rubber bellows.
• Place the circuit board operating computer on the snap-in lugs and press it down until
the circuit board is held securely.
• Restore all the socket connections to their condition before disassembly.
• Mount the rubber bellows, wedges and connection units carefully.
• Mount the cladding and restore the connections.
• Mount the head cover.
TEST!
Check the column functions.
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Mechanical Components of the SM/SF Columns
Tilting Drive/left
Removal:
1. Transfer the table top onto a shuttle and raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Remove 8 M4 screws from the head covering.
4.
ATTENTION!
Danger of damaging the rubber bellows.
Lever the head covering off carefully.
Do not use any sharp-edged tools.
Carefully lever the cover up at the corners alternately from below, lift it up slightly and
pull the contact plate plug out of the circuit board.
5. Lay the cover down.
6. Pull the battery plug out of the circuit board of the operating computer.
7. Lever the metal covers off both wedges (they are fixed with double-sided adhesive tape).
8. Loosen 2 wedges and 2 connection units.
9. Pull the rubber bellows out of the groove, out of the wedges and the suspension unit
and press it downwards.
10. Remove 7 M3 screws from the topmost cover component (without membrane keypad).
11. Remove the freed cover component and guide the remainder of the cladding
downwards.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
12. Unscrew the nuts (12 nuts) from the rubber bellows fixing frame.
13. Slide the rubber bellows upwards.
14. Unscrew the left-hand part of the fastening frame (6 M5).
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Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
2
3
1
4
5
6
7
8
Figure 58: Motor control
1 M4 screws
2 Cable binder
3
4
Plug
Screen for lifting motor cable
5
6
7
8
Stain relief clamp
Terminal block (left brown/right white)
cable to operating computer
Nuts
Terminal block (left brown/right white)
cable from lifting motor
15. Remove 6 M4 screws [1] from the motor control cover.
16. Remove the motor control cover.
17. Loosen the cable strain relief clamp [5] (3 nuts) and cut the cable binders [3].
18. Pull out the relevant plug connection of the sensor module of the tilting unit (left) on the
motor control.
19. Pull out the connecting cable to the circuit board operating computer on the side
opposite to the membrane keypad.
20. Beginning on one side, press together 5 snap-in lugs of the circuit board holder of this
circuit board and carefully pull the circuit board out in an upward direction.
21. Screw out 2 M5 screws and 2 M6 screws on the motor control suspension.
9
Figure 59: Cardan fixing device of the tilting module/left
9 M8 screws (6 items)
22. Remove the 6 M8 screws [9] holding the upper cardan of the tilting drive/left.
23. Screw out the 4 M10 screws on the drive suspension.
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Mechanical Components of the SM/SF Columns
24. Pull the drive module out carefully in a downward direction.
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Mechanical Components of the SM/SF Columns
Dismantling the Tilting Module/Left
1
9
2
6
4
7
5
8
1 0
3
Figure 60: Tilting drive module/left
1 Toothed belt
2 M4 screw
3 Flanged disk
4
5
M5 screws (4 items)
Motor toothed belt wheel
6
7
8
Spindle toothed belt wheel
M6 screws (6 items)
M5 countersunk screws (4items), motor
fixing
9 Spindle
10 Stop nut
Replacing the toothed belt of the tilting drive/left
1. Loosen the 4 M5 screws [8] of the spindle toothed belt wheel (do not screw them out!).
2. Slacken the toothed belt [1] and pull it off.
Reassemble observing the following instruction: set toothed belt tension.
Replacing the spindle/stop nut of the tilting drive/left
1. Screw out 6 M6 screws [7] while holding the wheel against the toothed belt [1].
2. Loosen the toothed belt [1], by slightly loosening 4 M5 screws [4].
3. Pull the toothed belt [1] off.
4. Loosen the M4 screw on the stop nut on the spindle [9].
5. Screw the stop nut [10] off the spindle [9].
6. Renew the spindle or stop nut.
Reassemble observing the following instruction: set toothed belt tension.
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Mechanical Components of the SM/SF Columns
Replacing the tilting drive motor/left
1. Screw the central M4 screw [2] of the flanged disk [3] out of the motor toothed belt
wheel [5].
2. Loosen 4 M5 screws [8] on the spindle toothed belt wheel [6] (do not screw them out!).
3. Slacken/pull off the toothed belt [1] and pull the toothed belt wheel off.
4. Screw 4 M5 screws [8] out of the motor fixing device.
5. Replace the motor.
Reassemble in the reverse order observing the following instructions:
ATTENTION!
Assembling the cardan incorrectly will cause the bearings to wear!
Make sure the cardan is fitted in a parallel position.
Check the parallelism with a caliper gauge (depth indicator).
• Fit the lower cardan in a parallel position. Check with a caliper gauge.
• Lay and fix the cables in the same places as they were before.
• Renew cable binders, set toothed belt tension.
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Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
Reassembly (fitting the tilting drive unit/left):
Reassemble in the reverse order observing the following instructions:
• Turn the spindle of the new module by hand and position it at the same height as the old
spindle had been at.
• Screw in the tilting module/left with 4 M10 screws. Ensure that the tapped hole is in the
correct position for the sensor screw (screw facing outwards).
•
ATTENTION!
Danger of property damage!
The cardan must be aligned parallel to the column head.
The distance between the outer edge of the cardan and the outer edge
of the column head must be equal. Check with a caliper gauge.
Screw the upper cardan onto the column head with 6 M8 screws. Ensure that it
is parallel.
TEST!
Check the parallelism of the cardan suspension.
• Remove sensor module of the tilting drive (left) from the old module and screw it onto
the new one.
• Restore the cables to their previous positions.
• Connect the cables to the motor control and fasten the strain relief clamp.
• Renew cable binders.
• Screw the motor control cover on (6 M4 screws).
• Adjust the end switches and check the column head settings with gauges 1, 2 and 3
(see „Replacing the End Switch”).
TEST!
Check the end switch adjustments and column head settings.
• Screw on the fastening frame for the rubber bellows with 5 M5 screws. Note that there
are short and long screws. The short screws go in the blind holes.
• Place the circuit board operating computer on the snap-in lugs and press it down until
the circuit board is held securely.
• Restore all the plug connections to their condition before disassembly.
• Mount the rubber bellows, wedges and connection units carefully.
• Mount the cladding and restore the connections.
• Mount the head cover.
TEST!
Test the column functions.
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Mechanical Components of the SM/SF Columns
4.9
Replacing the Main Spindle and Toothed Belt
Removal:
1. Transfer the table top onto a shuttle raise the column to its highest position. Use
emergency adjustment if motor is defective (see „Emergency Adjustment of Main Lift for
Service Work”).
2. Pull the power pack cable out of the column and switch the column off.
3. Screw 2 M3 screws out of the bottom of the sheet metal covering.
4. Open the sheet metal covering at the bottom, slide it upwards and secure it to the
Trendelenburg drive with the M6 fixing screw.
ATTENTION!
Danger of damaging the cladding!
Do not lower the column. This would damage the cladding.
5. Pull off either the positive or negative battery connection.
6.
CAUTION!
Danger of property damage and injuries!
Support the Trendelenburg holder with a suitable wooden support.
Support the Trendelenburg holder with a suitable piece of wood.
7. Note the assignment of the motor connection cables and then separate them from the
motor (please refer to the circuit diagram in the appendix).
5
2
6
3
1
H o
2
7
1
2
1
2
8
9
1 0
3
1
1 1
1
H u
2
3
4
Figure 61:
R
2
Connections to the lifting motor (Section of circuit diagram)
1 green
7 (line), brown
2 brown
8 GND, black
3 white
9 Upper end switch (grey)
4 blue
10 Reference (yellow)
5 GND (blue/violet/red-blue)
11 Lower end switch (green
6 +36 V (red/pink/pink-grey)
R
H
96
H
Reference
Lifting motor
Ho Upper lift position
Hu Lower lift position
Service Manual JUPITER 4 900 361 - 03/03
Mechanical Components of the SM/SF Columns
1 2
1 3
1 6
1 4
1 7
1 5
1 8
Figure 62: Lifting motor and column on its side
12 Lifting motor
13 Screws
14 Motor holder
15 Toothed belt
16 Pot
17 Wooden spacer (70 mm x 300 mm)
18 Base plate
8. Screw screws [13] out of the motor holder [14].
9. Remove the lifting motor [12] from the toothed belt [15].
10. Move the column upwards a little with an extended Allen key and remove the wooden
support on the Trendelenburg holder.
11. Lower the column carefully until column is about 10 cm above the lower stop.
12.
CAUTION!
Risk of injuries and property damage.
The column weighs 200 kg. Use two persons to lay it on its side.
Lay the column on its side and place a wooden spacer [17] under the pot [16].
1 9
2 0
Figure 63: Base plate
19 Base plate
20 M8 screw (7 items)
13. Screw 7 M8 screws [20] out of the base plate [19].
14. Remove the base plate [19].
ATTENTION!
Risk of losing column adjustment.
On no account loosen the 3 screws under the base plate.
The adjustment of the column holder to the wedges will be lost.
15. Remove 5 M6 screws in order to remove the bearing module.
16. Open the safety plate over slotted nut of the main spindle.
17. Remove the slotted nut.
18.
ATTENTION!
If too much force is used the toothed belt may be damaged!
Carefully unthread the toothed belt. Do not apply any force.
Take the bearing module out in a downwards direction.
19. Remove the main spindle.
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Mechanical Components of the SM/SF Columns
Dismantling the bearing module
6
7
1
2
3
4
5
Figure 64:
Bearing module
1 Allen screw (4 items)
2 Tapered roller bearing
3 Bearing tension ring
4 Toothed belt wheel
5
6
7
Toothed belt
Boreholes for sickle spanner
Bearing cover
Replacing the toothed belt of the bearing module
1. Screw 4 Allen screws [1] out of the bearing cover [7].
2. Open the bearing module.
3. Replace the toothed belt [5].
Reassemble in the reverse order observing the following instructions:
• Insert the toothed belt carefully.
• Check and, if necessary, set the bearing play in the bearing module.
Setting the bearing module (only if necessary!)
1. Insert a sickle spanner into the boreholes [6] of the bearing tension ring [3] and loosen
the bearing tension ring [3] (ca. 1 - 2 turns).
2. Screw the bearing cover [7] on tight again with 4 Allen screws [1].
3. Set the tapered roller bearing [2] correctly with the aid of the bearing tension ring [3]
(easy-running without play).
4. Check the incidence of the tapered roller bearing [2].
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Mechanical Components of the SM/SF Columns
Replacing the ball-bearing spindle in the bearing modules
1. Remove 6 M6 screws from the holding plate of the ball-bearing spindle nut.
2. Replace the ball-bearing spindle [1] together with the spindle nut.
Reassemble in the reverse order.
Reassembly (fitting the main spindle):
Reassemble in the reverse order.
TEST!
Test the column functions.
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Mechanical Components of the SM/SF Columns
4.10
Repairing and setting the brake on the SF column
The set of batteries must be removed first before work can start on the brake. When
renewing the batteries, always change the complete set (3 batteries stuck together as
a block).
Removing the set of batteries from the SF column
1. Transfer the table top onto a shuttle and raise the column to its highest position. If the
motor is defective, use the emergency adjustment (see „Emergency Adjustment of Main
Lift for Service Work”).
2. Remove the power pack line from the column and switch the column off.
1
2
3
Figure 65:
SF Column
1 Panel cladding
2 Screws M3
3
Brake
3. Screw 2 M3 [2] screws out of the bottom of the panel cladding [1].
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Mechanical Components of the SM/SF Columns
4
7
5
8
6
3
Figure 66: Fixing of the column cladding
3 Pedal
4 Panel cladding
5 M6 fixing screw
6
7
8
Trendelenburg drive
Clip screw
Battery block
4. Open the bottom part of the panel cladding [4], slide it upwards and fix it securely to
the Trendelenburg drive [6] with the M6 fixing screw [5].
5. Pull the battery connections off.
6. Screw 1 screw out of the clip [7] and dismount the battery block [8] in an upward
direction out of the holder. Dismount the holder and lay it down.
9
10
11
3
Figure 67: Removal of the SF column brake
3 Pedal
9 Screws of the gear shifting gate
10 Nuts of the brake rod
11 Brake fixing screws
7. Remove the screws [9] holding the gear shifting gate, watching out for any washers
which may have been inserted.
8. Remove the pedal [3].
9. Unscrew the locking nut and nut [10] from the brake rod holder.
10. Remove 4 fixing screws [11] from the brake and take the brake out.
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Mechanical Components of the SM/SF Columns
Reassembly:
1. Lift the brake (complete) into the column pot while
- allowing the brake rod to slide through the pressure piece (do not damage the
thread) and
- insert the pedal shaft through the column opening.
12
14
12
19
13
18
15
3
16
17
Figure 68:
Reassembly of the brake
3 Pedal
12 Gear shifting gate
13 Driving pin
14 Pedal shift
15 Spring
16
17
18
19
Washer
Sealing ring
2 threaded pins
Screw
2. Fix the gear shifting gate [12] with 2 screws [9] and allow the driving pin [13] of the
pedal shaft [14] to engage in the in the linking path.
ATTENTION!
Important pre-setting of the switching process. Insert or remove a
washer [16] under the switching fork. The switching fork forms the stop
for the switching mechanism.
3. Screw the gear shifting gate [12] and brake together.
4. Attach the pedal [3] and secure with pins [18]. Do not forget the sealing ring [17].
Check the function of the gear shifting gate/switching process:
- The upper edge of the pedal should be 80 to 95 mm above the floor in the upper
position,
- The floor clearance of the lower switching point is 5 to 15 mm
5. Bring the pedal [3] into the lower position (column braked).
6.
ATTENTION!
Set a brake torque of at least 340 Nm.
Do not tighten the nuts [10] in the upper pedal position.
Screw the nut [10] onto the brake rod and tighten the column until the brake torque has
reached at least 340 Nm.
7. Tighten the locking nut [10].
TEST!
Test the brake function.
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Electrical Components of the GM Table top
5
Electrical Components of the GM Table top
CAUTION!
Danger of infection!
Before beginning work, obtain confirmation from the medical facility, that
all the necessary measures for protection against infection have been
performed.
5.1
Contact Element
Removal:
1. Uncouple all functional accessories.
2. Transfer the table top onto a shuttle (if function is defective, lift it manually onto the
shuttle).
3. Remove the pad from the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
1
2
3
Figure 69: Disassembly of the contact element
1 Cables
2 M4 countersunk screw (underside of
table)
3
Contact element
7. Remove 3 cables [1] from contact element [3] (3 M4 screws).
8. Remove 2 M4 countersunk screws 4 [2] from the underside of the table top.
9. Pull the contact element out in a downward direction.
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Electrical Components of the GM Table top
Reassembly:
Reassemble in the reverse order observing the following instruction:
• When connecting the cables, do not forget the tooth-lock washer and plain washer.
a
b
Figure 70:
c
Disassembly of the contact element
a Data (green)
b +36 V (white)
c
Earth (brown)
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
5.2
Distributor Circuit Board
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Remove the pad from the seat section.
3. Remove the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws and 8 M4 screws).
1
J7
1 J1
1
a
1
J8
2 Machine screw
1 J4
c
2
Figure 71: Disassembly of the distributor circuit board
1 Distributor circuit board
1 J2
F1 6,3A
b
1 J5
a
b
c
d
e
f
g
1 J3
d
e
f
g
Reference sensor
longitudinal displacement/OR adapter
Motor plug longitudinal displacement
Contact element
Leg section/back section left
Leg section/back section right
Socket for additional accessories
End sensor longitudinal displacement
6. Remove all plugs [1] from the circuit board.
7. Screw out 4 machine screws [2] and replace the circuit board.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
5.3
Replacing the longitudinal displacement motor/toothed disc
Removal of Motor:
1. Uncouple all functional accessories.
2. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
3. Remove the pad from the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Pull the plug out of the distributor circuit board.
1
2
3
4
5
6
Figure 72:
Disassembly of the longitudinal displacement motor
1 M5 machine screw (underside of the
4 Belt disk
table)
2 M4 tensioning screw
5 Motor shaft
3 Toothed belt
6 Motor bearing plate
8. Screw 2 M5 machine screws [1] out of the underside.
9. Remove the toothed belt [3] from the motor shaft [5].
10. Remove the motor.
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Removing the toothed disc (motor pinion)
1. Hold the dismounted motor securely.
2. Heat the toothed disc with hot-air gun to a maximum temperature of 250 °C until the
toothed disc can be pulled off with a tool.
3.
CAUTION!
Danger of burns!
Wear protective gloves.
Degrease the motor shaft.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Glue the toothed disc to the motor shaft with Omnifit 200 (flange outwards).
ATTENTION!
Danger of the toothed disk becoming detached!
Do not place the toothed disc under load for at least 1 hour.
Do not put the toothed belt on until the adhesive has set.
• Screw the motor bearing plate (Figure 72: [6]) off the dismounted motor
(4 M5 countersunk screws) and fix it on the new motor paying attention to the position
of the cable outlet to the motor.
7
A
8
9
10
Figure 73: Disassembly of the longitudinal displacement motor
7 Toothed belt
10 Motor shaft
8 M4 tensioning screw
A < 0.5 cm
9 Belt disk
• The deviation of the toothed belt [7] from the central position when pulled or pushed with
moderate force with the hand should not exceed 0.5 cm.
• If necessary, re-tension the toothed belt (loosen 2 M5 screws [1]) with the tensioning
screw M4 [8] and tighten the M5 screws.
ATTENTION!
Danger of crushing the cable!
When fitting the motor, position it so that the cable screw connection
faces.
TEST!
Check the slack on the toothed belt.
Perform a functional test.
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Electrical Components of the GM Table top
5.4
Longitudinal Displacement Sensors
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Remove the pad from the seat section.
3. Remove the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, unscrew the bearing rails for X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws and 8 M4 screws).
a
Figure 74:
Disassembly of the longitudinal displacement sensors
a Socket on the distributor circuit board
6. Pull the sensor plug out of the socket [a] on the distributor circuit board.
1
2
3
Figure 75:
Disassembly of the longitudinal displacement sensors
1 M3 locking screw
3 Sensor
2 Clamping block
A = 0.2 mm ± 0.1 mm
7. Loosen the M3 locking screw [1].
8. Pull the sensor (3) out of the clamping block [2].
9. Remove the cables and screen (Figure 76: [2]) from the OR adapter sensor
(Figure 76: [1]. Unscrew the OR adapter sensor (Figure 76: [1]).
10. Screw the distributor circuit board off and remove the screen under the distributor circuit
board.
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Electrical Components of the GM Table top
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• When the new sensor has been inserted, move the longitudinal displacement up to the
foot-side end stop by moving the toothed belt by hand.
• Adjust the sensor to 0.2 mm ± 0.1 mm. Use a feeler gauge.
TEST!
Check the front switching point after starting up the operating table
(gap 0.2 mm ± 0.1 mm) and perform a functional test.
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Electrical Components of the GM Table top
5.5
Sensor for Detecting the OR Adapter
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Remove the pad from the seat section.
3. Unscrew plastic plate from seat section (4 ball-headed and 2 M8 countersunk screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws and 8 M4 screws).
1
2
3
4
5
a
Figure 76:
Disassembly of the sensor for detecting the OR adapter
1 OR sensor
4 M3 locking screw
2 Screen (M4 screw)
5 M4 machine screw
3 Reference sensor
a Socket
6. Pull the plug out of socket [a] distributor circuit board.
7. Remove 4 machine M4 screws [5] from the distributor circuit board, raise circuit board.
8. Remove the sensor module screen under the circuit board.
9. Remove the cable binders and cable straps if necessary.
10. Screw off the OR sensor [1] (2 M3 screws) and screen [2] (1 M4 screw).
11. Loosen the M3 locking screw [4] on the clamping block.
12. Remove the reference sensor [3] together with the OR sensor.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Adjust the reference sensor, to do this, move the longitudinal displacement from the foot
side over the central position.
• Set the reference sensor to a gap of 0.2 mm ± 0.1 mm.
NOTE!
The OR and reference sensors can also be replaced individually.
To do this, remove the module as described, unsolder the defective sensor
and solder the new one in as per the circuit diagram.
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
5.6
Leg Section Presence Sensor
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Remove the pad from the seat section.
3. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
6
Figure 77:
Disassembly of the leg section presence sensor
1 Cover
4
2 Motor plug
5
3 Socket
6
Cable guide cover
M3 screw
Screw for switching point of the
longitudinal displacement end sensor
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove the cover [1] (2 M4 screws).
6. Pull the motor plug out [2].
7. Unscrew the socket [3] (2 M3 screws).
8. Unclip the sensor connectors from the socket.
9. Unscrew the cable guide cover [4] (6 M3 screws [5], screw [6] serves as the switching
point for the longitudinal displacement end sensor/only on the right-hand side).
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Electrical Components of the GM Table top
7
8
9
10
11
12
Figure 78: Disassembly of the leg section presence sensor
7 M4 screw
10 M8 screw
8 Cover
11 Standard rail
9 Cover for cable guide
12 Sensor cable
10. Remove the standard rail [11] and cover for cable guide [9] on the leg section joint
(2 M8 screws [10]).
11. Remove the cover [8] on the joint (3 M4 screws [7]).
12. Pull out the sensor cable [12] together with the sensor.
Reassembly:
Reassemble in the reverse order observing the following instruction:
• Slide the sensor into the borehole as far as it will go before the standard rail is screwed
on.
ATTENTION!
Danger of damaging the sensor cable insulation!
Ensure that the sensor cable is not crushed when screwing on the
standard rail.
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
5.7
Reference and End Sensors for the Leg Section Joints
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column and switch the column off.
1. Uncouple all functional accessories.
2. Remove the pad from the seat section.
3. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
6
Figure 79:
Disassembly of the leg section reference and end sensors
1 Cover
4 Cable guide cover
2 Motor plug
5 M3 screw
3 Socket
6 Screw for switchingpoint of the
longitudinal displacement end sensors
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove cover [1] (2 M4 screws).
6. Pull the motor plug out [2].
7. Unscrew the socket [3] (2 M3 screws).
8. Remove cable guide cover [4] (6 M3 screws [5], screw [6] serves as the switching point
for the longitudinal displacement end sensor).
9. Unclip the connections of the sensors which are to be replaced from the socket.
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Electrical Components of the GM Table top
7
1 2
8
1 3
9
1 4
1 0
1 5
1 1
1 6
Figure 80: Disassembly of the leg section reference and end sensors
7 M4 screw
12 M8 machine screw
8 Cover
13 Reference sensor
9 Cover for cable guide
14 End sensor
10 M8 screw
15 Motor with gearbox
11 Standard rail
16 M6 countersunk screw
10. Remove 2 M8 machine screws [12] within the spar and 2 M6 countersunk screws [16]
underneath it.
11. Pull the gearbox together with the motor [15] about 35 mm forwards.
12. Loosen the M4 locking screw of the sensor which is to be replaced (reference sensor
[13], end sensor [14]) and pull the sensor out in the direction of the gearbox.
NOTE!
The sensor locking screws are secured with UHU screw fixing lacquer.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Put 1 drop of UHU screw fixing lacquer into the tapped holes for the locking screws.
• Adjust the sensor gap after all the components have been securely assembled.
• Set the sensor gap to 0.2 mm ± 0.1 mm.
• Then check the gap at the upper and lower end positions, and at the zero position again.
TEST!
Perform a functional test and check the sensor gap again
(gap 0.2 mm ± 0.1 mm).
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Electrical Components of the GM Table top
5.8
Reference and End Sensors for the Back Station
Removal:
1. Uncouple all functional accessories.
2. Separate the column from the power rack and switch it off.
3. Remove the pad from the back section.
4. Screw the plastic plate off the back section (4 ball-headed and 2 M8 countersunk
screws).
1
3
2
4
Figure 81:
Disassembly of the back section reference and end sensors
1 Motor plug
3 Cover
2 Socket
4 Cable guide cover
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove cover [3] (2 M4 screws).
6. Pull out the motor plug [1].
7. Unscrew the socket [2] (2 M3 screws).
8. Remove cable guide cover [4].
9. Unclip the bus cables from the socket and pull them out completely.
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Electrical Components of the GM Table top
5
6
7
8
9
A
1 0
Figure 82: Disassembly of the back section reference and end sensors
5 M8 screws
9 Reference sensor
6 Spar
10 M6 countersunk screw
7 M4 locking screw
A = 0.2 mm ± 0.1 mm
8 End sensor
10. Remove 2 M8 machine screws [5] within the spar and 2 M6 countersunk screws [10]
underneath it.
11. Pull spar [6] out in a backward direction.
12. Loosen the M4 locking screw [7] of the of the sensor to be replaced and pull the sensor
out forwards.
NOTE!
The sensor locking screws are secured with UHU screw fixing lacquer.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Put 1 drop of UHU screw fixing lacquer into the tapped holes for the locking screws.
• Adjust the sensor gap after all the components have been securely assembled.
• Set the sensors gap to 0.2 mm ± 0.1 mm and tighten the locking screw.
TEST!
Check the gap at the upper and lower end positions, and at the zero
position.
Perform a functional test and check the sensor gap again
(gap 0.2 mm ± 0.1 mm).
Testing the reference sensors:
• Attach both leg sections and approach the zero position from the same
direction.
• The ends of the leg sections should then not be more than a maximum
of 1 cm apart.
• If necessary, change the switch gap of the sensor (must not exceed
0.3 mm).
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Electrical Components of the GM Table top
5.9
Leg Section Motor
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
Removal:
1. Uncouple all functional accessories.
2. Separate the column from the power rack and switch it off.
3. Remove the pad from the seat section.
4. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
6
Figure 83:
Disassembly of the leg section motor
1 Cover
2 Motor plug
3 Socket
4
5
6
Cable guide cover
M3 screw
Switching screw for sensor longitudinal
displacement
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
6. Remove cover [1] (2 M4 screws).
7. Unscrew/pull off the motor plug [2].
8. Unscrew the socket [3] (2 M3 screws).
9. Remove cable guide cover [4] (6 M3 screws [5]).
10. Unclip the presence sensor and bus cables for motors from the socket [3] and pull the
sensor cable completely out.
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7
8
9
1 0
1 1
Figure 84: Disassembly of the leg section motor
7 M8 machine screw
8 Motor
9 M5 screw
10 Gearbox
11 M6 countersunk screw
11. Remove 2 M8 machine screws [7] within the spar and 2 M6 countersunk screws [11]
underneath it.
12. Pull the gearbox [10], together with the motor [8], out forwards about 15 mm.
13. Pull the leg section motor cable downwards out of the underside of the spar, while lifting
the motor [8] up slightly or tilting it.
14. Pull the motor [8] out forwards.
15. Unscrew the motor [8] from the gearbox [10] (4 M5 screws [9]).
16. Pull the gearbox [10], together with the joint, off the motor shaft, use a plastic hammer
if necessary.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• The cable outlet of the motor must face downwards when the gearbox is screwed to the
motor.
• Push the gearbox, together with the motor, into the spar to within ca. 15 mm of the stop,
and thread the leg section cable along the motor into the spar.
• The switching screw for the end sensor of the longitudinal displacement must be
readjusted when the right-hand leg section motor is fitted.
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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Electrical Components of the GM Table top
5.10
Back Section Motor
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Separate the column from the power rack and switch it off.
3. Remove the pad from the back section.
4. Unscrew plastic plate from back section (4 ball-headed and 2 M8 countersunk screws).
1
3
2
4
Figure 85:
Disassembly of the back section motor
1 Motor plug
2 Socket
3
4
Cover
Cable guide cover
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove cover [3] (2 M4 screws).
6. Unscrew/pull off the motor plug [1].
7. Unscrew the socket [2] (2 M3 screws).
8. Remove cable guide cover [4].
9. Unclip the bus cables from the socket and pull them out completely.
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5
6
7
8
9
1 0
Figure 86: Disassembly of the back section motor
5 Cylinder head screw M8
6 Spar
7 Motor
8 M5 screw
9 Gearbox
10 M6 countersunk screw
10. Remove 2 M8 machine screws [5] within the spar and 2 M6 countersunk screws [10]
underneath it.
11. Pull spar [6] out in a backward direction.
12. Unscrew the motor (4 M5 screws [8]) and pull it out of the gearbox [9].
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• The cable outlet of the motor must face downwards.
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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Electrical Components of the GM Table top
5.11
Connecting Socket for Additional Accessories
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column
- Switch the column off.
Removal:
1. Uncouple functional accessories from the leg end.
2. Separate the column from the power rack and switch it off.
1
2
3
Figure 87:
Disassembly of the connector socket for additional accessories
1 Cover with socket
3 M3 screw
2 Socket
3. Unscrew the cover [1] together with the socket (2 M3 screws [3]).
4. Remove cables with an ejector tool.
5. Separate the socket from the cover [1].
6. Renew the socket or the socket cover [2].
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
5.12
Electrical Cables
Additional Accessory Cable
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column, pull the power pack plug
out of the column and switch the column off.
1. Uncouple all functional accessories.
2. Bring the longitudinal displacement into the end position at the head end.
3. Remove the pad from the seat section.
4. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Pull the plug out of the distributor circuit board and unclip the cable.
3
4
1
2
Figure 88: Disassembly of the additional accessory cable
1 Distributor circuit board
2 M4 machine screw
3
4
Cover with socket
M3 screw
8. Remove 4 M4 machine screws [2] from the distributor circuit board [1].
9. Raise the distributor circuit board.
10. Loosen the cable screen under the distributor circuit board.
11. Remove the cable binders.
12. Unscrew the cover together with socket [3] for additional accessories (2 M3 screws [4]).
13. Remove the cable from the socket with a stripping tool and pull it out.
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Electrical Components of the GM Table top
Reassembly:
Reassemble in the reverse order observing the following instruction:
• Renew cable binders.
1
3
2
a b c
Figure 89:
Disassembly of the additional accessory cable (socket seen from the rear)
a Earth (brown)
c Data (green)
b +36 V (white)
TEST!
Perform a functional test.
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Contact Plate Cable
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories from the table top.
2. Remove the pad from the seat section.
3. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws and 8 M4 screws).
6. Pull the plug out of the distributor circuit board and unclip the leads.
1
2
Figure 90: Disassembly of the contact plate cable
1 Distributor circuit board
2
M4 machine screw
7. Remove 4 M4 machine screws [2] from the distributor circuit board [1].
8. Raise the distributor circuit board.
9. Loosen the cable screen under the distributor circuit board.
10. Remove cable binders and cable straps.
11. Unclip the cable from the contact plate.
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Reassembly:
Reassemble in the reverse order observing the following instruction:
• Renew cable binders.
a
b
Figure 91:
c
Disassembly of the cable contact plate
a Data (green)
b +36 V (white)
c
Earth (brown)
TEST!
Perform a functional test.
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Longitudinal displacement reference sensor/OR adapter cable
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple functional accessories from the table top.
2. Remove the pad from the seat section.
3. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws and 8 M4 screws).
1
2
3
4
5
a
Figure 92: Disassembly of the longitudinal displacement/OR adapter reference sensor cable
1 OR adapter sensor
4 M3 locking screw
2 Screen (M4 screw)
5 M4 machine screw
3 Reference sensor
a Socket
6. Pull the plug out of socket [a] distributor circuit board.
7. Remove 4 M4 machine screws [5] from the distributor circuit board.
8. Raise the circuit board.
9. Loosen the sensor module screen under the circuit board.
10. Remove cable binders and cable straps.
11. Unscrew the OR adapter sensor [1] (2 M3 screws) and screen [2] (1 M4 screw).
12. Loosen the M3 locking screw [4] on the clamping block.
13. Take out the reference sensor [3] together with the OR adapter sensor.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Renew cable binders.
• Adjust the reference sensor, to do this, move the longitudinal displacement from the foot
end over the central position.
• Set the reference sensor to a gap of 0.2 mm ± 0.1 mm.
7
8
a b c d
Figure 93:
Disassembly of the longitudinal displacement/OR adapter reference sensor
7 Reference sensor
a Earth (brown)
8 OR adapter senor
b Free
c Reference sensor (white)
d Additional accessory (green)
TEST!
Perform a functional test.
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Leg section cable left/right
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Move the longitudinal displacement into end position at the foot end.
3. Remove the pad from the seat section.
4. Unscrew plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Pull the plug out of the distributor circuit board and unclip it from the cable.
3
4
5
1
2
Figure 94: Disassembly of the leg section right/left cable
1 Distributor circuit board
2 M4 machine screw
3 Cover
4
5
Motor plug
Socket
8. Remove 4 M4 machine screws [2] from the distributor circuit board [1].
9. Raise the distributor circuit board.
10. Loosen the cable screen.
11. Remove cable binders.
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
12. Remove cover [3] (2 M4 screws).
13. Unscrew/pull off the motor plug [4].
14. Unscrew the socket [5] (2 M3 screws).
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6
1 1
7
1 2
8
1 3
9
1 4
1 0
Figure 95:
1 5
Disassembly of the leg section right/left cable
6 M4 screw
7 Cover
8 Cover for cable guide
9 M8 screw
10 Standard rail
11
12
13
14
15
M8 machine screw
Reference sensor
End sensor
Motor with gearbox
M6 countersunk screw
15. Unclip the presence sensor cables and leg section cable from the socket and pull the
sensor cable out completely.
16. Remove 2 M8 machine screws [11] within the spar and 2 M6 countersunk screws [15]
underneath it.
17. Pull the gearbox together with the motor [14] out about 15 mm forwards.
18. Pull the leg section cable out of the spar while lifting the motor up slightly.
19. Unscrew the cover plate from the wedge holder (4 M3 screws).
20. Displace the table top completely to the foot end by moving the toothed belt by hand.
21. Unscrew the upper end of the power train (2 M3 screws) and press power train out
backwards so that it lies straight.
22. Pull the leg section cable out of the power train.
23. Pull the motor together with the gearbox [14] out of the spar.
24. Bring the longitudinal displacement into the end position at the head end.
25. Pull the leg section cable out through the cable ducts in the mounting plate.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Push the gearbox together with the motor into the spar to within ca. 15 mm of the stop
and thread the leg section cable along the motor into the spar.
• Screw on the cable guide.
• Renew cable binders.
a b c d e f g h
Figure 96: Disassembly of the leg section right/left cable
a Earth (brown)
b +36 V (white)
c Data (green)
d Free
e
f
g
h
Earth 5 V (blue + black)
End sensor (brown)
Reference sensor (brown)
Additional accessory (black)
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a function test.
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Electrical Components of the GM Table top
Back section cable left/right
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Pull the pad off the table top.
3. Remove the plastic plates from the seat and back sections (each with 4 ball-headed and
2 countersunk M8 screws).
4. If present, remove bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
Figure 97:
Disassembly of the back section right/left cable
1 Cover
3
2 Motor plug
4
Socket
Cable guide cover
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove the cover [1] of the seat section spar (2 M4 screws).
6. Unscrew/pull off the motor plug [2].
7. Unscrew the socket [3] (2 M3 screws).
8. Unclip the back section cable from the socket.
9. Unscrew the seat section standard rail (3 M8 screws).
10. Remove the outer cable guide [4] on the back section joint (3 M3 screws).
11. Pull the back section cable out of the seat section spar.
12. Remove the back section spar cover [1] (2 M4 screws).
13. Remove the inner cable guide (7 M3 screws).
14. Unscrew socket [3] and unclip the cable.
15. Pull the cable out of the back section spar.
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Reassembly:
Reassemble in the reverse order.
a b c d e f g h
Figure 98: Disassembly of the leg section right/left cable
a Earth (brown)
b +36 V (white)
c Data (green)
d Free
e
f
g
h
Earth 5 V (blue+black)
End sensor (brown)
Reference sensor (brown)
Free
TEST!
Perform a functional test.
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Electrical Components of the GM Table top
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6
Mechanical Components of the GM Table top
CAUTION!
Danger of infection!
Before beginning work, obtain confirmation from the medical facility, that
all the necessary measures for protection against infection have been
performed.
6.1
Plastic Plates
Removal:
1. Remove the pad from the section concerned.
2. Unscrew the associated plastic plate.
Reassembly:
In the reverse order.
6.2
Covering Cap
Removal:
1. Remove the pad from the seat section.
2. Unscrew the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
3. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
4. Remove the covering cap fastening screws (4 M5 countersunk screws and 8 M4
countersunk screws).
5. Pull the covering cap off.
Reassembly:
In the reverse order.
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Mechanical Components of the GM Table top
6.3
Leg Section Gearbox
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all accessories from the foot end of the table top.
2. Remove the pad from the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
1
2
4
7
5
8
6
9
3
1 0
Figure 99:
Disassembly of the leg section gearbox
1 Cover
2 Motor socket
3 Plug
4 Joint
5 Cable guide
6
7
8
9
10
Cylindrical pins
Joint fixing screws
Cable guide cover
Cable guide cover fixing screws
Switching screw for sensor
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
5. Remove the cover [1], (2 M4 countersunk screws).
6. Unscrew/pull off the motor plug [2].
7. Unscrew the socket [3] (2 M3 screws).
8. Remove the cable guide [5] cover [8] (6 M3 countersunk screws). Screw [10] serves as
the switch point for the longitudinal displacement end sensor (only on the right-hand
side).
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1 1
1 2
1 3
7
1 4
1 6
1 5
1 7
Figure 100: Disassembly of the leg section gearbox
11 Fixing screws for coupling cover
12 Coupling cover
13 Cable guide
14 Standard rail fixing screws
15 Standard rail
16 Presence sensor cable
17 Joint/coupling point
9. Remove the standard rail [15] and cable guide [13] from the joint/coupling point
(2 M8 countersunk screws [14]).
10. Remove the cover [12] from the joint (3 M4 countersunk screws [11]).
11. Pull the presence sensor [16] completely out of the joint and gearbox.
12. Pull the cable guide [5] off the gearbox.
13. Remove 6 cylindrical pins Ø 10 x 24 [6] with the pin remover.
14. Remove 3 M4 countersunk joint [17] fixing screws [7] on the inside of the spar.
15. Pull the leg section [17] joint off.
1 8
1 9
Figure 101: Leg section gearbox
18 Seals with sliding disks
19 Gearbox casing
16. Screw out 2 M8 machine screws from within the spar.
17. Remove 2 M6 countersunk screws underneath the spar.
18. Pull the gearbox together with the motor out ca. 40 mm.
19. Remove 4 M5 machine screws.
20. Carefully separate the gearbox from the motor with a plastic hammer.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Screw the new gearbox to the motor.
• Fix the gearbox together with the motor to the spar.
• Renew the seals [18], if necessary, and lay them in the groove on the gearbox
casing [19].
• Press the sliding disks on the seals [18] and simultaneously slide the joint/
coupling point [17] onto the gearbox.
• Knock the cylindrical pins [6] in.
• Before the standard rail is screwed on, slide the sensor [16] into the borehole up to the
stop.
ATTENTION!
Danger of damaging the sensor cable insulation!
Ensure that the sensor cable is not crushed when screwing the standard
rail on. Incorrect positioning causes wear on the sliding disks. Ensure
that the sliding disks are in the correct position.
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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6.4
Leg Section Joint
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all accessories from the foot end of the table top.
2. Remove the pad from the seat section.
3. Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
1
4
2
5
3
6
7
Figure 102: Disassembly of the leg section joint
1 Joint
2 Cable guide
3 Cylindrical pins
4 Joint fixing screw
5
6
7
Cable guide cover
Cable guide cover fixing screws
Switching screw for sensors
5. Remove the cable guide [2] cover [5] (6 M3 countersunk screws [6]).
The sensor switching screw [7] serves as the longitudinal displacement end point (only
on the right-hand side).
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Mechanical Components of the GM Table top
8
9
1 0
3
1 1
1 3
1 2
1 4
Figure 103: Disassembly of the leg section joint
8 Fixing screws for coupling cover
9 Coupling cover
10 Cable guide
11 Standard rail fixing screws
12 Standard rail
13 Presence sensor cable
14 Joint/coupling point
6. Remove the standard rail [12] and cable guide [10] on the joint/coupling point
(2 M8 countersunk screws [11]).
7. Remove the cover [9] on the joint (3 M4 countersunk screws [8]).
8. Pull the sensor [13] completely out of the joint and the gearbox.
9. Remove 6 cylindrical pins Ø 10x24 [3] with the pin remover.
10. Remove 3 M4 countersunk screws from the joint [14] on the inner side of the spar.
11. Pull the joint/coupling point [14] off.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
1 5
1 6
Figure 104: Disassembly of the leg section joint
15 Seals with sliding disks
16 Gearbox casing
• Renew the seals [15] if necessary and insert them into the groove
on the gearbox casing [16].
• Press the sliding disks on the seals [15] and simultaneously slide the leg section joint [14]
onto the gearbox [16].
• Knock the cylindrical pins [3] in.
ATTENTION!
Incorrect positioning causes wear on the sliding disks.
Ensure that the sliding disks are in the correct position.
TEST!
Check the switch gap for the reference and sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the GM Table top
6.5
Back Section Gearbox
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all accessories from the head end of the table top.
2. Remove the pad from the back section.
3. Unscrew the plastic plate from the back section (4 ball-headed and 2 M8 countersunk
screws).
1
3
2
4
7
5
8
6
9
Figure 105: Disassembly of the back section gearbox
1 Motor socket
2 Motor plug
3 Cover
4 Joint
5 Joint fixing screws
6
7
8
9
Cylindrical pins
Cable guide
Cable guide cover
Cable guide cover fixing screws
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
4. Remove cover [3], (2 M4 countersunk screws).
5. Unscrew/pull off the motor plug [2].
6. Unscrew the motor socket [1] (2 M3 screws).
7. Remove the cable guide [7] cover [8] (7 M3 countersunk screws).
8. Unclip the sensor cables from the motor socket [1].
9. Pull the cables out completely.
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1 0
1 5
1 1
6
1 2
1 6
1 3
1 7
1 4
Figure 106: Disassembly of the back section gearbox
10 Gearbox casing
11 Cable guide
12 Cable guide countersunk screw
13 Motor
14
15
16
17
Standard rail countersunk screw
M8 machine screw
Cables
M6 countersunk screw
10. Screw out 2 machine screws M8 [15] from within the spar.
11. Remove 2 M6 countersunk screws [17] beneath the spar.
12. Pull the spar off.
13. Unscrew the motor [13] (4 M5 machine screws).
14. Carefully separate the gear from the motor [13] with a plastic hammer.
15. Remove the M8 countersunk screw [14] nearest to the gear from the standard rail
together with the spacing sleeve.
16. Remove the cover of the outer cable guide [11] (3 M4 countersunk screws).
17. Pull the cables [16] completely out.
18. Screw the countersunk screws [12] in again and tighten them to prevent the spar plate
springing when the cylindrical pins [6] are pulled out.
19. Remove 6 cylindrical pins [6] Ø 10 x 24 with the pin remover.
20. Screw out 6 M4 countersunk screws [5], [12].
21. Take out the gear.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Renew the seals if necessary and lay them in the grooves of the new gear.
• Slide the gearbox between both legs of the spar.
• Knock in 6 cylindrical pins Ø 10 x 24 [6].
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a function test.
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Mechanical Components of the GM Table top
6.6
Back Section Joint
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all accessories from the head end of the table top.
2. Remove the pad from the back section.
3. Screw the plastic plate off the back section (4 ball-headed and 2 M8 countersunk
screws).
X
1
2
5
3
6
7
4
8
Figure 107: Back section joint
1 Holding bolt
2 Joint
3 Disk springs/pressure disk
4 Cylindrical pin
5 Stopping lever
6
7
8
X
Compressing spring
Cam lever
Pressure disk
Borehole for cylindrical pin 4
4. Open the cam lever [7] of the associated joint.
5. Knock out the cylindrical pin [4].
NOTE!
Prevent the compression spring [6] from springing out.
6. Carefully remove the cam lever [7].
7. Remove the disk springs [3] and pressure disk.
8. Knock out the holding bolt [1].
9. Remove the joint [2].
10. Exchange defective parts.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Ensure that the disk springs [3] are inserted in the correct position.
• After the joint [2] has been inserted, the cam lever [7] must be freely moveable.
• There must not be any play when the gear teeth are under load.
• Readjust with shim rings if necessary, these can be found under the pressure disk [8].
TEST!
Perform a functional test.
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Mechanical Components of the GM Table top
6.7
Back Section Spar
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all the accessories on the head end of the table top.
2. Remove the pad from the back section.
3. Unscrew the plastic plate (4 ball-headed and 2 M8 countersunk screws).
4. Open the cam lever (Figure 107: [7]) of the associated joint (Figure 107: [2]).
5. Knock out the cylindrical pin (Figure 107: [4]).
6. Carefully remove the cam lever (Figure 107: [7]).
NOTE!
Prevent the compression spring (Figure 107: [6]) from springing out.
7. Remove the disk springs (Figure 107: [3]) and pressure disk.
8. Carefully knock the holding bolt (Figure 107: [1]) out with a plastic hammer.
9. Remove the joint (Figure 107: [2]).
1
3
2
4
7
5
8
6
9
Figure 108: Disassembly of the back section gearbox
1 Motor socket
2 Motor plug
3 Cover
4 Joint
5 Joint countersunk screws
6
7
8
9
Cylindrical pins
Cable guide
Cable guide cover
Cable guide cover countersunk screws
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
10. Remove the cover [3] (2 M4 countersunk screws).
11. Unscrew/pull off the motor plug [2].
12. Unscrew the motor socket [1] (2 M3 screws).
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13. Remove the cover [8] of the cable guide [7] (7 M3 countersunk screws [9]).
14. Unclip the cables from the motor socket [1] and pull them out completely.
1 0
1 6
1 1
1 3
1 2
1 3
A
1 4
1 5
Figure 109: Disassembly of the back section
10 M8 machine screw
11 Socket
12 Locking screen
13 End sensor
14
15
16
A
Reference sensor
M6 countersunk screw
Seat section spar
Gap 0.2 mm ± 0.1 mm
15. Screw 2 M8 machine screws [10] out from within the spar.
16. Remove 2 M6 countersunk screws [15] underneath the spar.
17. Pull the spar off and dismount the standard rail.
18. Loosen the locking screws [12] for the reference sensor [14] and the end sensor [13].
19. Unclip both sensors from the socket [11] and remove them.
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Reassembly:
Reassemble in the reverse order, observing the following instruction:
• Fix the new spar onto the gearbox.
• Slide the sensors [13], [14] into the spar.
• Put 1 drop of UHU screw-fixing lacquer into the tapped holes for the locking screws [12].
• Set the sensor gap to 0.2 mm ± 0.1 mm and tighten the locking screws [12].
a b c d e f g h
Figure 110: Socket on back section spar
a Earth 36 V (brown)
b +36 V (white)
c Data (green)
d Free
e
f
g
h
Earth 5 V (blue)
End switch (brown)
Reference switch (brown)
Free
• Clip the back section and sensor cables to the socket [11].
• Mount the coupling point on the back section.
• Ensure that the disk springs are inserted in the correct position.
• After the joint has been inserted the cam lever must be freely moveable.
• There must not be any play when the gear teeth are under load.
• Readjust with shim rings under the pressure disk if necessary.
• Attach both leg sections.
• The misalignment of the leg sections should be < 1 cm at their ends.
• Correct the gap on the sensors if necessary (A = 0.3 mm maximum).
TEST!
Perform a functional test.
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6.8
Power train
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all accessories from the table top.
2. Remove the pad from the seat section.
3. Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
4. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
5. Remove covering cap (4 M5 screws, 8 M4 screws).
1
2
3
Figure 111: Distributor circuit board
1 M4 machine screw
2 Bus cable plug
3
Bus cable plug right
6. Pull the socket off plug J1 [2] (left-hand power train) or J2 [3] (right-hand power train).
7. Unclip the leads from the socket.
8. Remove the fastening screws [1] from the distributor circuit board (4 M4 machine
screws).
9. Lift up the distributor circuit board.
10. Unscrew the screen of the relevant cable from the mounting plate.
11. Cut the cable binders if necessary.
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Mechanical Components of the GM Table top
4
5
7
6
8
9
1 0
Figure 112: Disassembly of the leg section gearbox
4 Cover
5 Motor socket
6 Motor plug
7 Cable guide
8 Cable guide fixing screws
9 Cover
10 End point of longitudinal displacement
ATTENTION!
Do not allow screws to fall into the spar.
Any that do so must be removed.
12. Remove the cover [4] (2 M4 countersunk screws).
13. Unscrew/pull off the motor plug [6].
14. Unscrew the socket [5] (2 M3 screws).
15. Remove the cover [9] of the cable guide [7] (6 M3 countersunk screws).
16. Unclip the presence sensor cables and leg section bus cable from the socket.
17. Pull the sensor cable out completely.
1 1
1 4
1 2
1 3
a b c d e f g h
Figure 113: Exposing leg section bus cable
11 M8 machine screw
12 Gearbox with motor
a Earth 36 V (brown)
b +36 V (white)
c Data (green)
d Free
13
14
e
f
g
h
M6 countersunk screw
Motor plug
Earth 5 V (blue + black)
End switch (brown)
Reference switch (brown)
Additional accessory (black)
18. Remove 2 M8 machine screws [11] from within the spar.
19. Remove 2 M6 countersunk screws [13] underneath the spar.
20. Pull the gearbox together with the motor [12] ca. 15 mm out of the spar.
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21. Pull the leg section bus cable on the upper fastening point of the power train carefully
out of the spar while lifting the motor up slightly if necessary.
22. Unscrew the cover plate from the wedge holder (4 M3 countersunk screws).
23. Displace the table top fully towards the leg end by moving the toothed belt by hand.
24. Unscrew the upper end of the power train (2 M3 screws).
25. Push the power train backwards until it lies straight.
26. Pull the leg section bus cable out of the power train.
27. Pull the motor together with the gearbox out of the spar.
28. Bring the longitudinal displacement manually into the head-side end position.
29. Unscrew the lower end of the power train (2 M3 screws).
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Slide the gearbox together with the motor into the spar to within ca. 15 mm of the stop
and thread the leg section cable along the outside of the motor into the spar.
TEST!
Check the switch gap on the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the GM Table top
6.9
Bevel Wheel Gear
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that both
spars retain their position relative to each other.
Unscrew the plastic plate from the seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
6. Remove the covering cap (4 M5 screws and 8 M4 screws).
1
2
3
4
5
6
Figure 114: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
4
5
6
Shaft
Gearbox
Gearbox pressure screw
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
8. Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the under side of the table top).
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
9. Loosen the pressure screw [6] of the gearbox [5].
10. Unscrew the gearbox [5] from the table top (4 M6 machine screws on the underside).
11. Knock the cylindrical pin out to replace the bevel wheel [3].
12. Replace the bevel wheel [3].
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Reassembly:
Reassemble in the reverse order observing the following instructions:
• Insert the gearbox [5] with the new bevel wheel [3] while pressing the gearbox [5] with
the hand against the toothed rack and tighten 4 M6 machine screws.
• Tighten the pressure screw [6].
• Loosen the threaded pins on the bevel wheels [2].
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2], while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt on to the motor’s toothed disk and shaft’s toothed disk.
TEST!
Check the tension of the toothed belt.
TEST!
Adjust and check the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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153
Mechanical Components of the GM Table top
6.10
Linear Guide
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all the accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that when
the linear guide is removed the spar affected does not tip to the side.
Never remove both linear guides at the same time.
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws, 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 115: Longitudinal displacement
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
8.
4
5
6
Shaft
Gearbox
Gearbox pressure screw
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
9. Loosen the pressure screw [6] of the corresponding gearbox [5].
10. Unscrew the gearbox [5] from the table top (4 M6 machine screws on the underside).
11. Pull 7 plastic caps off the fastening boreholes of the guide rail.
12. Remove M5 machine screws from the guide rail (make the screws accessible by shifting
the table top manually).
13. Loosen 4 M5 screws beneath the guide carriage.
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14. Remove 8 M5 screws from the guide carriage.
15. Pull the linear guide out at the head end while lightly supporting the spar (use a plastic
hammer if necessary).
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Slide the new guide in from the head end.
• Fasten the rail with 2 screws at the front and back.
• Shift the guide carriage into the correct position.
• Lightly tighten 8 M5 screws.
• Tighten 4 M5 screws underneath the guide carriage.
• Tighten 8 M5 screws.
• Screw the remaining screws into the guide rail, put on the caps.
• Fit the gearbox [5], while doing so hold the gearbox [5] with the hand against the toothed
rack and tighten 4 M6 machine screws.
• Tighten the pressure screw [6].
• Loosen the threaded pins on the bevel wheels [2].
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2] while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt on to the motor’s toothed disk and shaft’s toothed disk.
A
Figure 116: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and check the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm). Perform a functional test.
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Mechanical Components of the GM Table top
6.11
Toothed Rack
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that when
the linear guide is removed the spar affected does not tip to the side.
Never remove both linear guides at the same time.
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws, 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 117: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
8.
4
5
6
Shaft
Gearbox
Gearbox pressure screw
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
9. Loosen the pressure screw [6] of the corresponding gearbox [5].
10. Unscrew the gearbox [5] from the table top (4 M6 machine screws on the underside).
11. Remove 3 M5 screws from the toothed rack on the underside of the spar (make the
screws accessible by shifting the table top manually).
12. Pull the toothed rack out.
13. Replace with a new toothed rack.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Fit the gearbox [5], while doing so hold the gearbox [5] with the hand against the toothed
rack and tighten 4 M6 machine screws.
• Tighten the pressure screw [6].
• Loosen the threaded pins on the bevel wheels [2].
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2] while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt on to the motor’s toothed disk and shaft’s toothed disk.
A
Figure 118: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and check the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the GM Table top
6.12
Bevel Wheel Shaft
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that both
spars retain their position in relation to one another (the gearbox
ensures the movement of the spars is synchronised).
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 119: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
8.
4
5
6
Shaft
Gearbox
Gearbox pressure screw
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
9. Loosen the M4 threaded pins on the bevel wheels [2].
10. Exchange the bevel wheels [2], do not tighten the M4 threaded pins yet.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2] while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt onto the motor’s toothed disk and shaft’s toothed disk.
A
Figure 120: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and check the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the GM Table top
6.13
Shaft’s Toothed Disc
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that both
spars retain their position in relation to one another (the gearbox
ensures the movement of the spars is synchronised).
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 121: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
4
5
6
Shaft
Gearbox
Gearbox pressure screw
8. Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft (4) has been removed.
9. Loosen the M4 threaded pin on the bevel wheel [2] in front of the toothed disk shaft.
10. Remove the bevel wheel [2].
11. Exchange the shaft’s toothed disk (M4 threaded pin).
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Reassembly:
Reassemble in the reverse order, with the following instructions:
• Mount the bevel wheel [2] (align with the gearbox, tighten the M4 threaded pin tightly).
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Place the toothed belt over the toothed disks.
A
Figure 122: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and set the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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161
Mechanical Components of the GM Table top
6.14
Ball Bearing of the Longitudinal Displacement Shaft
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that both
spars retain their position in relation to one another (the gearbox
ensures the movement of the spars is synchronised).
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 123: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
8.
4
5
6
Shaft
Gearbox
Gearbox pressure screw
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
9. Remove the M4 threaded pins from the bevel wheels [2] and toothed disk shaft.
10. Remove the bevel wheel [2].
11. Remove the shaft’s toothed disk.
12. Pull the bearing blocks off the shaft.
13. Exchange the ball bearing.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2] while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt on to the motor’s toothed disk and shaft’s toothed disk.
A
Figure 124: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and set the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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163
Mechanical Components of the GM Table top
6.15
Toothed Belt
Removal:
1. Transfer the table top onto a shuttle (if function defective, lift it manually onto the
shuttle).
2. Remove all accessories from the foot end of the table top.
3. Remove the pad from the seat section.
4.
ATTENTION!
The spar loses its rigidity without the plastic plate.
The back part of the plastic plate must remain screwed on so that both
spars retain their position in relation to one another (the gearbox
ensures the movement of the spars is synchronised).
Unscrew the plastic plate from seat section (4 ball-headed and 2 M8 countersunk
screws).
5. If present, remove the bearing rails for the X-ray cassettes (6 M4 screws).
6. Remove covering cap (4 M5 screws and 8 M4 screws).
7. Remove the toothed belt from the motor’s toothed disk and the shaft’s toothed disk.
1
2
3
4
5
6
Figure 125: Longitudinal displacement drive
1 Bearing blocks
2 Shaft bevel wheel
3 Gearbox bevel wheel
8.
4
5
6
Shaft
Gearbox
Gearbox pressure screw
ATTENTION!
Be careful not to lose the synchronised positioning of the spars.
Therefore, never turn the bevel wheels [3] of the gearbox [5] when the
shaft [4] has been removed.
Unscrew the bearing blocks [1] together with the shaft [4] and bevel wheels [2]
(4 M5 machine screws on the underside).
9. Exchange the toothed belt.
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Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Screw on the bearing blocks [1] together with the shaft [4] and bevel wheels [2] while
inserting the toothed belt, but do not yet slide it onto the motor’s toothed disk and the
shaft’s toothed disk.
• Align the bevel wheels [2] with the bevel wheels [3] on the gearbox by sliding them axially
along the shaft.
ATTENTION!
Avoid wear on the drives!
The shaft must move easily without rattling.
• Tighten the threaded pins on the bevel wheels [2].
• Slide the toothed belt on to the motor’s toothed disk and shaft’s toothed disk.
A
Figure 126: Toothed belt slack
A = 0.5 cm
TEST!
Check the tensions of the toothed belt.
TEST!
Adjust and set the longitudinal displacement reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the GM Table top
6.16
Power Train Cover
Removal:
1
2
Figure 127: Power train cover
1 M3 countersunk screw
2
Bracket
1. Unscrew the bracket [2] (3 M3 countersunk screws [1]).
(Make the screws accessible by shifting the table top longitudinally.)
2. Exchange the bracket [2].
Reassembly:
Screw on a new bracket [2] (3 M3 countersunk screws [1]).
TEST!
Perform a functional test.
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Mechanical Components of the GM Table top
6.17
Cam Lever
Removal:
1. Remove all accessories from the head end of the table top.
X
1
2
5
3
6
7
4
8
Figure 128: Back section joint
1 Holding bolt
2 Joint
3 Disk springs/pressure disk
4 Cylindrical pin
X Borehole for cylindrical pin 4
5
6
7
8
Stopping lever
Compression spring
Cam lever
Pressure piece
2. Open the cam lever [7] on the corresponding joint.
3. Knock the cylindrical pin [4] out.
NOTE!
Prevent the compression spring [6] from springing out.
4. Carefully remove the cam lever [7].
5. Remove the disk springs [3] and pressure disk.
6. Knock the holding bolt [1] out.
7. Remove the joint [2].
8. Exchange defective parts.
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Ensure that the disk springs [3] are inserted in the correct position.
• The cam lever [7] must be freely moveable after the joint has been inserted [2].
• There must not be any play when the gear teeth are under load.
• Readjust with shim rings if necessary (1/10 or 2/10), they can be found under the
pressure disk.
TEST!
Perform a functional test.
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Mechanical Components of the GM Table top
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Additional Components
7
Additional Components
7.1
Remote Control with circuit board 4 144 709 (old version)
6
2
7
IR
1
3
8
4
9
5
1 0
1 1
Figure 129: Remote control
1
Battery
2
Casing, lower part
3
EPROM
4
M4 screw
5
Casing, upper part
6
IR Code
7
8
9
10
11
SP1 (coding switch for IR code)
SP2 (coding switch for IR code)
Processor
IR LED
SP3 (coding switch for IR code)
ATTENTION!
Keep the coding sequence (IR code).
1. SP3
2. SP2
3. SP1
Removing the battery
1. Screw 5 M3 screws out of the rear side of the remote control.
2. Lay the remote control with operating membrane keypad face down on a soft surface,
remove the lower part of the casing [2] and lay it next to the upper part
(caution: cable connection).
3. Take the battery out of the holder.
4. Pull the contact clips off and renew the battery.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Press the clips back onto the battery [1] contacts, make sure that the polarity is correct.
• Press the battery into the holder until it latches in.
• Check the seal and exchange it if necessary.
ENVIRONMENT!
Dispose of the battery in a way that does not harm the environment.
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169
Additional Components
Replacing the circuit board
1. Screw 5 M3 screws out of the rear side of the remote control.
2. Lay the remote control with operating membrane keypad face down on a soft surface,
remove the lower part of the casing [2] and lay it next to the upper part
(caution: cable connection).
3. Take the battery [1] out of the holder.
4. Pull the contact clips off.
5. Remove 2 M4 screws [4] from the lower narrow side of the circuit board and unsolder
at the charging coil.
6. Remove the flat ribbon cable from the connection (slide the clip contact back and then
pull the flat ribbon cable out).
7. Renew the circuit board.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Re-insert the isolating foil on the under side of the circuit board.
• Check that the IR code agrees with the type plate/column code.
• Only use original spare parts.
• Make sure that the polarity is correct.
Replacing the EPROM
1. Screw 5 M3 screws out of the rear side of the remote control.
2. Lay the remote control with operating membrane keypad face down on a soft surface,
remove the lower part of the casing [2] and lay it next to the upper part
(caution: cable connection).
3. Exchange the EPROM, ensure that it is fitted with the correct orientation
(lug to the casing).
Reassembly:
Reassemble in the reverse order.
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Additional Components
Replacing the foil
1. Screw 5 M3 screws out of the rear side of the remote control.
2. Lay the remote control with operating membrane keypad face down on a soft surface,
lever off the lower part of the casing [2] off and lay it next to the upper part
(caution: cable connection).
3. Remove 2 M4 screws [4] from the lower narrow side of the circuit board.
4. Remove the flat ribbon cable from the connection (slide the clip contact back and then
pull the flat ribbon cable out).
5. Renew the membrane keypad.
Reassembly:
Reassemble observing the following instructions:
• Re-insert the isolating foil on the under side of the circuit board.
TEST!
Test the column functions.
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171
Additional Components
7.2
Cable remote control with circuit board 4 144 996
NOTE!
The cable remote control is an exchangeable module. Therefore it is not
possible to replace individual parts within the remote control.
The complete cable remote control must always be replaced if there is a
defect.
Settings:
1. Open the remote control (5 M3 screws).
2. Carefully remove the rear part of the casing and lay it down.
3. The following settings are possible on the board:
- the code is set with the rotary selection switch,
- the device is selected with the rotary selection switch,
- the transmit power is selected with the rotary selection switch,
- jumper settings.
4. The code setting for the cable remote control is always 5 (S1).
S2 and S3 are not used.
5. Please take the device selection (S4) from the table below.
6. The operating mode setting (S5) is to be set to 0 for cable remote control.
7. The jumper settings may only be changed by the customer service.
8. Do not damage the rubber seal! Close the remote.
S4 Device
0
JUPITER EU
1
JUPITER USA
2
MARS Endourology EU
3
MARS Endourology USA
4
MARS EU
5
MARS USA
Stellung 5
S1
S2
S3
6
S4
7
EU:
8
S5
• each key switches on
9
• off after two seconds
A
B
USA:
C
• only ON key switches on
D
• off after 25 seconds
E
F
TEST!
Perform a functional test.
172
1
2
3
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Additional Components
7.3
Infrared remote control with circuit board 4 144 995
NOTE!
The IR remote control is an exchangeable module. Therefore it is not
possible to replace individual parts within the remote control (except for the
batteries). The complete IR remote control must always be replaced if there
is a defect.
Settings:
1. Open the remote control (5 M3 screws).
2. Carefully remove the rear part of the casing and lay it down.
3. Fit a new battery when required:
- pull connector off,
- remove the battery carefully from the holder.
4. The following settings are possible on the board:
- the code is set with the rotary selection switch,
- the device is selected with the rotary selection switch,
- the transmit power is selected with the rotary selection switch,
- jumper settings.
5. The code setting for the IR remote control is always to be taken from the type plate of
the relevant operating table (e. g. A01).
Infrared code setting
A
0
1
S3
S2
S1
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Additional Components
6. Please take the device selection (S4) and the operating mode setting (S5) from the
following table, the frequency and mark to space ratio (transmit power) may be
changed 8 (36 kHz T1/4) is used as the standard setting.
S4 Device
S5 Operation mode
0
JUPITER EU
0
1
JUPITER USA
1
2
MARS
Endourology EU
2
Cable remote
control
S1
3
MARS
3
Endourology USA
4
MARS EU
4
5
MARS USA
5
S4
6
6
S5
7
7
8
8
36 kHz T1/4
EU:
9
9
36 kHz T1/10
• each key switches on
A
A
56 kHz T1/4
• off after two seconds
B
B
56 kHz T1/10
C
C
D
D
E
E
F
F
S2
S3
rot
USA:
• only ON key switches on
• off after 25 second
Test operation
1 2 3 4
7. The jumper settings may only be changed by the customer service.
8. Do not damage the rubber seal! Close the remote.
TEST!
Perform a functional test.
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7.4
Power Pack for the SM Column
WARNING!
Danger to life and limb!
Separate the power pack from the mains supply.
Ensure that it cannot be switched on again.
1
2
3
4
Figure 130: Column power pack
1
Casing
2
4 A/230 V fuse, delay-action
6.3 A/115 V fuse, delay-action
3
4
2.5 A fuse, delay-action
10 A fuse, delay-action
Removal:
1. Pull off the cable to the column.
2. Open the power pack on both sides.
3. While it is open, check the fuses [2], [3], [4] and replace where necessary (see
„Overview of Fuses”).
4. To exchange the mains connection cable, open the cover of the cable screw
connections.
5. Unclip the mains connection cable.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Only use original spare parts.
• Replace the protective caps on the fuses.
• Restore the cables to their previous positions.
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Additional Components
7.5
Power Pack for the SF Column
WARNING!
Danger to life and limb!
Separate the power pack from the mains supply.
Ensure that it cannot be switched on again.
Removal:
1. Open the power pack.
2. While it is open, check the fuses and replace where necessary (see „Overview of
Fuses”).
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Only use original spare parts.
• Replace the protective caps on the fuses.
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Additional Components
7.6
Charging Unit for the Remote Control (Table Model)
WARNING!
Danger to life and limb!
Separate the power pack from the mains supply.
Ensure that it cannot be switched on again.
Figure 131: Power pack/table model
Removal:
1. Separate the charging unit from the mains supply.
2. Open the charging unit.
3. While it is open, check the fuses and replace where necessary.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Only use original spare parts.
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7.7
Charging Unit for Remote Control (Wall Model)
WARNING!
Danger to life and limb!
Separate the power pack from the mains supply.
Ensure that it cannot be switched on again.
Figure 132: Power pack/wall model
Removal:
1. Separate the charging unit from the mains supply.
2. Open the charging unit.
3. While it is open, check the fuses and replace where necessary.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Only use original spare parts.
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Accessories
8
Accessories
8.1
Section Control Unit and Power Pack
Power pack
WARNING!
Danger to life and limb!
Make sure that the power pack is separated from the mains supply
before opening it.
Replacing the Mains Cable
Removal:
1
2
4
3
a b c d
Figure 133: Power pack for section control unit
1
M4 screws
2
Cover
3
Mains cable with anti-kink
4
Mains input wire assignment
a green/yellow c brown
b green/yellow d blue
1. Unscrew 4 M4 screws [1] on the mains cable inlet side.
2. Remove the cover [2].
3. Unclip the mains cable [3].
4. Open the anti-kink device.
5. Replace the cable (ensure the wire assignment [4] is correct).
Reassembly:
Reassemble in the reverse order with the following instruction:
• Test the earth wire after completing the work.
TEST!
Perform a functional test.
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Accessories
Testing/Replacing the Fuses
Removal:
1. Unscrew 4 M4 screws [1] from each side of the power pack.
2. Remove both covers [2].
3. Pull out the PCB.
4. Test the fuses while disassembled and replace them as and where necessary (see
„Overview of Fuses”).
Reassembly:
Reassemble in the reverse order with the following instructions:
• Test the earth wire after completing the work.
TEST!
Perform a functional test.
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Accessories
8.2
Section Control Unit
Replacing the Batteries
Removal:
1
3
6
2
1 4
8
1 1
7
1 2
9
5
4
Figure 134: Section control unit
1
Section control unit
2
Negative output voltage
3
Bridge
4
Bridge
5
Positive output voltage
6
EPROM
7
Fuse F1 = 6.3 A, delay-action
1 3
1 0
8
9
10
11
12
13
14
Fuse F2 = 630 mA, delay-action
Battery connection
Table top connection
Serial interface connection
Fuse F3 = 630 mA, delay-action
Power pack connection
Operating membrane connections
1. Unscrew 4 M4 screws on the cover.
2. Remove the cover together with the cable screw connection.
3. Carefully remove the PCB.
4. Detach the flat ribbon cable from the connection to the operating membrane [14]
(slide the clip contact back and then pull out the flat ribbon cable).
5. Pull out the plugs [2], [3], [4], [5].
6. Remove the batteries and replace with new ones.
Reassembly:
Reassemble in the reverse order with the following instruction:
• Connect the new batteries as before.
Environment!
Dispose of the batteries in a way which does not harm the environment.
TEST!
Perform a functional test.
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Accessories
Testing/Replacing the Fuses
Removal:
1. Unscrew the 4 M4 screws on the cover.
2. Remove the cover together with the cable screw connection.
3. Carefully remove the PCB.
4. Test the fuses [7], [8], [12] while disassembled and replace them as and where
necessary.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
Replacing the EPROM
Removal:
1. Unscrew the 4 M4 screws on the cover.
2. Remove the cover together with the cable screw connection.
3. Carefully remove the PCB.
4. Detach the flat ribbon cable from the connection to the operating membrane [14]
(slide the clip contact back and then pull out the flat ribbon cable).
5. Carefully pull the EPROM [6] out of the mounting.
Reassembly:
Reassemble in the reverse order with the following instructions:
ATTENTION!
Avoid electrostatic charges building up when handling the EPROM.
NOTE!
Ensure that the markings on the EPROM and its mounting are aligned
when it is inserted.
• Set the new EPROM carefully on its mounting.
• Check whether all the pins are lying in the correct position on the mounting guides.
• Press the EPROM in evenly making sure that none of the pins buckle.
TEST!
Perform a functional test.
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Accessories
Replacing the Connecting Cable
Removal:
1. Unscrew 4 M4 screws from the cover.
2. Remove the cover together with the cable screw connection.
3. Open the cable screw connection.
4. Insert the pre-fabricated cable and connect it as before.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
Replacing the PCB
Removal:
1. Unscrew the 4 M4 screws on the cover.
2. Remove the cover together with the cable screw connection.
3. Carefully remove the PCB.
4. Pull out the plug.
5. Insert the new PCB.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Accessories
Replacing the Membrane Keypad
Removal:
1. Unscrew the 4 M4 screws on the cover.
2. Remove the cover together with the cable screw connection.
3. Carefully remove the PCB.
4. Detach the flat ribbon cable from the connection to the operating membrane [14]
(slide the clip contact back and then pull out the flat ribbon cable).
5. Pull out the flat ribbon cable.
6. Pull out the membrane keypad.
7. Remove any residual adhesive.
Reassembly:
Reassemble in the reverse order with the following instruction:
• When inserting the membrane keypad, ensure that it is exactly in the correct position.
It cannot be repositioned later.
TEST!
Perform a functional test.
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9
PSA Electrical Components
9.1
Replacing the Connecting Cable/PSA
1
2
3
Figure 135: Motorised seat section extension - cable side
1
Pad
2
Cable screw connection
3
Connecting cable
1. Detach the motorised seat section extension and place it pad side down [1] on a clean
surface.
2. Unscrew the 4 M4 countersunk screws out of the cover on the cable side.
3. Remove the cover.
4
5
6
Figure 136: Wire connections
4
Green wire
5
White wire
6
Brown wire
4. Unclip the cables [4], [5], [6].
5. Open the cable screw connection [2].
6. Replace the connecting cable [3].
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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PSA Electrical Components
9.2
Replacing the Socket for the Section Control Unit
Removal:
1
2
Figure 137: Motorised seat section extension - socket side
1
Pad
2
Socket with cover
1. Detach the motorised seat section extension and place it pad side down [1] on a clean
surface.
2. Unscrew the 4 M4 countersunk screws out of the cover on the socket side.
3. Remove the cover.
3
4
5
Figure 138: Wire connections
3
Green wire
4
White wire
5
Brown wire
4. Unclip the cables [3], [4], [5].
5. Dismantle the socket [2].
6. Replace the socket [2] or its cover.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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PSA Electrical Components
9.3
Replacing the Electronics
Removal:
1. Detach the motorised seat section extension and place it pad side down on a clean
surface.
2. Unscrew the 4 M4 countersunk screws out of the cover.
3. Remove the cover.
4. Unclip the cables and pull out the plug.
5. Remove the 4 machine screws from the PCB cooling plate.
6. Carefully remove the PCB and replace it with a new one.
Reassembly:
Reassemble in the reverse order with the following instruction:
• Connect the cables as shown in the circuit diagram.
TEST!
Perform a functional test.
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PSA Electrical Components
9.4
Replacing the Leg Section Presence Sensor
Removal:
1. Detach the motorised seat section extension and place it pad side down on a clean
surface.
1
2
5
3
6
4
Figure 139: Disassembling the leg section joint
1
Cable guide
2
Cable guide cover
3
6 M3 countersunk screws
4
5
6
4 M4 countersunk screws
Sensor plug
Cover
2. Unscrew the 4 M4 countersunk screws [4] out of the cover [6] on the corresponding
side. Remove the cover [6].
3. Pull out the sensor plug [5].
4. Press out the presence sensor cables.
5. Attach the motorised seat section extension to the table top and bring it into the zero
position.
6. Remove the pad from the seat section extension.
7. Remove the 6 M3 countersunk screws [3] on the cable guide [1].
8. Remove the cover of the cable guide [2].
7
8
9
1 0
1 2
1 1
Figure 140: Removing the presence sensor
7
Fixing screws for the coupling cover
8
Coupling cover
9
Cable guide
188
10
11
12
Fixing screws for standard rail
Standard rail
Presence sensor cable
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PSA Electrical Components
9. Remove the standard rail [11] and cable guide [9] at the joint/coupling point
(2 M8 countersunk screws [10]).
10. Screw out the 3 M4 countersunk screws [7] on the cover [8] of the joint and remove the
cover [8].
11.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
12. Pull out the sensor cable [12] together with the presence sensor and replace it with a
new one.
Reassembly:
Reassemble in the reverse order with the following instructions:
• Clip on the presence sensor as shown in the circuit diagram.
ATTENTION!
Risk of damaging the insulation on the sensor cable!
When screwing on the standard rail ensure that the sensor cables are
not crushed.
• Slide the sensor into the borehole as far as the stop before screwing on the standard rail.
• Screw on the plastic plate (the seat section extension can now be detached from the table
top once again).
TEST!
Perform a functional test.
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PSA Electrical Components
9.5
Replacing the Reference/End Sensors
Removal:
1. Detach the motorised seat section extension and place it pad side down on a clean
surface.
1
2
5
3
6
4
Figure 141: Disassembling the leg section joint
1
Cable guide
2
Cable guide cover
3
6 M3 countersunk screws
4
5
6
4 M4 countersunk screws
Sensor plug
Cover
2. Unscrew the 4 M4 countersunk screws [4] out of the cover [6] on the corresponding
side. Remove the cover [6].
3. Pull out the sensor plug [5].
4. Press out the cables of the reference or end sensor.
5. Attach the motorised seat section extension to the table top and bring it into the zero
position.
6. Remove the pad from the seat section extension.
7. Remove the 6 M3 countersunk screws [3] on the cable guide [1].
8. Remove the cover of the cable guide [2].
9.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
10. Pull the relevant sensor cable up through the assembly window.
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PSA Electrical Components
7
8
9
1 0
1 1
A
1 2
Figure 142: Removing the reference and end sensors
7
2 M8 cheese head screws
8
Spar
9
2 M4 locking screws
A
Gap (0.2 mm ± 0.1 mm)
10
11
12
End sensor
Reference sensor
2 M6 countersunk screws
11. Remove the 2 M8 cheese head screws [7] within the spar [8] and 2 M6 countersunk
screws [12] beneath it.
12. Pull the gear and the motor out about 35 mm in a forward direction.
13. Loosen the M4 locking screw [9] of the sensor to be replaced (end sensor [10],
reference sensor [11]) and pull out the sensor in the direction of the gear.
NOTE!
The sensor locking screws are secured with UHU screw fixing lacquer.
Reassembly:
Reassemble in the reverse order with the following instructions:
• Put 1 drop of UHU screw fixing lacquer in the tapped holes of the locking screws [9].
• Adjust the sensor gap after all the parts have been securely mounted.
• Set the sensor gap [A] to (0.2 mm ± 0.1 mm).
• Attach both leg sections and move them both to the zero position from the same
direction.
• Any misalignment of the leg sections should be < 1 cm at their ends.
• If necessary, correct the sensor gap (A = maximum 0.3 mm).
TEST!
Perform a functional test.
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PSA Electrical Components
9.6
Replacing the Connecting Cable
Removal:
1. Attach the motorised seat section extension to the table top and move it upwards into
the 90° position.
1
4
2
5
3
Figure 143: Replacing the connecting cable
1
Assembly window
2
Cable tube
3
4 M4 countersunk screws
4
5
Connecting cable
Cover
2. Screw the 4 M4 countersunk screws [3] out of the cover [5] on each side and remove
the cover [5].
3. Unclip the connecting cable [4] on both sides.
4. Attach the motorised seat section extension to the table top and bring it into the zero
position.
5. Remove the pad from the seat section extension.
6.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
7. Pull the connecting cable [4] up through the assembly window [1] on both sides and
remove from the cable tube [2].
Reassembly:
Reassemble in the reverse order with the following instruction:
• Connect the cables as shown in the circuit diagram.
TEST!
Perform a functional test.
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9.7
Replacing Motors
Removal:
1. Attach the motorised seat section extension to the table top and move it upwards into
the 90° position.
1
5
2
6
3
7
4
Figure 144: Disassembling the leg section joint
1
Assembly window
2
Cable guide cover
3
6 M3 countersunk screws
4
4 M4 countersunk screws
5
6
7
Motor and sensor cables
Connecting cable
Cover
2. Screw the 4 M4 countersunk screws [4] out of the cover [7] on the appropriate side and
remove the cover [7].
3. Unclip or press out all the motor and sensor cables [5].
4. Attach the motorised seat section extension to the table top and bring it into the zero
position.
5. Remove the pad from the seat section extension.
6. Remove the 6 M3 countersunk screws [3] on the cable guide [2].
7. Remove the cover from the cable guide [2].
8.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
9. Pull the sensor and motor cables [5] as well as the connecting cable [6] up and out
through the assembly window [1].
10. Pull the presence sensor cable out of the spar.
11. Pull the cable guide out of the gear.
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PSA Electrical Components
8
9
1 0
1 1
1 2
A
1 3
1 4
Figure 145: Replacing the motor
8
2 M8 cheese head screws
9
Spar
10 2 M4 locking screws
11 End sensor
12
13
14
A
Reference sensor
4 M5 cheese head screws
2 M6 countersunk screws
Gap (0.2 mm ± 0.1 mm)
12. Remove the 2 M8 cheese head screws [8] within the spar and the 2 M6 countersunk
screws [14] beneath it.
13. Pull the motor out forwards.
14. Unscrew the motor from the gear (4 M5 cheese head screws [13]).
15. Pull the gear together with the joint off the motor shaft, use a plastic hammer if
necessary.
Reassembly:
Reassemble in the reverse order with the following instructions:
• Screw the gear onto the motor. Watch out for the cable outlet.
• Connect as shown in the circuit diagram.
• Slide the gear together with the motor into the spar to within about 15 mm of the stop
and thread the cable into the spar passing the motor on the outside.
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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10
PSA Mechanical Components
10.1
Replacing the Plastic Plate
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Removal:
1. Attach the motorised seat section extension to the table top and bring it into the zero
position.
1
2
3
4
Figure 146: Motorised seat section extension with and without pad
1
Pad
3
Plastic plate
2
Ball-headed pin
4
Spar
2. Remove the pad [1] from the seat section extension.
3. Screw off the 4 ball-headed pins [2] and remove the plastic plate [3] from the seat
section extension.
Reassembly:
Reassemble in the reverse order.
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PSA Mechanical Components
10.2
Replacing the Gear
Removal:
1. Attach the motorised seat section extension to the table top and bring it into the zero
position.
2. Remove the pad from the seat section extension.
1
2
3
4
5
Figure 147: Leg section joint - inner side
1
6 cylindrical pins
2
Fixing screws for joint
3
Cable guide
4
5
Cable guide cover
Fixing screws for cable guide cover
3. Remove the cover [4] of the cable guide [3] (6 M3 countersunk screws [5]).
4.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the tabletop.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
6
7
8
1
9
1 1
1 0
1 2
Figure 148: Leg section joint - outer side
6
Fixing screws for coupling cover
7
Coupling cover
8
Spacer plate
9
Fixing screws for standard rail
10
11
12
Standard rail
Presence sensor cable
Joint/coupling point
5. Remove the standard rail [10] and spacer plate [8] from the joint/coupling point [12]
(2 M8 countersunk screws [9]).
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PSA Mechanical Components
6. Remove the cover [7] from the joint [12] (3 M4 countersunk screws [6]).
7. Pull the presence sensor [11] completely out of the joint and gear.
8. Pull the cable guide [3] out of the gear.
9. Remove the 6 cylindrical pins 10 mm x 24 mm [1] with a pin remover.
10. Remove the 3 M4 countersunk screws [2] from the inner side of the spar.
1 3
2 0
1 4
1 2
1 5
1 6
1 7
1 8
1 9
Figure 149: Replacing the leg section joint
13 2 M8 cheese head screws
14 Spar
15 M4 locking screws
16 End sensor
17
18
19
20
Reference sensor
4 M5 cheese head screws
2 M6 countersunk screws
Seals with slip rings
11. Pull out the leg section joint [12].
12. Unscrew the 2 M8 cheese head screws [13] within the spar [14].
13. Remove the 2 M6 countersunk screws [19] underneath the spar.
14. Pull the gear and motor out about 40 mm.
15. Remove the 4 M5 cheese head screws [18].
16. Carefully separate the gear from the motor with a plastic hammer.
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PSA Mechanical Components
Reassembly:
Reassemble in the reverse order with the following instructions:
• Screw a new gear onto the motor.
• Fix the gear and motor to the spar.
• Renew the seals [20] if necessary and insert them into the groove on the gear casing.
• Press the slip rings onto the seals [20] and slide the joint/coupling point [12] onto the
gear.
• Knock in the cylindrical pins [1].
•
ATTENTION!
Risk of damaging the insulation on the sensor cable!
When screwing on the standard rail, ensure that the sensor cable is not
crushed. The slip rings are subject to excessive wear if they are not
inserted in the correct positions. Ensure that the slip rings are lying in the
correct positions.
Slide the sensor [11] into the borehole up to the stop before screwing on the standard
rail [10].
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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10.3
Replacing the Joint
Removal:
1. Attach the motorised seat section extension to the table top and bring it into the zero
position.
2. Remove the pad from the seat section extension.
1
2
3
4
5
Figure 150: Disassembling the leg section joint
1
6 cylindrical pins
2
Fixing screws for joint
3
Cable guide
4
5
Cable guide cover
Fixing screws for cable guide cover
3. Remove the cover [4] from the cable guide [3] (6 M3 countersunk screws [5]).
4.
ATTENTION!
The option of adjusting the spars is lost.
Only remove the plastic plate from the seat section extension if the seat
section extension is coupled to the table top.
Screw off the 4 ball-headed pins and remove the plastic plate from the seat section
extension.
6
7
8
1
9
1 1
1 0
1 2
Figure 151: Leg section joint - outer side
6
Fixing screws for the coupling cover
7
Coupling cover
8
Spacer plate
9
Fixing screws for standard rail
10
11
12
Standard rail
Presence sensor
Joint/coupling point
5. Remove the standard rail [10] and spacer plate [8] from the joint/coupling point [12]
(2 M8 countersunk screws [9]).
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PSA Mechanical Components
6. Remove the cover [7] from the joint (3 M4 countersunk screws [6]).
7. Pull the sensor [11] completely out of the joint and gear.
8. Pull the cable guide [3] off the gear.
9. Remove the 6 cylindrical pins 10 mm x 24 mm [1] with a pin remover.
1 2
1 3
1 4
Figure 152: Replacing the leg section joint
12 Joint/coupling point
13 Seals with slip rings
14
Gear casing
10. Remove the 3 M4 countersunk screws from the joint [12] on the inner side of the spar.
11. Pull out the joint/coupling point [12].
Reassembly:
Reassemble in the reverse order with the following instructions:
• Renew the seals [13] if necessary and insert them into the groove on the gear casing [14].
• Press the slip rings onto the seals [13] and slide the leg section joint [12] onto the
gear [14].
ATTENTION!
The slip rings are subject to excessive wear if they are not inserted in the
correct positions.
Ensure that the slip rings are lying in the correct positions.
• Knock in the cylindrical pins [1].
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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10.4
Coupling Mechanism
Removal:
1. Detach the motorised seat section extension and place it pad side down on a clean
surface.
1
2
5
3
6
4
7
Figure 153: Coupling mechanism
1
Screw grip cover
2
Screw grip
3
Lower claw
4
Upper claw
5
6
7
Holding bolt
Retaining washer
Compression spring
2. Remove the covering cap [1] from the screw grip [2].
3. Remove the M4 cheese head screw together with the stop washer from the holding
bolt [5].
4. Unscrew the screw grip [2] from the holding bolt [5].
5. Knock the grooved pins out of the lower claw [3] and remove the claw [3].
6. Knock the grooved pins out of the upper claw [4].
7. Remove the retaining washer [6] with a screwdriver and remove the compression
spring [7].
8. Turn the seat section extension and remove the pad.
9. Pull out the upper claw [4] together with the holding bolt [5] in an upward direction.
10. Knock the cylindrical pin out of the upper claw [4].
11. Remove the holding bolt [5].
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
11
Electrical Components of the RY Table top
CAUTION!
Danger of infection!
Before beginning work, obtain confirmation from the medical facility that all
the necessary measures for protection against infection have been
performed.
11.1
Contact Element
Removal:
1. Uncouple all functional accessories.
2. Transfer the table top onto a shuttle (lift it manually onto the shuttle if function
defective).
3. Pull the pad off the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
5. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
6. Remove the covering cap (8 M4 screws).
1
2
3
Figure 154: Disassembling the contact element
1
Cables
3
2
M4 countersunk screw (underside of table)
Contact element
7. Separate 3 cables [1] from the contact element [3] (3 M4 screws).
8. Remove the 2 M4 countersunk screws [2] from the under side of the table top.
9. Pull the contact element out in a downward direction.
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Electrical Components of the RY Table top
Reassembly:
Reassemble in the reverse order with the following instruction:
• When connecting the cables, do not forget the tooth-lock washer and plain washer.
a
b
c
Figure 155: Disassembling the contact element
a
Data (green)
b
+36 V (white)
c
Earth (brown)
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
11.2
Distributor Circuit Board
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Pull the pad off the seat section.
3. Remove the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
5. Remove the covering cap (8 M4 screws).
1
1
1
J 7
J 1
J 2
c
1
a
1
J 4
J 8
2
Figure 156: Disassembling the distributor PCB
1
Distributor PCB
2
Machine screw
1
F 1 6 ,3 A
1
b
a
b
c
d
J 5
1
J 3
d
Contact element
Leg section, left
Leg section, right
Socket for additional accessories
6. Pull all plugs out of the PCB [1].
7. Screw out 4 machine screws [2] and replace the PCB.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
11.3
Leg Section Presence Sensor
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
Figure 157: Disassembling the leg section presence sensor
1
Cover
2
Motor plug
3
Motor socket
4
5
Cable guide cover
M3 screw
ATTENTION!
Do not allow any screws to fall into the spar.
If this does happen, they must be removed without fail.
5. Remove the cover [1] (2 M3 screws).
6. Pull out the motor plug [2].
7. Unscrew the motor socket [3] (2 M3 screws).
8. Unclip the sensor connections from the socket.
9. Unscrew the cover of the cable guide [4] (6 M3 screws [5]).
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Electrical Components of the RY Table top
7
8
9
10
11
12
Figure 158: Disassembling the leg section presence sensor
7
M4 screw
8
Cover
9
Cable guide cover
10
11
12
M8 screw
Standard rail
Sensor cable
10. Remove the standard rail [11] and cable guide [9] from the leg section joint
(2 M8 screws [10]).
11. Remove the joint cover [8] (3 M4 screws [7]).
12. Pull out the sensor cable [12] together with the sensor.
Reassembly:
Reassemble in the reverse order with the following instruction:
•
ATTENTION!
Risk of damaging the insulation on the sensor cable!
When screwing on the standard rail, ensure that the sensor cable is not
crushed.
Slide the sensor into the borehole as far as the stop before screwing on the standard rail.
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
11.4
Reference and End Sensors for the Leg Section Joints
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column and switch the column off.
1. Uncouple all functional accessories.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
Figure 159: Disassembling the leg section reference and end sensors
1
Cover
4
Cable guide cover
2
Motor plug
5
M3 screw
3
Motor socket
ATTENTION!
Do not allow any screws to fall into the spar.
If this does happen, they must be removed without fail.
5. Remove the cover [1] (2 M3 screws).
6. Pull out the motor plug [2].
7. Unscrew the motor socket [3] (2 M3 screws).
8. Unscrew the cover of the cable guide [4] (6 M3 screws [5]).
9. Unclip the connections of the sensor to be replaced from the socket.
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7
1 2
8
1 3
9
1 4
1 0
1 5
1 1
1 6
Figure 160: Disassembling the leg section reference and end sensors
7
M4 screw
12 M8 machine screw
8
Cover
13 Reference sensor
9
Cable guide screw
14 End sensor
10 M8 screw
15 Motor with gear
11 Standard rail
16 M6 countersunk screw
10. Remove the 2 M8 machine screws [12] within the spar and the 2 M6 countersunk
screws [16] underneath.
11. Pull the gear and motor [15] out about 35 mm in forward direction.
12. Loosen the M4 locking screw of the sensor to be replaced (reference sensor [13],
end sensor [14]) and pull the sensor out in the direction of the gear.
NOTE!
The sensor locking screws are secured with UHU screw fixing lacquer.
Reassembly:
Reassemble in the reverse order with the following instructions:
• Put 1 drop UHU screw fixing lacquer in the tapped holes of the locking screws.
• Adjust the sensor gap after all the parts have been securely mounted.
• Set the sensor gap to 0.2 mm ± 0.1 mm.
• Then check the gaps at the upper and lower end positions and the zero position once
again.
TEST!
Perform a functional test and check the sensor gap again
(gap 0.2 mm ± 0.1 mm).
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Electrical Components of the RY Table top
11.5
Leg Section Motor
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
Removal:
1. Uncouple all functional accessories.
2. Separate the column from the power pack and switch off.
3. Pull the pad off the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
5. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
1
2
3
4
5
6
Figure 161: Disassembling the leg section motor
1
Cover
2
Motor plug
3
Motor socket
4
5
6
Cable guide cover
M3 screw
End point of longitudinal displacement
ATTENTION!
Do not allow any screws to fall into the spar.
If this does happen, they must be removed without fail.
6. Remove the cover (1) (2 M4 screws).
7. Unscrew/pull out the motor plug [2].
8. Unscrew the motor socket [3] (2 M3 screws).
9. Remove the cable guide cover [4] (6 M3 screws [5]).
10. Unclip the presence sensor cables and bus cables from the motor socket [3] and pull
the sensor cable completely out.
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7
8
9
1 0
1 1
Figure 162: Disassembling the leg section motor
7
M8 machine screw
8
Motor
9
M5 screw
10
11
Gear
M6 countersunk screw
11. Remove the 2 M8 machine screws [7] within the spar and 2 M6 countersunk screws
[11] underneath.
12. Pull the gear [10] and motor [8] out forwards.
13. Unscrew the motor [8] from the gear [10] (4 M5 screws [9]).
14. Pull the gear [10] and joint off the motor shaft, use a plastic hammer if necessary.
Reassembly:
Reassemble in the reverse order with the following instructions:
• The cable outlet on the motor must point downwards when screwing the gear to the
motor.
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1 mm).
Perform a functional test.
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Electrical Components of the RY Table top
11.6
Connecting Socket for Additional Accessories
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
Removal:
1. Uncouple functional accessories from the leg end.
2. Separate the column from the power pack and switch off.
1
2
3
Figure 163: Disassembling the connecting socket for additional accessories
1
Cover with socket
3
M3 screw
2
Socket cover
3. Screw off the cover [1] and socket (2 M3 screws [3]).
4. Remove the cables with an ejector tool.
5. Separate the socket from the cover [1].
6. Replace with a new socket or socket cover [2].
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
11.7
Electrical Cables
Additional Accessory Cables
Removal:
NOTE!
Disassembly can also be performed on the column. When performing the
replacement on the column, pull the power pack plug out of the column and
switch the column off.
1. Uncouple all functional accessories from the table top.
2. Move the horizontal displacement to the end position on the head side.
3. Pull the pad off the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
5. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
6. Remove the covering cap (8 M4 screws).
7. Pull the plug out of the distributor PCB and unclip the cable.
3
4
1
2
Figure 164: Disassembling the additional accessory cable
1 Distributor PCB
2 M4 machine screw
3
4
Cover with socket
M3 screw
8. Remove the 4 machine screws M4 [2] from the distributor PCB [1].
9. Raise the distributor PCB.
10. Release the cable screening under the distributor PCB.
11. Remove the cable binder.
12. Unscrew the cover and the socket [3] for additional accessories (2 M3 screws [4]).
13. Remove the cable from the socket with a stripping tool and pull it out.
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Electrical Components of the RY Table top
Reassembly:
Reassemble in the reverse order with the following instruction:
• Renew cable binder.
1
3
2
a b c
Figure 165: Disassembling the additional accessory cable (rear view of socket)
a
Earth (brown)
c
Data (green)
b
+36 V (white)
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
Cable Contact Plate
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories from the table top.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
5. Remove the covering cap (8 M4 screws).
6. Pull the plug out of the distributor PCB and unclip the leads.
1
2
Figure 166: Disassembling the contact plate
1
Distributor PCB
2
M4 machine screw
7. Remove the 4 machine screws M4 [2] from the distributor PCB [1].
8. Raise the distributor PCB.
9. Release the cable screening under the distributor PCB.
10. Remove the cable binder and cable straps.
11. Unclip the cable from the contact plate.
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Electrical Components of the RY Table top
Reassembly:
Reassemble in the reverse order with the following instruction:
• Renew cable binder.
a
b
c
Figure 167: Disassembling the contact plate cable
a
Data (green)
b
+36 V (white)
c
Earth (brown)
TEST!
Perform a functional test.
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Electrical Components of the RY Table top
Leg Section Cable - Right/Left
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Uncouple all functional accessories.
2. Move the horizontal displacement to the end position on the foot side.
3. Pull the pad off the seat section.
4. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
5. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
6. Remove the covering cap (8 M4 screws).
7. Pull the plug out of the distributor PCB and unclip it from the cable.
3
4
5
1
2
Figure 168: Disassembling the leg section cable right/left
1
Distributor PCB
2
M4 machine screw
3
Cover
4
5
Motor plug
Motor socket
8. Remove 4 machine screws M4 [2] from the distributor PCB [1].
9. Raise the distributor PCB.
10. Release the cable screening.
11. Remove the cable binder.
ATTENTION!
Do not allow any screws to fall into the spar.
If this does happen, they must be removed without fail.
12. Remove the cover [3] (2 M4 screws).
13. Unscrew/pull out the motor plug [4].
14. Unscrew the motor socket [5] (2 M3 screws).
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Electrical Components of the RY Table top
15. Unclip the bus cables from the socket.
16. Pull the cable out of the spar.
Reassembly:
Reassemble in the reverse order with the following instructions:
• Screw on the cable guide.
• Renew cable binder.
a b c d e f g h
Figure 169: Disassembling the leg section cable right/left
a
Earth (brown)
b
+36 V (white)
c
Data (green)
d
Free
e
f
g
h
Earth 5 V (blue + black)
End sensor (brown)
Reference sensor (brown)
Additional accessory (black)
TEST!
Check the switch gaps of the reference and end sensors
(0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the RY Table top
12
Mechanical Components of the RY Table top
CAUTION!
Danger of infection!
Before beginning work, obtain confirmation from the medical facility that all
the necessary measures for protection against infection have been
performed.
12.1
Plastic Plates
Removal:
1. Pull the pad off the section concerned.
2. Unscrew the associated plastic plate.
Reassembly:
Reassemble in the reverse order.
12.2
Covering Cap
Removal:
1. Pull the pad off the seat section.
2. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
3. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
4. Remove the fixing screws from the covering cap (8 M4 countersunk screws).
5. Pull out the covering cap.
Reassembly:
Reassemble in the reverse order.
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Mechanical Components of the RY Table top
12.3
Leg Section Gear
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all the accessories from the foot end of the table top.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for X-ray cassettes (6 M4 screws).
1
2
4
7
5
8
6
9
3
Figure 170: Disassembling the leg section gear
1
Cover
2
Motor plug
3
Motor socket
4
Joint
5
Cable guide
6
7
8
9
Cylindrical pins
Joint fixing screws
Cable guide cover
Cable guide cover fixing screws
ATTENTION!
Do not allow any screws to fall into the spar.
If this does happen, they must be removed without fail.
5. Remove the cover [1] (2 M4 countersunk screws).
6. Unscrew/pull out the motor plug [2].
7. Unscrew the motor socket [3] (2 M3 screws).
8. Remove the cover [8] from the cable guide [5] (6 M3 countersunk screws).
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Mechanical Components of the RY Table top
1 1
1 2
1 3
7
1 4
1 6
1 5
1 7
Figure 171: Disassembling the leg section gear
11 Fixing screws for the coupling cover
12 Coupling cover
13 Cable guide
14 Fixing screws for the standard rail
15
16
17
Standard rail
Presence sensor cable
Joint/coupling point
9. Remove the standard rail [15] and cable guide [13] at the joint/coupling point
(2 M8 countersunk screws [14]).
10. Remove the cover [12] on the joint (3 M4 countersunk screws [11]).
11. Pull the presence sensor [16] completely out of the joint and gear.
12. Pull the cable guide [5] out of the gear.
13. Remove the 6 cylindrical pins Ø 10 mm x 24 mm [6] with a pin remover.
14. Remove the 3 M4 countersunk screws [7] from the joint [17], they are located on the
inner side of the spar.
15. Pull out the leg section joint [17].
16. Unscrew the 2 M8 machine screws within the spar.
17. Remove the 2 M6 countersunk screws underneath the spar.
18. Pull the gear and motor out about 40 mm.
19. Remove the 4 M5 machine screws.
20. Carefully separate the gear from the motor with a plastic hammer.
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Mechanical Components of the RY Table top
Reassembly:
Reassemble in the reverse order with the following instructions:
1 8
1 9
Figure 172: Leg section gear
18 Seals with slip rings
19
Gear casing
• Screw a new gear onto the motor.
• Fix the gear and motor to the spar.
• Renew the seals [18] if necessary and place them in the groove on the gear casing [19].
• Press the slip rings on the seals [18] and slide the joint/coupling point [17] onto the gear.
• Knock in the cylindrical pins [6].
•
ATTENTION!
Risk of damaging the insulation on the sensor cable!
When screwing on the standard rail, ensure that the sensor cable is not
crushed. The slip rings are subject to excessive wear if they are not
inserted in the correct positions. Ensure that the slip rings are lying in the
correct positions.
Slide the sensor [16] into the borehole up to the stop before screwing on the standard
rail [15].
TEST!
Check the switch gaps on the reference and end sensors
(gaps 0.2 mm ± 0.1 mm).
Perform a functional test.
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Mechanical Components of the RY Table top
12.4
Leg Section Joint
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all the accessories from the foot end of the table top.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
4. If present, dismount the bearing rails for the X-ray cassettes (6 M4 screws).
1
4
2
5
3
6
Figure 173: Disassembling the leg section
1
Joint
2
Cable guide
3
Cylindrical pins
4
5
6
Joint fixing screws
Cable guide cover
Fixing screws for the cable guide
5. Remove the cover [5] of the cable guide [2] (6 M3 countersunk screws [6]).
8
9
1 0
3
1 1
1 3
1 2
1 4
Figure 174: Disassembling the leg section
8
Fixing screws for the coupling cover
9
Coupling cover
10 Cable guide
11 Fixing screws for the standard rail
12
13
14
Standard rail
Presence sensor cable
Joint/coupling point
6. Remove the standard rail [12] and cable guide [10] from the joint/coupling point
(2 M8 countersunk screws [11]).
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Mechanical Components of the RY Table top
7. Remove the cover [9] on the joint (3 M4 countersunk screws [8]).
8. Pull the sensor [13] completely out of the joint and gear.
9. Remove the 6 cylindrical pins Ø 10 mm x 24 mm [3] with a pin remover.
10. Remove the 3 M4 countersunk screws from the joint [14] which are located on the inner
side of the spar.
11. Pull out the joint/coupling point [14].
Reassembly:
Reassemble in the reverse order with the following instructions:
1 5
1 6
Figure 175: Disassembling the leg section joint
15 Seals with slip rings
16
Gear casing
• Renew the seals [15] if necessary and insert them into the groove on the gear casing [16].
• Press the slip rings onto the seals [15] and slide the joint/coupling point [14] onto the
gear [16].
ATTENTION!
The slip rings are subject to excessive wear if they are not inserted in the
correct positions.
Ensure that the slip rings are lying in the correct positions.
• Knock in the cylindrical pins [3].
TEST!
Check the switch gap of the reference and end sensors
(gap 0.2 mm ± 0.1mm).
Perform a functional test.
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Mechanical Components of the RY Table top
12.5
Seat Section Joint
Removal:
NOTE!
Disassembly can also be performed on the column.
When performing the replacement on the column:
- Pull the power pack plug out of the column.
- Switch the column off.
1. Remove all the accessories from the head end of the table top.
2. Pull the pad off the seat section.
3. Unscrew the plastic plate from the seat section (4 ball-headed pins and 2 M8
countersunk screws).
X
1
2
5
3
6
7
4
8
Figure 176: Back section joint
1
Holding bolt
2
Joint
3
Disk springs/pressure disk
4
Cylindrical pin
5
Stopping lever
6
7
8
Compression spring
Cam lever
Pressure disk
X
Borehole for cylindrical pin 4
4. Open the cam lever [7] on the joint concerned.
5.
NOTE!
Prevent the compression spring [6] from flying off.
Knock in the cylindrical pin [4].
6. Remove the cam lever [7] carefully.
7. Remove the disk springs [3] and pressure disk.
8. Knock the holding bolt [1] in.
9. Remove the joint [2].
10. Replace the defective parts.
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Mechanical Components of the RY Table top
Reassembly:
Reassemble in the reverse order with the following instructions:
• Ensure that the disk springs [3] are inserted the correct way round.
• The cam lever [7] must be easy to actuate after the joint [2] has been assembled.
• There must not be any play in the gear teeth when the joint has been clamped.
• If necessary, readjust with shim rings which are located under the pressure disk [8].
TEST!
Perform a functional test.
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Repair Instructions Shuttle 1, 2, 3
13
Repair Instructions Shuttle 1, 2, 3
13.1
Fender and Initiator Plate
1. Brake the wheels.
2. Lay the shuttle on its side.
1
2
Figure 177: Fender and initiator rail
1
Fender
2
Initiator rail
3. Dismount the initiator rail [2].
4. Dismount the fender [1].
NOTE!
Use the dismounted fender as a drilling template for the new fender.
1
3 3 8 ±
2
0 ,5
a
Figure 178: Adjusting the fender and initiator rails
1
Fender
a
2
Initiator rail
ATTENTION!
Adjust the spacing of the fender [1] exactly central to the holding wedges.
The initiator rails [2] must not project beyond the front edge of the
fender [1] (a).
Service Manual JUPITER 4 900 361 - 03/03
227
Repair Instructions Shuttle 1, 2, 3
Reassembly:
Reassemble in the reverse order observing the following instructions:
1. Spacing between the fenders 338 mm ± 0.5 mm.
2. Ensure that the fenders are parallel to one another.
TEST!
Perform a functional test.
228
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.2
Changing the Adjustable Feet
1
2
Figure 179: Adjustable feet
1
Part 1 (foot)
2
Part 2
1. Screw/force out the defective foot [1] (it is secured with fixing lacquer!).
If necessary, also remove part 2 [2] (glued in with 2-component adhesive!).
Parts 1 and 2 [1]/[2] are supplied as a single spare part.
3
4
3 m m
3 m m
2. If part 2 [2] has been removed, this must be previously knocked in and glued in with
2-component adhesive.
Screw new foot [1] into part 2 [2] with fixing lacquer.
1
5
Figure 180: Setting range for adjusting the adjustable feet
3
Holding wedge
4
SM Column wedge holder
5
Operator side
3. Adjust the spacing of the adjustable feet as shown in Figure 181.
When the shuttle is docked on the column, the distance between the holding wedge [3]
and the column [4] must be 3 mm (column 3 mm in front of the wedges). The adjustable
feet [1] touch the column.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
Service Manual JUPITER 4 900 361 - 03/03
229
Repair Instructions Shuttle 1, 2, 3
13.3
Takeover Release
4 x
1 1
1 0
9
8
7
6
5
4
3
2
1
1 0 m m
Figure 181: Exploded view of the release
1
Push rod
2
Bolt with locking clip
3
Fork
4
Nut
5
Spring
6
Spring
7
8
9
10
11
Washer
Spring
Initiator plate
Countersunk screw
Adjustable feet
1. Remove the bolt with the small clip [2].
2. Remove the push rod [1].
3. The path of the initiator plate can be adjusted with the fork [3].
NOTE!
Make sure that the springs [5]/[6] and washer [7] are positioned
correctly when assembling.
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Use the nut [4] to lock the fork [3].
• The maximum distance between the initiator plate [9] and the adjustable feet [11] is
10 mm.
TEST!
Perform a functional test.
230
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.4
Changing the Front Wheel
NOTE!
Do not change the travel mode any more during the assembly work.
The exchange is made in the central position.
Note the position of the wheel before the wheel change.
The new wheel must be inserted in the same position.
1. Lay the shuttle on its side on a support.
2. Set free-wheel mode (central position).
3. Dismount the relevant fender and indicator rail.
1
3
2
2
3
4
5
6
Figure 182: Front wheel change (directionally running wheel)
1
Wheel support, front
4
2
Screw
5
3
Axle clamp
6
Gear shift control
Hexagonal shaft
Wheel, front
4. Remove the screw [2] in the axle clamp [3].
5. Pull the hexagonal shaft [5] out.
6. Screw 4 screws out of the wheel support [1].
7. Mark the direction of insertion of the wheel [6] in the wheel support [1].
8. Pull the wheel [6] out and remove the wheel support [1].
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Insert the new wheel in the same lock-in position as the old wheel was removed from.
TEST!
Perform a functional test.
Service Manual JUPITER 4 900 361 - 03/03
231
Repair Instructions Shuttle 1, 2, 3
13.5
Rear Wheel Change
NOTE!
Do not change the travel mode any more during the assembly work.
The exchange is made in the central position.
Note the position of the wheel before the wheel change.
The new wheel must be inserted in the same position.
1. Lay the shuttle on its side on a support.
2. Set free-wheel mode (central position).
3. Dismount the relevant fender and indicator rail.
1
3
2
2
3
4
5
6
Figure 183: Rear wheel change (wheels braked)
1
Wheel support, back
2
Screw
3
Axle clamp
4
5
6
Gear shift control
Hexagonal shaft
Wheel, back
4. Remove the screw [2] in the axle clamp [3] remove the retaining pin on the left-hand
side of the hexagonal shaft [5].
5. Pull the hexagonal shaft [5] out.
6. Screw 4 screws out of the wheel support [1].
7. Mark the direction of insertion of the wheel [6] in the wheel support [1].
8. Pull the wheel [6] out and remove the wheel support [1].
Reassembly:
Reassemble in the reverse order observing the following instructions:
• Insert the new wheel in the same lock-in position as the old wheel was removed from.
TEST!
Perform a functional test.
232
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.6
Replacing the Table top Locking Mechanism
1
2
6
3
4
5
Figure 184: Locking device
1
Releasing bolt
2
Clevis
3
Fork
4
5
6
Sprung folding bolt
Cover cap
Rod
1. Remove the covering cap [5].
2. Remove the pin with the sprung folding bolt [4].
3. Turn clevis [2] out of the releasing bolt [1].
4. Unscrew the fork [3] from the rod [6].
5. Replace the defective parts.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
Service Manual JUPITER 4 900 361 - 03/03
233
Repair Instructions Shuttle 1, 2, 3
13.7
Table/Column Changeover Switch
1
2
3
4
5
Figure 185: Table/column changeover switch
1
Spring core
2
Compression spring
3
Cross shaft
3
6
4
5
6
Lever arm
Allen screw
Covering cap
1. Remove the covering cap [6].
2. Grip the spring core [1] together with the compression spring [2] and pull it out with the
spring pressed together.
3. Unscrew the allen screw [5].
NOTE!
Grip the spring core [1] together with the compression spring [2] and, with
the compression spring [2] pressed together, first slot it into lever arm [4]
and then into the recess.
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
234
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.8
Replacing the Hydraulic Lifting Unit (Shuttle 3)
NOTE!
Put a support underneath to avoid scratching the shuttle.
1. Move the shuttle to the upper end position.
5
1
6
2
7
3
8
4
9
Figure 186: Hydraulic lifting unit
1
Screw
2
Hydraulic lifting unit
3
Countersunk screw
4
Pump lever
5
Countersunk screw
6
7
8
9
Cladding
Slotted holder
Holder
Cylinder pin
2. Screw out the 11 countersunk screws [5].
3. Remove the cladding [6].
4. Loosen screw [1] to obtain access to the piston rod.
5. Remove the cylinder pin [9].
6. Pull off the pump lever [4].
7.
ATTENTION!
Do not separate the upper and lower parts of the shuttle.
Brake the shuttle and lay it on its side.
8. Unscrew the countersunk screws [3] on both sides of the hydraulic lifting unit [2].
9. Remove the slotted holder [7].
10. Dismount the hydraulic lifting unit [2].
11. Remove the holder [8] and insert it on the new pump.
Service Manual JUPITER 4 900 361 - 03/03
235
Repair Instructions Shuttle 1, 2, 3
Reassembly:
Reassemble in the reverse order.
TEST!
Perform a functional test.
236
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.9
Bowden Cable (Shuttles 2 and 3)
1. Transfer the table top onto the column and bring the shuttle’s Trendelenburg setting
into the zero position. Raise the shuttle into its highest position (shuttle 3 only).
1
2
7
3
4
5
6
5
4 9
1 6
1 0
1 1 1 2
1 5
1 3
1 4
8
4
5
6
Figure 187: Bowden Cable
1
Push joint
2
Spring (1 x for shuttle 2; 1½ x for shuttle 3)
3
Screw plug
4
Lock nut
5
Adjusting screw
6
Bowden cable
7
Sleeve (shuttle 3 only)
8
Holder
9
10
11
12
13
14
15
16
Pin
Spring
Bolt
Locking bolt
Screw
Cover
Screw
Release lever
2. Remove screw [13] and then the cover [14].
3. Loosen the lock nuts [4] and tension the bowden cable [6] at both ends by screwing out
the adjusting screws [5] until the bolt [11] lies against the stop of the holder [8].
4. Loosen screw [15] and slide the complete holder [8] backwards out of the guide
(mind. the release lever [16]).
5. Slacken the bowden cable [6] (screw the adjusting screws [5] in).
6. Loosen screw plug [3] and remove the complete bowden cable unit from the foot of the
shuttle.
7. Unhook the lower end of the bowden cable [6].
8. Remove bolt [11] with a pair of pliers or similar tool.
9. Locking bolt [12] can now be slid out of the holder [8] in order to unhook the upper
end of the bowden cable [6].
Service Manual JUPITER 4 900 361 - 03/03
237
Repair Instructions Shuttle 1, 2, 3
Reassembly:
Reassemble in the reverse order, observing the following instructions:
• Ensure that the bowden cable [6] is inserted the correct way round (short end up, long
end down).
• Screws [5] must be adjusted to ensure that there is a safe takeover release by the initiator
plate in the zero position, and that the initiator plate is securely blocked when the shuttle
is in the Trendelenburg or anti-Trendelenburg position.
TEST!
Perform a functional test.
238
Service Manual JUPITER 4 900 361 - 03/03
Repair Instructions Shuttle 1, 2, 3
13.10
Drive (Shuttles 2 and 3)
1. Transfer the table top onto the column and bring the shuttle’s Trendelenburg setting
into the zero position. Raise the shuttle into its highest position (shuttle 3 only).
2. Loosen screw plug (Figure 187: [3]) and remove the complete bowden cable unit from
the foot of the shuttle.
1
2
5
8
3
4
7
6
Figure 188: Drive
1
M5 or M6 screw
2
Retaining ring
3
Retainer
4
M5 screw
5
6
7
8
Holder
Axle
Retaining ring
Adjusting screw
3. Remove retaining ring [7] and remove the axle [6] from the guide (take the load off the
shuttle fork while doing so).
4. Loosen the screws [1] of the drive holder (shuttle 2: 2x M6; shuttle 3: 6x M5).
5. Remove the drive from the holder.
6. Use the holder [5] for the new drive (remove retaining ring [2] and remove holder).
Service Manual JUPITER 4 900 361 - 03/03
239
Repair Instructions Shuttle 1, 2, 3
Reassembly:
Reassemble in the reverse order observing the following instructions:
• To adjust the new drive, first completely install it, bring the shuttle into the zero position,
and check that the fork is in a horizontal position with a spirit level (ensure that the floor
is level).
Remove the screw [4], retainer [3] and the axle [6], and align the zero position by turning
the lower suspension.
• The bowden cable must be adjusted with the screws [8] so that there is a safe takeover
release by the initiator plate in the zero position, and that the initiator plate is securely
blocked when the shuttle is in the Trendelenburg or anti-Trendelenburg position.
TEST!
Perform a functional test.
240
Service Manual JUPITER 4 900 361 - 03/03
Appendices
14
Appendices
Operating Instructions in brief...................................A
Fault Tracing Guide ................................................. B
Technical Support ................................................... C
Test Programs......................................................... D
PC Service Program ................................................. E
Circuit Diagrams ..................................................... F
Overview of Fuses .................................................. G
Maintenance Work ................................................. H
Spare parts SM/SF column ........................................ I
Spare parts GM table top ..........................................J
Spare parts Shuttle 1, 2, 3 ........................................K
Status and Error Messages........................................ L
Operation and power supply ................................... M
Second-hand parts.................................................. N
Abbreviations Used
BS ..........................................................Back section
FC.........................................................Fixed column
IR ..................................................................Infrared
LD ...................................... Longitudinal displacement
LED ............................................. Light emitting diode
LS.............................................................Leg section
MC .................................................... Mobile column
MCtrl.................................................... Motor control
PC................................................. Personal computer
PCB.............................................Printed circuit board
PP ........................................................... Power pack
SP ....................................... Spare parts, held in stock
TT .............................................................. Table top
UEB.............................................. Handover/takeover
Service Manual 4 900 361 - 03/03
Appendices
Service Manual JUPITER 4 900 361 - 03/03
Appendix A
Operation Instruction in brief JUPITER
K u r z Operating
g e b r a u c h s a n w Instructions
e is u n g
O p e r in
a t i o brief
n in s tr u c tio n in b r ie f
1 .
M o d e d 'e m p l o i a b r é g é
In s tr u c c io n e s d e u s o e n b r e v e
2 x
O N
JU
P I
T
E R
J U P IT E R
T
P I
JU
E R
2 .
J U P IT E R
3 .
J U P IT E R
J U P IT E R
J U P IT E R
E R
P IT
JU
J U P IT E R
J U P IT E R
JU
P IT
E R
G e b r a u c h s a n w e is u n
R e fe r to o p e r a tin g m
V o ir le s in s tr u c tio n s
V é a s e in s tr u c c io n e s
Service Manual JUPITER 4 900 361 - 03/03
g b e a c h te n !
a n u a l!
d e s e r v ic e !
d e u so !
J U P IT E R
4 9 0 0 3 5 4 - 0 9 / 0 0
A1
Appendix A
Operation Instruction in brief JUPITER
1 .
1 .
1 .
1 .
2 .
2 .
2 .
2 .
3 .
3 .
3 .
2 .
1 .
1 .
2 .
3 .
1 .
2 .
Service Manual JUPITER 4 900 361 - 03/03
4 .
3 .
A2
Appendix A
Operation Instruction in brief Shuttle 1, 2, 3
K u r z g e b r a u c h s a n w e is u n g
O p e r a tio n in s tr u c tio n in b r ie f
M o d e d 'e m p l o i a b r é g é
S h u ttle 1
In s tr u c c io n e s d e u s o e n b r e v e
S h u ttle 3
S h u ttle 2
1 .
1 .
1
2 .
1
2 .
2
2
1
2
2
1
B L A N C O
G e b r a u c h s a n w e is u n
R e fe r to o p e r a tin g m
V o ir le s in s tr u c tio n s
V é a s e in s tr u c c io n e s
Service Manual JUPITER 4 900 361 - 03/03
g b e a c h te n !
a n u a l!
d e s e r v ic e !
d e u so !
S h u ttle 1 , S h u ttle 2 , S h u ttle 3
4 9 0 0 3 5 9 - 0 9 / 0 0
A3
Appendix A
Operation Instruction in brief Shuttle 1, 2, 3
1 .
1 .
1 .
2 .
2 .
2 .
3 .
3 .
3 .
4 .
J U P IT E R
4 .
4 .
J U P IT E R
J U P IT E R
5 .
5 .
5 .
6 .
6 .
6 .
J U P IT E R
J U P IT E R
J U P IT E R
Service Manual JUPITER 4 900 361 - 03/03
A4
Appendix B
Fault Tracing to the JUPITER Operating Table
Note:
Before searching for faults, the device must be separated from the mains supply and
switched off at the remote control by pressing the Shift and Zero keys simultaneously. Then
switch the device on again and return the functions to zero as follows:
• Move the longitudinal displacement, and back sections and leg sections across zero.
• Move lift, tilting and Trendelenburg slightly.
• Press the Zero key.
SF and SM Column Functions
Cause of
Fault
Further Test
Points
Fault
Test Point
Result
No main lift
Does the
motor run?
Yes
(column
subsided,
additional lift
possible)
Toothed belt
defective or too
loose
No
(additional lift
possible)
Motor fault
Test all motor
parameters with an
external PC
Correct
parameters,
possibly replace
motor
End switch
always open
Unclip from motor
and test
Replace switch
or cable, adjust
switch setting
Replace toothed
belt or tighten it
Cabling to the lift
motor
No
(no additional
lift possible)
Main lift only in
one direction
Test end
switch in nonfunctioning
direction
Service Manual JUPITER 4 900 361 - 03/03
No
transmission
Fuse F1 on
operating
computer
Action
Cabling from
MCtrl to lift
motor defective
Remove fuse
to test it
Replace
defective fuse
with one of the
same type
Operating
computer
defective
Replace
operating
computer
Cabling from
operating
computer to
MCtrl and
main lift
Replace
defective cable
End switch
always open
Unclip from motor
and test
Replace switch
or cable, adjust
switch setting
B1
Appendix B
Fault
Test Point
Main lift does
Test end
not stop at the
switch
end of a function
Incorrect
movement and/
or incorrect or
no tilting/
Trendelenburg
movement with
additional lift
Does the
motor of the
retarded drive
run
Result
Cause of
Fault
Further Test
Points
Always
transmission
End switch
always closed
Unclip from motor
and test
Yes
Toothed belt
defective (belt
disk on motor
still turns)
Replace toothed
belt
Gearbox (belt
disk stands still)
Replace motor
No
No additional lift Test LED 4x in
and/or only one MCtrl
direction
possible
Unclip and
test the end
switch above
the additional
lift-spindles of
the MCtrl
(not in the
end position)
Tilting/
Trendelenburg
only can only be
moved with the
zero key and
only in the zero
direction
B2
Action
Replace switch
or cable, adjust
switch setting
Motor defective
Cabling
MCtrl
Detect detective
element by
exchanging
components
Replace element
Spindle stuck
Test drive end
switch, pay
attention to an
attempt to start the
motor
Free the spindle
from the position
in which it has
stuck
Flickers or
does not light
up
Defective MCtrl
Replace MCtrl
No
transmission
End switch
always open
Replace switch
or cable, adjust
switch setting
Switch in
working order
MCtrl defective
Replace MCtrl
Test Namur
sensors for
zero position
(not in the end
position)
Always
activated
Sensor
Sensor in
working order
MCtrl defective
Replace MCtrl
Test end
switch above
main lift
Always
transmission
End switch
always closed
Replace end
switch
Switch in
working order
MCtrl defective
or gap to switch
plate too large
Test
inclination
sensor with
external PC
Inclination
sensor outside
its value range
Inclination
sensor defective
Unclip sensor and
test it
Test switch plate
gap
Replace sensor
or cable, adjust
sensor setting
Replace MCtrl
or adjust switch
plate gap
Replace
inclination
sensor
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
Cause of
Fault
Further Test
Points
Action
Out of range
Column is not
standing
vertically, longterm drift or
defective
inclination
sensor
Column must
stand on a level
surface
Adjust or replace
inclination
sensor
Within range
MCtrl position
lost
Zeroing and
repeated operation
of the tilting/
Trendelenburg
movements
Only replace
MCtrl if this
occurs
repeatedly
Test wedge
locking with
test program
point 2
Sensor does
not switch
Catch not
latched in
Test TT
presence with
test program
point 2
Reed switch
does not
switch
Fault
Test Point
Result
Tilting is limited
to ca. 10°
LED D15 flashes
Test
inclination
sensor with
test program
point 4
(if possible
test with
external PC,
display values
of MCtrl and
inclination
sensor)
No tilting/
Trendelenburg
adjustment
possible
Test LED 4x in
MCtrl
No operation via Is operating
membrane
column
plugged in?
operation
possible
Sensor defective
Check cabling and
sensor, test with
voltmeter
Replace sensor
Reed switch
defective
Test with external
magnet
If the Reed
switch does not
switch, replace
operating
computer
Magnet not
present
Use magnet
Flickers or
does not light
up
defective MCtrl
Replace MCtrl
Yes
Operating
membrane
defective
Replace
operating
membrane
Distributor board
defective
Replace
distributor board
Cabling to
operating
computer
defective
Operating
computer
defective
No
Service Manual JUPITER 4 900 361 - 03/03
Shake TT
Test cabling
integrity
Cabling replace
Replace
operating
computer
Make
connection
B3
Appendix B
Fault
Test Point
No operation via Test LEDs on
IR possible
IR remote
control
Result
No display
when key
pressed
Green LED
lights up when
key pressed
Limited
operation via IR
possible
B4
Remove IR
receivers
alternately
and operate
with IR remote
control
Cause of
Fault
Further Test
Points
Battery flat or
defective
Test battery voltage Recharge or
under load
replace battery
Action
Operating
membrane not
plugged in or
defective
Make
connection or
replace
operating
membrane
CB defective
Replace CB
EPROM out of its
slot
Plug EPROM in
Distance too
great
Reduce distance
IR code
incorrectly set
IR code on remote
control must be
same as that on
operating
computer (see
label on foot of
column)
Change IR code
if necessary
Remote control
CB defective
Replace CB
Green and red
LEDs light up
when key
pressed
Battery flat
Recharge battery
Localisation of
defective
receiver or
input on
operating
computer
Receiver
defective
Replace receiver
Operating
computer
defective
Replace
operating
computer
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
Fault
Test Point
No operation via Is operating
cable-remote
membrane
control possible plugged in?
No acoustic
signals
Creaking during
additional lift
movement
Test signals
for LS 1/2 to
CB adapter
Check
additional lift
spindles
Column wobbles Check rubber
feet
Service Manual JUPITER 4 900 361 - 03/03
Result
Yes
Cause of
Fault
Further Test
Points
Action
Cable and plug
defective
Test integrity of
cable and plug
Replace cable or
plug
Remote control
Test integrity of
Replace element
socket and
cabling and socket
cabling defective
EPROM out of its
slot
Plug EPROM in
Remote control
operating
membrane
defective
Replace
operating
membrane
Remote control
CB defective
Replace CB
Operating
computer
defective
Replace
operating
computer
No
Make
connection
Signals present CB adapter LS
1/2 defective
Replace CB
adapter
Signals not
present
Cable
Test integrity of
cable
Replace cable
Operating
computer
Test Signals to
operating
computer X2
Replace
operating
computer
No lubricant
Lubricate
spindles
(only use
recommended
lubricants)
Rubber foot
loose or missing
Screw rubber
foot tight or
renew
B5
Appendix B
Only for SF Column
Cause of
Fault
Further Test
Points
In order
Gear shifting
gate defective
Pay attention to
gear change noises
Too low (no
free movement)
Pin sheared off
or pedal bent
Insert new pin or
replace pedal
Is the braking
force greater
when the pedal
is pressed
down?
Yes
Brake lining
worn
Readjust brake
No
Brake defective
Replace brake
Is the brake
truss bar stuck?
Yes
Bearing stuck
Clean or replace
bearing
No
Linings stuck
Knock brake
truss bar
downwards
Column
wobbles in
relation to
floor
Bearing
defective or
flange screws
loose
Tighten screws
or replace
bearing
Fluid leaks
out of the
foot of the
column after
several
revolutions
Seal worn or
defective
Replace seal
Fault
Test Point
Result
Brake can
neither be
applied nor
released
Check pedal
height
Column can
be turned
even when
braked
Column
remains
immovable
when brake
is released
B6
Action
Adjust gear
shifting gate or
replace brake
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
GM/RY Table top Functions
Cause of
Fault
Further Test
Points
Fault
Test Point
Result
Leg sections
cannot be
moved
independently
Are the
elements
plugged in on
the leg section
side?
Yes
Independent
movement is not
possible with
one-piece
elements
Remove
elements
Check if head
end is correctly
set on column
Incorrect head
end set
LS is controlled
as BS
Switch over
Test with test
program point
2 without
one-piece TT
segment
Sensor is
indicated as
active
Sensor active
Unclip sensor from
without actuation motor and test it
Replace sensor if
defective,
otherwise
replace motor
Test whether
motor runs
(running noise)
Running noise
audible
Planetary gear
defective
Replace motor
Test operating
voltage and
k-line at the
drive, test
contact points
Operating
voltage and
k-line present
when key
pressed
Motor fault
Operating
voltage and
k-line not
present when
key pressed
Cabling fault
Replace
defective
element
Sensor always
on
Sensor defective
Replace sensor
Catch not
latched in
Shake TT
Not possible
to adjust a
spar drive
No section
function
Test shuttle
presence
sensor with test
program
point 2
Sensor does
Test wedgelocking with test not switch
program point
2
Test TT
presence with
test program
point 2
Reed switch
does not switch
Correct
parameters,
possibly replace
motor
Sensor defective
Check cabling and
sensor, test with
voltmeter
Replace sensor
Reed switch
defective
Test with external
magnet and with
test program
point 2
Replace
operating
computer if the
Reed switch does
not switch
Magnet not
present
Service Manual JUPITER 4 900 361 - 03/03
Test all motor
parameters from an
external PC
Action
Put magnet in
B7
Appendix B
Fault
No LD
adjustment
Test Point
Result
Cause of
Fault
Test operating
voltage and
k-line to
contact plate
Operating
voltage and
k-line present
Distributor CB,
fuse or cabling
defective
Operating
voltage and/or
k-line not
present
Interface in
column
B8
Action
Replace
defective
element
Cable, soldered
joints, screw
connection,
CB contact pins
Replace
defective
element
Contact
problems
Clean
Operating
computer
defective
Replace
Test LD motor
with external
PC
Not accessible
Motor
electronics
defective
Replace LD
motor
Is OR-adapter
plugged in?
Yes
LD with
OR-adapter not
possible
Remove
OR-adapter
Test OR-sensor
with test
program
point 2
Sensor is
indicated as
active
Sensor or motor
defective
Motor runs
Yes
Toothed belt
defective or too
loose
Replace toothed
belt or tighten it
Toothed beltdisk is loose on
motor shaft
Re-glue belt disk
No
Section
segment
cannot be
moved
downwards
Further Test
Points
Longitudinal
displacement
position
Motor fault
LD is in the
range of the
angle limitation
of the nonadjustable
element
Test sensor, unclip
from motor and test
again
Test all motor
parameters with
external PC
Replace sensor if
defective,
otherwise
replace motor
Correct
parameters,
possibly replace
motor
Change position
of longitudinal
displacement
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
Fault
Test Point
Result
Section
segment and
LD can only
be moved in
one direction
Test voltage at
reference and
end position
sensors ca. 2.5
V non-actuated
ca. 4.0 V
actuated
Voltage out of
range
Green LED
D15 display
Section
segment or
LD pass end
switch
Section
segments
only move
jerkily
Play in
TT joints too
great
Gear clutch
does not
disengage
when the
cam lever is
opened
Cause of
Fault
Further Test
Points
Motor
electronics
defective
Test motor
Correct
parameters with
parameters,
external PC
replace motor
REFLIM = 850
POSMIN = -30000
POSMAX = 30000
Action
Sensor defective
Replace sensor
Flashes
Motor position
lost
Move all
TT functions
across zero
Check switch
gap and
mechanical
condition
In order
Sensor or motor
defective
Test sensor, unclip
from motor and test
again
Replace sensor if
defective,
otherwise
replace motor
Test section
end position
D11 with test
program
point 2
Lights up
Reed switch
always on at
operating
computer
Test with external
PC program
Replace Reed
switch
Does not light
up
TT variables not
set correctly
Remove
gearbox, check
advance
threaded ring
Advance
threaded ring
loose
Check
condition of
disk springs
Play in gear
clutch
present
Service Manual JUPITER 4 900 361 - 03/03
Advance
threaded ring
tight
Set TT variables
in the motors
according to
TT type
Tighten and
secure advance
threaded ring
Gearbox worn
Replace gearbox
(possibly turn
worm gears 180
degrees)
Disc springs
worn
Replace springs
Function
elements worn
Readjust with
shim disks or
replace element
B9
Appendix B
Handover Function
Cause of
Fault
Further Test
Points
Sensors OK
Switch gap too
large
Check switch gap
between sensor and
screw
Readjust screw
or sensor
If necessary free
spindle if it has
jammed
No function
Sensor or
evaluation
electronics in the
MCtrl defective
Unclip sensor and
test it
Replace sensor
or MCtrl
Test Namur
sensor function
for main lift
zero position
Sensor OK
Switch gap too
great
Check switch gap
between sensor and
plate
Readjust sensor
No function
Sensor or
evaluation
electronics on lift
motor defective
Unclip sensor and
test it
Replace sensor
or evaluation
electronics on lift
motor
Main lift does
not find zero
with TT
Test end switch
above main lift
Always
transmission
End switch
always closed
Switch in
working order
MCtrl defective
or gap to switch
plate too large
Test switch plate
gap
Replace MCtrl or
adjust switch
plate gap
Section
segment
moves
through
horizontal
position
segment
angled
downwards
or upwards
does not
move into the
horizontal
position
Check voltage Voltage out of
range
at reference
and end
position sensors
ca. 2.5 V nonactuated
ca. 4.0 V
actuated
Motor
electronics
defective
Test motor
parameters with
external PC
REFLIM = 850
POSMIN = -30000
POSMAX = 30000
Correct
parameters,
replace motor
Table top LD
does not
move to zero
Test voltage at
reference
sensor
ca. 2.5 V nonactuated
ca. 4.0 V
actuated
Fault
Test Point
Result
No move to
zero with the
additional lift
Trendelenburg, tilting
Test functions
of Namur
sensors with PC
program and
actuate
manually
Main lift does
not find zero
without TT
B10
Voltage out of
range
Voltage OK
Replace end
switch
Sensor defective
Motor
electronics
defective
Action
Replace sensor
Test motor
parameters with an
external PC
REFLIM = 850
Correct
parameters,
replace motor
Sensor defective
Replace sensor
Switch gap too
great
Adjust sensor
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
Cause of
Fault
Further Test
Points
Indicator on
operating
membrane on
column does
not follow
actuation
Sensor defective
Cancel parallel
switching of
UEB1/2 head end
foot end at the plug
(black cable) and
test again
Zero position
not reached
(metal plate for
takeover
sensor
blocked)
No zero position
Set shuttle to
zero
Set bowden
cable
Adjust if
necessary
Fault
Test Point
Result
No takeover
possible
(table in zero
LED D15
green lights
up)
Test the sensors
with test
program
point 2
Test shuttle zero
position (only
shuttles 2
and 3)
Test plate for
presence
sensor on
shuttle
No indication
for presence
sensor
Check height of Shuttle low
shuttle (only
shuttle 3)
Service Manual JUPITER 4 900 361 - 03/03
Action
Replace sensor
Blocking
mechanism
defective
Test bowden cable,
ball
Replace
defective
element
Condition of
actuation plate
Check position and
levelness
Replace
defective
element
Plate bent or gap
too great
Check distance
between plates
Readjust or
replace plate
Shuttle low or
hydraulic pump
defective
Pump shuttle
upwards and test
hydraulic pump
under load
Replace
hydraulic pump
B11
Appendix B
Fault
Test Point
Result
Cause of
Fault
Further Test
Points
Column
cannot be
lowered
(column is
switched on)
Test presence
with test
program
point 2
Presence exists
UEB2 defective
Cancel parallel
switching of UEB2
(lower) head end
foot end at the plug
(black cable) and
test separately
Replace sensor
Stops after short
approach: UEB1
defective
Cancel parallel
switching of UEB1
(upper) head end
foot end at the plug
(black cable) and
test separately
Replace UEB1
Presence does
not exist
Operating error:
height of shuttle
3 changed after
takeover
Lower column
with shuttle 3
Presence sensor
defective
Replace sensor
Plate bent or gap
too great
Readjust or
replace plate
Column has
been moved into
a position which
is too high
Column is
lifted
although the
TT is set for a
shuttle
B12
Check column
and column
head with spirit
level
Column or
column head
not vertical
Action
Cancel parallel
switching of UEB1
(upper) head end
foot end at the plug
(black cable) and
test separately
Rubber feet
damaged
Additional lift
sensors
incorrectly
adjusted
Replace sensor
Replace rubber
feet
Test additional lift
sensor with gauges
1, 2, 3
Adjust column
head with sensor
setting
Service Manual JUPITER 4 900 361 - 03/03
Appendix B
Power Supply
Fault
Test Point
Result
Cause of
Fault
Column
cannot be
switched on
with green
key
Plug PP into
column and
connect with
mains
Column
switches on
Battery charging, Check batteries
defective
Recharge or
replace batteries
Cabling to
membrane
Test cabling
Replace
defective
element
Operating
computer
Test signals to
operating computer
Replace
operating
computer
Battery
indicator
shows flat,
despite
regular
charging
Plug PP into
column and
connect with
mains
Operating
computer
All LEDs on PP
light up
Battery status
Test battery
Replace batteries
Charging cable
Test integrity
Replace
charging cable
Operating
computer fuse
Test charging
current fuse
Replace
operating
computer or fuse
Column head
connecting
socket
Test integrity
Replace unit
Replace fuses
Test integrity
Replace
charging cable
Test PP fuses
Replace fuses
Test integrity
Replace unit
Only one or no Secondary fuses
orange LEDs on
Test PP fuses
Replace fuses
All LEDs at PP
on
Charging cable
Test integrity
Replace
charging cable
Column head
connecting
socket
Test integrity
Replace unit
Column head
connecting
socket
Service Manual JUPITER 4 900 361 - 03/03
Replace
operating
computer
PP, primary fuses
Only green LED Charging cable
on, one or both
orange LEDs off
Secondary fuses
Plug PP into
column and
connect to
mains
Action
Column does
not switch on
No LED lights
up
Direct
operation not
possible with
PP
Further Test
Points
B13
Appendix B
B14
Service Manual JUPITER 4 900 361 - 03/03
Appendix C
Explanation of the Operating States
On
Standby
Off
Operating computer and
motors on (arrow keys lit)
Operating computer and
motors off (arrow keys unlit)
Everything off
300 mA (without movement)
65 mA
500 µA
For operating same behavior (time delay with standby)
5 min
Technical Support
On only with the green key
3 h column only
10 h column and TP
5 min handover and SF column
Any operation
Power off (manual)
Power off (manual)
Green key/operating voltage
Service Manual JUPITER 4 900 361 - 03/03
C1
Appendix C
Explanation of the Visual and Acoustic Signals
Visual error signals
•
Flashes for:
- Difference in inclination measurement (sensor and software) greater than
5 degrees
- Lost positions in the drive
•
Flash alternately if pl_n (table top position normal sensor) and pl_g (table top
position reversed sensor) are actuated simultaneously.
•
Flash simultaneously if the table top is not locked (wedge sensor not
active).
Acoustic signals
•
•
•
•
C2
Short beep (1x) for information (e. g. end position)
Short beep (2x) for confirmations (e. g. zero position reached)
Long beep for errors
Intermittent beep for:
- Missing LD zero with mechanical desktop (pl_e not active)
- Table top drives moving against each other
- An attempted movement after the table top drives have lost position (against zero)
Service Manual JUPITER 4 900 361 - 03/03
Appendix C
Explaining the Basic Circuit Diagram: Electronics
Column head
Inclination sensor
Wedge sensor
Table top sensor
Takeover sensor
Presence sensor
I2C
Operating
computer
IR receiver
K-Line
Motor
computer
Column keypad
Interface socket
Column
232
485
Addr.10
Tr
TR
Lift
TL
PC (232)
Foot control
Man. operation
Addr.11
Motor control
addresses
8
7
9
Column head
contact plate
Table top
Addr. 4
Addr. 5
(right BS)
(right LS)
Addr. 6
(LD)
Addr. 3
(left LS)
Addr. 2
(left BS)
Single motor sensors
Extra
REF
END
Socket for additional
electrical components
(max. two drives) or
section control unit
Addr.13
(right)
SCU
(left)
Add.
Service Manual JUPITER 4 900 361 - 03/03
Addr.12
C3
Appendix C
Explaining the Power Supply and Charging Activity
Column
Power
pack
Charging
controller
Charging current 48 V/1 A
48 V/1 A
LED orange
(left)
Battery
(36 V)
Power supply 40 V/10 A
40 V/10 A
LED orange
(right)
LED
orange
LED
red
LED
green
Power supply
operating table
Mains (220 V)
LED green
LEDs orange (PP)
• on if the charging cable is plugged in (charging current and power supply on)
LED green (PP)
• on if the mains is connected
LED red (column)
• off when batteries fully charged
• on if battery has less than 35.5 V
• flashes if battery has less than 32 V
LED orange (column)
•
•
•
•
off if no charging current flows
on if charging current > 155 mA
flashes if charging current < 155 mA
1 s on 9 s off, if charging takes more than 10 hours
LED green (column)
• on if power supply present
C4
Service Manual JUPITER 4 900 361 - 03/03
Appendix C
Explaining the Battery Charge Indicator LED (red)
U
[V]
LED off, function normal
35.5
34.0
LED lit
function normal
LED lit
single beep
function normal
∆U
32.0
LED flashes, single beep, motors blocked (takeover can be completed).
Column switches itself off after 30 seconds.
30.0
Column switches off
t
When batteries discharging
When batteries charging
Service Manual JUPITER 4 900 361 - 03/03
C5
Appendix C
Explaining the Angle-Limiting Monitoring of the Tilt and Trendelenburg
X
Inclination sensor
ellipse
F
E
B
A
C
D
G
X
Trendelenburg axis in degrees
Y
Tilting axis in degrees
Motor software
ellipse
Y
H
A, B, C, D Free range for Trendelenburg and tilting
F, G
Blocked ranges for Trendelenburg and tilting (blocked by software)
E, H
Blocked ranges for Trendelenburg and tilting (blocked by inclination sensor)
If the difference between the angular values of the motor control and those of the inclination
sensor is greather than 5 degrees, then the tilting function is restricted by10 degrees both
to the left and to the right. This serves to protect the mechanics.
Normally, the two ellipses lie exactly over each other. In this case there are no limitations
on the range of the tilting and Trendelenburg movements. Both movements can be utilised
throughout their full ranges (tilting 25 degrees, Trendelenburg 40 degrees).
If the angular values of the inclination sensor lies outside the predefined range, then the
tilting and Trendelenburg can only move in the direction of the zero position, a takeover is
also possible.
C6
Service Manual JUPITER 4 900 361 - 03/03
Appendix C
Explanation of how the Table top is Switched on after a Takeover
If the column and table top are directly interconnected, the high current flow (caused by the
empty capacitors of the table top motors) leads to a drop in the operating voltage, and this
in turn leads to position losses. Therefore the column and the table top are interconnected
as shown below.
U
Table top
t
U
Column
t
1
2
3
4
5
6
1
Presence exists, UEB 1 and 2 actuated
Takeover takes place
2
Section orientation detected, wedge sensor active
Presence no longer actuated, column motors switched off
3
Operating voltage to the column motors is switched off
(capacitors are discharged)
4
Column and table top are connected
Operating voltage for column and table top motors are switched on
5
Column and table top stand under operating voltage
Interrogation from M6 (GM) or M3 (RY)
6
If no M6 or M3 is found on the table top, the operating voltage to the
table top is switched off (mechanical table top)
Service Manual JUPITER 4 900 361 - 03/03
C7
Appendix C
Explaining the Reed Contacts in the Column Head
Charging socket
pl_e
pl_n
Column head
pl_g
pl_e
485/232 socket
pl_e
LD zero for the table top without electrical LD
pl_n
normal section position
pl_g
reversed section position
The Reed contact reacts to permanent magnets which are glued into the underside of the
table top.
C8
Service Manual JUPITER 4 900 361 - 03/03
Appendix C
Explaining the Function of the Table top Sensors
U
End sensor
α
U
Ref. sensor
α
Lower end position by
end sensor high and
reference sensor low
Service Manual JUPITER 4 900 361 - 03/03
Zero position by
switching
reference sensor
Upper end position by
end sensor high and
reference sensor high
C9
Appendix C
Explaining the Motor Position Memory
EEPROM
Valid
Normal
switching
on and off
procedure
Switch on procedure
Valid
Invalid
Valid
Switching on
procedure
with voltage
breakdown
RAM
Valid
Storage signal
Switch on procedure
Valid
Valid
Invalid
Valid
Invalid
Switching on
without
previously
stored positions
Invalid
Error message
(flashing zero)
Invalid
Valid
C10
Switch on procedure
Voltage breakdown
Storage signal
Valid
Position OK
Service Manual JUPITER 4 900 361 - 03/03
Appendix D
Test Programs
ATTENTION!
Danger of property damage!
The monitoring functions are switched off when the test program starts, and
incorrect operation can lead to the destruction of the device!
The column contacts are electrically live during the testing even if the section
has not been attached.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
Key code for accessing the test programs:
- Tilting/right [16]
- Trendelenburg [11]
- Lower column [14]
- Anti-Trendelenburg [12]
- Tilting/left [15]
Operation:
Enter the key code on the IR or cable remote control in the given order and within 5 seconds.
If this is successful, both direction indicators on the membrane keypad of the column flash
in unison.
Then select the test program with the keys [1] – [4].
The program number is confirmed by the corresponding number of beeps.
Exit the test program with the Zero key [19].
Return to the main program with the Shift key [20].
Service Manual JUPITER 4 900 361 - 03/03
D1
Appendix D
Test Program 1 - Testing the movement function
ATTENTION!
Danger of property damage!
The movement functions are executed irrespective of the possible positions.
All the movement functions are possible. However, take note of the following instructions:
• The functions: lifting, tilting and Trendelenburg are executed irrespective of the presence
sensor’s transporter, the section orientation, the takeover sensor, the inclination sensor
and the wedge locking.
• The leg and back section functions move irrespective of the position of the longitudinal
displacement.
• The longitudinal displacement function moves irrespective of the positions of the back
and leg sections.
• The battery charging current is switched off.
• The head section contacts are always electrically live.
D2
Service Manual JUPITER 4 900 361 - 03/03
Appendix D
Test Program 2 - Sensor test
The following sensors are tested:
• Transporter presence sensor
• Takeover sensors 1 and 2
• Section direction sensor
• Section end sensor
• Wedge locking sensor
• Accessory module on leg section
• Accessory module longitudinal displacement
If a sensor is actuated, the corresponding LED lights up on the membrane keypad of the
column.
Membrane keypad on the column:
Section position, normal
Section position, reversed
OR-adapter
section end position
Lights up when one
or more drives do
not respond
Leg section, left
takeover sensor, upper
Service Manual JUPITER 4 900 361 - 03/03
Wedge sensor
presence
Leg section, right
takeover sensor, lower
D3
Appendix D
Test Program 3 - Individual drives
ATTENTION!
Danger of property damage!
The motors travel to the hardware end switch.
Improper operation can lead to a crash or the destruction of the device.
IR remote control
Motor selection
Up/down
D4
back section-left
leg section-left
back section-right
leg section-right
longitudinal displacement
Trendelenburg
tilting-left
tilting-right
lifting
additional lifting
accessory motors-left
accessory motors-right
motors up
motors down
leave test program
return to main menu
Service Manual JUPITER 4 900 361 - 03/03
Appendix D
Membrane keypad on column
LED 2
LED 1
LED 3
LED 4
LED 1 =
LED 2 =
LED 3 =
LED 4 =
20
21
22
23
x
Motor
address
Motor
Key on
IR-F
x
2
back left
1
x
3
legs left
2
x
4
back right
3
x
5
legs right
4
x
x
6
displacement
5
x
x
7
Trendelenburg
6
x
8
tilting left
7
x
9
tilting right
8
x
x
10
main lift
9
x
x
11
column motors
10
x
x
12
accessory_1
11
x
x
13
accessory_2
12
x
x
x
x
x
Service Manual JUPITER 4 900 361 - 03/03
D5
Appendix D
Test Program 4 - Sensor test/Level
Membrane keypad on the column:
LED 1
LED 6
LED 2
Alignment X
LED 3
LED 5
LED 4
Trendelenburg
Values in degrees
LED 1
-2
x
-1
x
LED 2
x
0
x
1
x
2
Alignment Y
D6
x
x
Tilting
Values in degrees
LED 4
-2
x
-1
x
LED 5
LED 6
x
0
x
1
x
2
LED 3
x
x
Service Manual JUPITER 4 900 361 - 03/03
Appendix E
Explaining the Sensor Menu
Table top status
Patient reversed
Table top rotated
Single leg allowed
Legs without add. mod.
Mechanical table top
Electrical table top
OR-adapter
Reed sensors
1 - LD end (mech.)
2 - Section position (normal)
3 - Section position (reversed)
4 - LD end (mech.)
PC Service Program
Battery voltage
Charging current
Jumper 1 perm. mount
Jumper 2-4 are free
Motor current
Sensors for:
Presence
Transfer 1
Transfer 2
(Free)
Wedge sensor
Trendelenburg
inclination sensor
Tilt inclination sensor
Software versions of
operating computer and
motor computer
Power on
Permanent read all
Service Manual JUPITER 4 900 361 - 03/03
Read
Perm. read motor current
Table top type
Serial no.
E1
Appendix E
Explaining the Motor Menu Driving
ATTENTION!
Risk of property damage!
Be careful when traversing the individual back section motors and the motors 7, 8 and 9.
Single motor
Movement
Position difference
Temperature error
Software limit 1
Software limit 0
Additional module
Brake
(Free)
Reference position
Reference position error
Upper end switch *
(Free)
Lower end switch *
End switch error
Position memory error
Hardware error
Positive direction of
movement
Negative direction of
movement
Speed
Test mode on/off
Number of test runs
Motor control
Delay time/seconds
Motor position
Current consumption of
motor
Motor or address selection
* For lifting motor (no. 10):
limit 0 = Upper end switch and
limit 1 = Lower end switch
Service Manual JUPITER 4 900 361 - 03/03
Status (hexadecimal)
No longer used
End of ellipse
End switch limit
Zero position
Zero position of address 11
(Free)
Initialisation error address 7, 8, 9
(Free)
Temperature error
Reference position
Reference position error
Additional lift, upper end
Additional lift, lower end
(Free)
(Free)
(Free)
E2
Appendix E
Explaining the Motor Parameter Menu
Maximum current
Maximum position
deviation
Speed
Motor or address
selection
Motor displays
Movement
Position difference
Temperature error
Software limit 1
Software limit 0
Additional module
Brake
(Free)
Reference position
Reference position error
Upper end switch
(Free)
Lower end switch
End switch error
Position memory error
Hardware error
Proportional control
parameter
Integral control
parameter
Time factor
Max. end position
Switching threshold
Braking torque
Min. end position
Motor position
Status (hexadecimal)
Table top variable
Temperature
Writing
To read out all the
motor parameters at the
same time
Service Manual JUPITER 4 900 361 - 03/03
Reading
Correction of the mechanical
zero position of the individual
TT motors (see options)
Version
E3
Appendix E
Explaining the Column Parameter Menu
Control parameter for
lifting column
No longer used
End of ellipses
End switch limit
Zero position
Zero position of address 11
(Free)
Initialisation error addr. 7, 8, 9
(Free)
Temperature error
Reference position
Reference position error
Additional lift, upper end
Additional lift. lower end
(Free)
(Free)
(Free)
Braking torque rotating left
Braking torque rotating
right
Software position
Trendelenburg
Sensor switching threshold
Braking torque motor
control
Software position tilting
Writing
Service Manual JUPITER 4 900 361 - 03/03
Reading
Motor control software
version
Status
(hexadecimal)
E4
Appendix E
Explaining the Motor Status Menu
Status of leg section motor
Positions of back section
motors
Main lift position
Positions of longitudinal
displacement motors
Status of lift motor
Additional lift status
Status of the single motors
in additional lift
Trendelenburg position
Tilting position
Status of back section and
long. displacement motors
Service Manual JUPITER 4 900 361 - 03/03
Reading
Position of leg section
motors
Positions of the single
motors in additional lift
E5
Appendix E
Explaining the Bus-Scan Menu
Software version
back sec. motor left
Software version
Trendelenburg drive
Software version
leg sec. motor left
Software version
tilting drive left
Software version
back sec. motor right
Software version
tilting drive right
Software version
leg sec. motor right
Software version
motor control (Add. lift)
Software version
long. displacement
Software version
main lift
Interrogation results:
Software version
electrical accessory left
14 - No motor
15 - Sender incorrect
16 - Parity error
17 - Time exceeded data
18 - Check sum error
19 - Receiving error
20 - Motor reply error
>100 - Interrogation OK
Service Manual JUPITER 4 900 361 - 03/03
Interrogate software
versions of motor
Set motor address
(only one motor
may be connected)
Software version
electrical accessory right
E6
Appendix E
Explaining the Command Menu
Command code
Parameter
Motor or address selection
Send code
Answer from
operating table
Service Manual JUPITER 4 900 361 - 03/03
E7
Appendix E
Explaining the EEPROM Menu
Working hours
(HH:MM:SS)
Miscellaneous
Miscellaneous
Add. element mixed
Add. element right
Add. element left
Zero
Flex/Antiflex
Tilting
Column lift
Trendelenburg
Long. displacement
Back section
Leg sections together
Leg section right
Leg section left
Handover
Loaded
Total
Interrogate working
hours
Interrogate error memory
Delete error memory
Delete working hours and
error memory
Print/save window
contents
Delete window contents
NOTE!
Evaluation of the EEPROMs with appendix M.
Service Manual JUPITER 4 900 361 - 03/03
E8
Appendix E
Explaining the Test Menu
Test mode on/off
LED test on/off
Test TT
Key test on/off
Key code
Interrogate IR code
column/IR code
Delay time
(sec between runs)
Delay on/off
Number of test runs
Beep 1 (zero)
Beep 2 (error)
Status window
(display of individual test
steps)
Set clock from PC
Date and time
Read column clock
Service Manual JUPITER 4 900 361 - 03/03
E9
Appendix E
Explaining the Monitor Menu
Command entry field
Service Manual JUPITER 4 900 361 - 03/03
Send command
Send values
E10
Appendix E
Explaining the Final Testing Menu
Comments for final report
Table top serial no.
Column serial no.
Save TT-serial no. in the LD motor
Extra serial no.
Start/stop the current final test
Call report of current final test
Print current final test
Service Manual JUPITER 4 900 361 - 03/03
Status window
(display of individual test steps)
E11
Appendix E
Explaining the Options Menu
The segments in the positive area
are included in the zeroing
Ref. stop for the leg and back
sections
Ref. stop for tilting and
Trendelenburg
Ref. stop for longitudinal
displacement
Ref. stop for transversal
displacement
Shuttle 1.5-3.5
Set zero position
Service Manual JUPITER 4 900 361 - 03/03
Correction of the
mechanical zero position of
the individual TT motors
Read all options
Set all options
E12
Appendix F
Circuit Diagrams
Service Manual JUPITER 4 900 361 - 03/03
F1
Appendix F
F2
Service Manual JUPITER 4 900 361 - 03/03
Appendix F
Service Manual JUPITER 4 900 361 - 03/03
F3
Appendix F
F4
Service Manual JUPITER 4 900 361 - 03/03
Appendix F
Pos.
Item no.
10
4 220 710
Cable motor control Ub
20
4 220 711
Cable motor control K-line
30
4 220 712
Cable main lift motor
40
4 220 713
Cable accumulator connection
50
4 220 742
Signal transmitter
60
4 220 766
Connecting cable (short) - only JUPITER Universal
70
4 099 053
Fuse holder 5x20 mm, bayonet closure
80
4 099 054
Fuse 10 A delay-action 5x20 mm
90
4 221 058
Cable fuse-battery
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
F5
Appendix F
F6
Service Manual JUPITER 4 900 361 - 03/03
Appendix G
Overview of Fuses
Operating Computer
TRUMPF no.: 4 144 703
No.
Des.
Rating
Type
Shape
DIN/IEC
4 099 040
F1
10 A
delay-action
6.3x32
4 099 049
F3
2.5 A
delay-action
5x20
IEC
127-2-5
4 099 042
F4
630 mA
delay-action
5x20
IEC
127-2-3
4 099 042
F5
630 mA
delay-action
5x20
IEC
127-2-3
4 099 034
F6
400 mA
delay-action
5x20
IEC
127-2-3
TRUMPF no.: 4 144 991
No.
Des.
Rating
Type
Shape
4 099 054
F1
10 A
delay-action
5x20
4 099 034
F2
400 mA
delay-action
5x20
IEC
127-2-3
4 099 049
F3
2.5 A
delay-action
5x20
IEC
127-2-5
4 099 042
F4
630 mA
delay-action
5x20
IEC
127-2-3
Service Manual JUPITER 4 900 361 - 03/03
DIN/IEC
G1
Appendix G
Power Pack
Mobile
Fixed
TRUMPF no.: 4 544 121/4 544 181
TRUMPF no.: 4 220 701
No.
Des.
Rating
Type
Shape
4 099 044
4 099 045
F1
230 V
115 V
4A
6.3 A
4 099 044
4 099 045
F2
230 V
115 V
4A
6.3 A
4 099 040
F3
4 099 049
F4
DIN/IEC
delay-action
5x20
IEC
127-2-5
delay-action
5x20
IEC
127-2-5
10 A
delay-action
6.3x32
2.5 A
delay-action
5x20
IEC
127-2-5
Table top Distributor
TRUMPF no.: 4 144 707
No.
Des.
Rating
Type
Shape
4 099 045
F1
6.3 A
delay-action
5x20
DIN/IEC
IEC
127-2-5
Section Control Unit
TRUMPF no.: 4 544 148
G2
No.
Des.
Rating
Type
Shape
DIN/IEC
4 099 045
F1
6.3 A
delay-action
5x20
IEC
127-2-5
4 099 042
F2
630 mA
delay-action
5x20
IEC
127-2-3
4 099 042
F3
630 mA
delay-action
5x20
IEC
127-2-3
Service Manual JUPITER 4 900 361 - 03/03
Appendix G
Power Pack Section Control Component
TRUMPF no.: 4 544 149
No.
Des.
Rating
Type
Shape
DIN/IEC
4 099 041
F1
1.6 A
delay-action
5x20
IEC
127-2-5
4 099 046
F2
230 V
1.0 A
delay-action
5x20
IEC
127-2-5
4 099 046
F3
230 V
1.0 A
delay-action
5x20
IEC
127-2-5
Charging Unit of the IR Control
TRUMPF no.: 4 544 122/4 544 123/4 544 139
No.
Des.
Rating
Type
Shape
4 099 052
F1
32 mA
semi
delay-action
5x20
DIN
41571
4 099 048
F2 24 V
PP only
250 mA
quick-brake
5x20
IEC
127-2-2
Service Manual JUPITER 4 900 361 - 03/03
DIN/IEC
G3
Appendix G
G4
Service Manual JUPITER 4 900 361 - 03/03
Appendix H
Annual Maintenance Work: JUPITER System
SM and SF Columns
Before starting the maintenance work, lift the table top off the column with the shuttle and
separate it from the power supply. Raise the column into its highest position.
No.
Task Description
Test Method
Target Value/Display
1
Check the head covering
visual
no damage
2
Check the contact plate in the
head covering
visual
no contamination
3
Check the pictograms on the
head covering
visual
good recognisability
4
Check the contact condition and visual
covers of NT socket and remote
control socket
no contamination,
no charring
5
Check the potential equalisation
plug on the NT socket
visual
no contamination,
no damage
6
Check the IR receiver
visual
no contaminations
7
Check the rubber bellows
visual
no damage
8
Check the cladding
visual
no damage
9
Check the membrane keypad
visual
no damage
10 Check the position and surface of visual
the takeover sensors and the
presence sensor
no damage,
tightly seated
11 Check the seal round the base
plate
visual
no damage
12 Check the potential equalisation
contact in the base plate
visual
moves easily and
sufficient spring force,
no contamination
13 Check the functioning of all keys press key
all keys function
reliably
14 Test the zero potential of the outer voltmeter
contacts of the contact plate to
the casing
(test program item 1)
no potential difference
between the contacts
and the casing
15 Test the functions of all sensors
(test program item 2)
magnet
sensors switch reliably
16 Check the battery connections
visual
connection terminals
seated securely
17 Check all cables and lines
(and behind the rubber bellows)
for chafing and crushing
(cable layout)
visual
no damage to the
cables and lines and
safely laid
18 Lifting motor fixture
shake
tightly seated
19 Check the condition and tension visual
of the toothed belt of the lifting
motor
Service Manual JUPITER 4 900 361 - 03/03
Actual Value/
Test Remark
no damage,
max. 5 mm inward play
H1
Appendix H
No.
H2
Task Description
Test Method
Target Value/Display
20 Grease the running surfaces on
the column telescope
sufficient lubrication
with spindle grease
21 Check the conditions and tension visual
of the toothed belts for the tilting
drives and Trendelenburg drive
no damage,
max. 5 mm inward play
22 Grease the tilting spindles and
Trendelenburg spindle
spindle grease
sufficient lubrication
with spindle grease
23 Check that all mechanical
elements are tightly seated
(cardans and suspensions for
tilting drives and Trendelenburg
drive)
visual
cardans parallel,
suspensions fixed
securely
24 Check the function of the end
switches for the lifting stroke
visual
switching point must be
in the 1st third of the
actuating diagonal
25 Test the function and switch gap
of the reference stroke
feeler gauge
switch gap
0.2 mm ± 0.1 mm
26 Check the function of the end
switches of the tilting drives and
Trendelenburg drive
visual
switching point must be
in the 1st third of the
actuating diagonal of
the stop nut
feeler gauge
27 Test the functions of the end
switch gaps of the reference tilting
and Trendelenburg drives
switch gap
0.2 mm ± 0.1 mm
28 Test the switch and sensor settings gauges 1-3
gaps as per gauges
1-3
Actual Value/
Test Remark
Service Manual JUPITER 4 900 361 - 03/03
Appendix H
Additional Items for the SF Column
No.
Task description
Test Method
Target Value/Display
29 Test the brake
spring balance reliable switching,
max. adjusting force,
unbreaked < 50 Nm
max. holding force,
braked > 450 Nm
30 Check the sunken base plate for
leaks
visual
no water leaking out
after turning the
column several times, if
necessary, visual check
after dismounting the
column
31 Check the battery
visual
actuate additional lift
for at least 5 min
(without mains)
Actual Value/
Test Remark
Power pack
No.
Task description
Test method
Target Value/Display
32 Check the mains line
visual
no damage
33 Check the connecting line to the
column and plug
visual
no damage,
no charring
34 Check the socket in the power
pack
visual
no damage,
no charring
35 Test the insulation between the
socket and the power pack
circuit tester
no continuity between
casing and socket
36 Check the power supply from the visual
power pack
(connection to the mains, but no
connection to the column)
on the power pack,
only the green LED is
on
37 Check the power pack
(connection made to the
operating table)
all LEDs on the power
pack are on
Service Manual JUPITER 4 900 361 - 03/03
visual
Actual Value/
Test Remark
H3
Appendix H
IR Remote Control
No.
Task description
Test Method
Target Value/Display
38 Check the membrane keypad
visual
no damage
39 Check the suspension
visual
no damage,
tightly seated
40 Check the casing
visual
no damage
41 Check the seal
visual
no damage
42 Check the keys
visual
green LED on when
sending
43 Check the IR code pictogram
visual
easily recognisable
44 Check the EPROM
(Attention ESD)
visual
seated securely
45 Check the battery
visual
seated securely
46 Check the connections and
soldered joints of the battery
cable
visual
reliable soldered joints
and tight connection
Actual Value/
Test Remark
IR Power Pack
No.
H4
Task description
Test Method
Target Value/Display
47 Check the casing
visual
no damage
48 Check the power cable
visual
no damage
49 Check the charging activity
visual
when the power supply
is on, the green LED on
the PP is on, when
using the remote
control, the orange
LED on the remote
control is on
Actual Value/
Test Remark
Service Manual JUPITER 4 900 361 - 03/03
Appendix H
Table top GM
No.
Task Description
Test Method
Target Value/Display
50 Check the pad
visual
no damage,
tightly seated
51 Check the connection plates
visual
no damage,
tightly seated
52 Check the standard rails
visual
no damage,
tightly seated
53 Check the contact pins
visual
move easily and
sufficient spring force,
no contamination
54 Functional test of all sensors
(test program item 2)
magnet
sensors switch reliably
55 Check the sensors (END, REF) of visual,
all motors by approaching the
acoustic
end or zero position
no damage,
no contamination,
seated tightly,
switch gap
0.2 mm ± 0.1 mm
56 Check all cables and lines for
chafing and crushing
(cable layout)
no damage to the
cables and lines, and
safely laid
visual
57 Check the condition and tension visual
of the toothed belt for the
LD-motor
no damage,
max. 5 mm inward play
58 Check the mechanical elements
(motor, gear, bevel wheels,
pedestals)
visual
no damage,
tightly seated
59 Grease bevel wheels
(reduces noise)
spindle grease
sufficient lubrication
with spindle grease
60 Check the locking catches in the
wedge holders
visual
move easily and
sufficient spring force
61 Check the mechanical joints
visual
no play when in the
locked state,
sufficient spring force
and the safety catch
snaps in securely
Service Manual JUPITER 4 900 361 - 03/03
Actual Value/
Test Remark
H5
Appendix H
Testing with PC
No.
H6
Task Description
Test Method
Target Value/Display
62 Read operating computer and
motor computer software
PC
current version
63 Read lifting motor software
PC
current version
64 Read motor control software
PC
current version
65 Read table top motors software
PC
current version
66 Read parameters of the column
motors
PC
correct values
67 Read the parameters of the table PC
top motors
correct values
68 Check the operating computer
clock
correct time
PC
69 Check the IR codes of the column PC
and remote control
identical IR codes on
the labels on the foot of
the column and on the
remote control
70 Check all keys and displays on
the membrane keypad
PC
reliable functioning of
all keys and displays
71 Check all the keys on the
IR remote control
PC
reliable function of all
keys
72 Battery voltage
(without charger)
PC
UB > 36 V
73 Test the charging current
PC
ILmax = 1.2 A
may be less depending
upon the condition of
the batteries
74 Test the external operating
voltage
PC
display "Mains"
75 Test the sensors
PC
reliable switching of all
sensors
76 Test the buzzer
PC
signals are heard
clearly
77 Check and store error memory
and operating hours
PC
no unexplained errors
78 Adjust inclination sensor
PC and test
adjust zero position on
program item 4 a level floor
(record deviation)
79 Test completion
PC
Actual Value/
Test Remark
file report
Service Manual JUPITER 4 900 361 - 03/03
Appendix H
Zero Potential
No.
Task Description
80 Test that the casing is at zero
potential
Test Method
voltmeter
Target Value/Display
Actual Value/
Test remark
no stable potential
difference between
contacts 1/ 2 and
casing
Safety Test as per IEC 601
No.
Task Description
81 Check the protective conductor,
fuses, labels, connection lines,
etc.
Test Method
visual
Target Value/Display
no damage,
no contamination
82 Test the resistivity of the protective testing device
conductor
< 0.2 Ω
83 Test the resistivity of the primary
insulation
testing device
> 2 MΩ
84 Test the earth leakage current
(N interrupted)
testing device
AC < 1 mA
85 Test the patient leakage
(N interrupted)
testing device
AC < 50 µA
86 Test the earth leakage current
(normal conditions)
testing device
AC < 0.5 mA
87 Test the casing leakage current
(normal conditions)
testing device
AC < 100 µA
88 Test the patient leakage current
(normal conditions)
testing device
AC < 10 µA
DC < 10 µA
89 Test the casing leakage current
testing device
(protective conductor interrupted)
AC < 0.5 mA
90 Test the patient leakage current testing device
(protective conductor interrupted)
AC < 50 µA
DC < 50 µA
91 Test the earth leakage current
(normal conditions, polarity
reversed)
testing device
AC < 0.5 mA
92 Test the casing leakage current
(normal conditions, polarity
reversed)
testing device
AC < 0.1 mA
93 Test the patient leakage current
(normal conditions, polarity
reversed)
testing device
AC < 10 µA
DC < 10 µA
94 Test the casing leakage current
testing device
(protective conductor interrupted,
polarity reversed)
AC < 0.5 mA
95 Test the patient leakage current testing device
(protective conductor interrupted,
polarity reversed)
AC < 50 µA
DC < 50 µA
Service Manual JUPITER 4 900 361 - 03/03
Actual Value/
Test Remark
H7
Appendix H
H8
Service Manual JUPITER 4 900 361 - 03/03
Appendix I
Spare parts SM/SF column
Service Manual JUPITER 4 900 361 - 03/03
I1
Feet column SM
Feet column SM
16/2x
1
17/2x
18/2x
3/2x
2
4
5
6
7/7x
8/4x
9/4x
10
11
12
14/20x
13/2x
15/4x
I2
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
4 220 519
Pot
2
4 144 739
Sealing
3
4 081 015
Countersunk socket screw M4x8 DIN7991- A2
4
4 220 443
Cover
5
4 220 430
Ground plate
6
4 220 532
Rubber profile
7
1 215 346
Cylinder head screw M8x30 DIN7984-A2
8
4 220 533
Print plate
9
4 220 534
Rubber foot
10
4 121 031
Pressure spring
11
4 220 825
Spring cage
12
4 220 829
Ring
13
4 081 028
Hexagon socket head cap screw M4x8 DIN912-A2
14
4 081 015
Countersunk socket screw M4x8 DIN7991-A2
15
1 215 411
Countersunk socket screw M6x10 DIN7991-A2
16
4 220 737
Sensor Transfer short
X
17
4 220 738
Sensor Transfer long
X
18
4 220 739
Sensor Presence
X
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
X
I3
Feet column SF
Feet column SF
12/2x
1
13/2x
14
2
3
4
5
6/8x
7
8/6x
9/6x
10
11/6x
I4
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
4 220 519
Pot
2
4 144 739
Sealing
3
4 220 770
Finishing plate
4
4 220 786
Brake rod
5
4129 009
Sliding ring flat IS 17
6
1 215 554
Parallel pin 8M6x20 1.4301 DIN7
7
4 220 771
Brake disc
8
4 144 756
Cover
9
1 215 348
Hexagon socket head cap screw M10x35 DIN7984-A2
10
4 144 751
Needle bearing
11
1 215 362
Hexagon socket head cap screw M8x40 DIN7984-A2
12
4 220 737
Sensor Transfer short
X
13
4 220 738
Sensor Transfer long
X
14
4 220 739
Sensor de Presence
X
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
I5
Brake, column SF
1
Brake, column SF
2
3
7/3x
4
5
6
10
9
11
8
12
16
17
18
13
15/2x
22
20
14
19/2x
21
22
24
25
27/2x
14
25
23
26
28
29
33
31/2x
30
32
I6
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
1 215 443
Hexagon socket head cap screw M5x8 DIN912-A2
2
1 215 507
Disc 5,3 DIN9021 A2
3
4 220 807
Bush teflon
4
4 220 781
Bearing block
5
1 215 358
Hexagon socket head cap screw M6x16 1.4301 DIN912
6
4 220 808
Disc
7
4 081 015
Hexagon socket countersunk head screw
M4x8 DIN7991-A2
8
4 220 806
Pattern carrier
9
4 220 779
Star
10
4 220 778
Pattern
11
4 220 809
Pin
12
4 220 791
Pedal shaft
13
1 215 425
Hexagon socket countersunk head screw
M8x50 DIN7991-A2
14
4 220 795
Linkage
15
1 215 354
Hexagon socket head cap screw M6x30 DIN912-A2
16
4 220 799
Transmission shaft
17
4 213 827
Bolt Ø 6x8
18
4 220 800
Release handle
19
4 081 090
Hexagon socket head cap screw M6x60 DIN912-A2
20
4 121 106
Pressure spring
21
4 220 796
Bearing block
22
4 220 803
Collar bushing
23
4 220 797
Shaft
24
4 220 789
Bush
25
4 220 774
Crank pin
26
4 220 772
Crank
27
4 082 003
Hexagon nut M10x1 DIN934-A2
28
4 220 790
Thrust piece
29
4 220 798
Guide sleeve
30
4 144 753
Sealing rubber
31
4 083 234
Parallel pin D6 M6x30 DIN7-A2
32
4 220 782
Foot pedal
33
4 081 110
Lens head screw M I6KT M4x8
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
I7
Head
Head
31
32
1
2/8x
7
4/2x
3/5x
5
25
24
27
6/5x
8
9/5x
14
15/2x
24
26
11/5x
10/5x
12
16
13
17
22
28/2x
20/4x
23
19/10x
15/2x
16
18
21
14
29/6x
30/6x
I8
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
*
Item no.
Description
SP
1
4 220 340
Head cover
2
4 081 110
Hexagon socket fillister head screw M4x8 ISO7380-A2
3
4 220 375
Bolt, long
4
4 220 540
Insulating foil
5
4 220 374
Coupling
6
1 215 457
Hexagon nut M3
7
4 133 037
Pictogram manual operation
X
8
4 220 716
Connection docking + Circuit board
X
9
4 083 010
Toothed washer A4,3 DIN6797-A2
10
1 215 497
Grommet A4,3 1.4301 DIN125
11
4 079 000
Cylinder head screw AM4x6 DIN84
12
4 220 529
Housing bush charging for SM
X
13
4 220 549
Housing without bush charging for SF
X
14
4 211 723
Cover
X
15a
1 215 379
Hexagon socket head cap screw M10x25 1.4301 DIN912
(to 17a/23a)
15b
1 215 346
Hexagon socket head cap screw M8x25 1.4301 DIN912
(to 17b/23b)
16
1 215 551
Parallel pin 8M6x30 DIN7-A2
17a
4 220 403-L
S-Wedge left (to 22a) (to serial number (SNO) 1 146 488)
17b
4 220 599-L
S-Wedge left (to 22b) (from SNO 1 146 515)
18
4 220 496
Housing Interface socket SB
19
4 144 738
Spacer
20
1 215 459
Hexagon nut M5 1.4301 DIN934
21
4 220 740
Sensor wedge blocking
22a
4 220 405
Head
22b
4 220 595
Head
23a
4 220 403-R S-Wedge right (to 22a)
X
23b
4 220 599-R S-Wedge right (to 22b)
X
24a
4 144 703
Main circuit board
X
24b
4 144 991
Main circuit board (sensor inclination contained)
X*
25
4 102 122
Sensor inclination (only with 4 144 703)
X
26
4 102 123
Control cable 12-core
X
27
4 102 124
Control cable 10-core
X
28
4 081 010
Cylinder head screw AM3x16 DIN84-A2
X
X
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
I9
Head
31
32
1
2/8x
7
4/2x
3/5x
5
25
24
27
6/5x
8
9/5x
14
15/2x
24
26
11/5x
10/5x
12
16
13
17
22
28/2x
20/4x
23
19/10x
15/2x
16
18
21
14
29/6x
30/6x
I10
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
29
4 102 084
Cable bushing Sensors Foot
4 102 083
Cable bushing Cable Accumulator
4 102 083
Cable bushing UB MS
4 102 084
Cable bushing Data MS
4 102 087
Cable bushing Touch panel column
4 102 087
Cable bushing Cable SF
4 220 714
Terminal block 1
X
4 220 713
Cable Accumulator connection
X
4 220 711
Cable Motor control DATA
X
4 220 710
Cable Motor control UB
X
4 220 715
Cable Touch panel
X
4 220 727
Cable supply Fixed version
X
31
1 216 352
Label earth clamp
X
32
4 133 038
Pictogram charge
X
30
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
I11
Main drive
1
2
Main drive
3
13
4
14
5/4x
15/6x
7
6/4x
8/4x
12
9
11
10
16
17/4x
18
19
12
20
19
21
22
24
23/5x
25
I12
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
Description
SP
1
4 220 712
Cable main lift motor
X
2
4 220 721
Sensor contact Lift up
X
3
4 220 720
Sensor contact Lift down
X
4
4 144 719-E Motor lift with brake (incl. Pos. 6, 7, 9, 10, 11)
5
4 075 007
Hexagon socket head cap screw M5x35
6
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
7
4 220 333
Motor holding (main drive)
8
4 220 329
Stay bolt
9
4 220 389
Pinion, main drive
10
4 220 337
Disc, main drive
11
4 081 015
Hexagon socket countersunk head screw M4x8
12
4 144 745
Toothed belt
13
4 220 359
Ball spindle with nut
14
4 220 323
Coupling
15
1 215 371
Hexagon socket head cap screw M6x12
16
4 220 322
Adapter ring
17
1 215 353
Hexagon socket head cap screw M6x40
18
4 220 321
Bearing cover
19
4 130 027
Roller-bearing
20
4 220 348
Toothed disc
21
4 220 320
Bearing support
22
4 220 517
Spacer plate
23
4 075 006
Hexagon socket head cap M6x8
24
4 144 746
Locking washer
25
4 144 744
Lock nut
Service Manual JUPITER 4 900 361 - 03/03
X
X
I13
Trendelenburg drive
Trendelenburg
drive
1
2
3
4/4x
4/6x
5/4x
6
20/6x
8
7/4x
26
19
9
10
14
18
25
35
8
34
24
34
36
11
34
23
13
34
27
14
12
19
28
16/4x
31
9
22/4x
32
15
29
16/4x
21
33
17
18
34
30
34
19
34
I14
19
34
20/6x
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
4 081 015
Hexagon socket countersunk head screw M4x8
2
4 220 500
Disc additional drive
3
4 220 420
Belt pinion
4
4 075 007
Hexagon socket head cap screw M5x35
5
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
6
4 220 331
Motor support
7
4 220 328
Stay bolt
8
4 130 027
Roller-bearing
9
4 220 495
Bearing assembly
10
4 220 728
Trendelenburg sensor TR 1.1
11
4 144 742
Slotted nut self-locking
12
4 144 783
Motor Trendelenburg
13
see Pos. 29
Stop nut
14
4 081 028
Hexagon socket head cap screw M4x8
15
4 144 736
Slotted nut self-locking
16
1 215 358
Hexagon socket head cap screw M6x16 1.4301 DIN912
17
4 220 363
Cardan bearing Trendelenburg
18
4 220 361
Cardan
19
4 220 364
Cardan bearing block
20
1 215 355
Hexagon socket head cap screw M8x20
21
4 220 345
Hangers Trendelenburg
22
1 215 379
Hexagon socket head cap screw M10x25 1.4301 DIN912
23
4 220 412
Spindle tube Trendelenburg
24
see Pos. 29
Spindle nut
25
4 220 424
Bush Trendelenburg
26
4 220 421
Belt wheel
27
4 220 516
Bearing angle
28
4 083 212
Dowel pin 4x50
29
4 220 538
Trapezoidal spindle Trendelenburg with spindle nut
30
4 144 741
Toothed belt
31
1 215 458
Hexagon nut M4
32
4 079 025
Hexagon screw M4x30
33
4 220 365
Bearing angle Trendelenburg support
34
4 144 463
Bush DU
35
1 215 497
Grommet A4,3 1.4301 DIN125
36
4 220 366
Cardan bearing
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
X
I15
Tilt drive, left
Tilt drive, left
1
4/6x
21/6x
2
16
22
3
4/4x
23
15
5/4x
6
22
34
14
34
34
24
7/4x
25
34
13
26
8
12
11
20
27
31
32
35
10/4x
30
9
12
28
33
18
19
17
I16
29
20
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
4 081 015
Hexagon socket countersunk head screw M4x8
2
4 220 500
Disc additional drive
3
4 220 420
Belt pinion
4
4 075 007
Hexagon socket head cap screw M5x35
5
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
6
4 220 331
Motor support
7
4 220 328
Stay bolt
8
4 220 718
Sensor Tilt left
9
4 220 495
Bearing assembly
10
1 215 379
Hexagon socket head cap screw M10x25 1.4301 DIN912
11
4 220 360
Housing 1 tilt drive left
12
4 130 027
Roller-bearing
13
4 220 344
Spindle type tilt
14
see Pos. 28
Spindle nut
15
4 220 423
Bush tilt
16
4 220 421
Belt wheel
17
4 144 782
Motor tilt left
18
4 144 742
Slotted nut self-locking
19
see Pos. 28
Stop nut
20
4 081 028
Hexagon socket head cap screw M4x8
21
1 215 355
Hexagon socket head cap screw M8x20
22
4 220 364
Cardan bearing block
23
4 220 361
Cardan
24
4 220 366
Cardan bearing
25
4 220 367
Bearing angle
26
4 083 212
Dowel pin 4x50
27
1 215 358
Hexagon socket head cap screw M6x16 1.4301 DIN912
28
4 220 536
Trapezoidal spindle tilt complete
29
4 144 741
Toothed belt
30
4 220 356
Housing 2 tilt drive left
31
1 215 458
Hexagon nut M4
32
4 079 026
Hexagon screw M4x16
33
4 144 851
Bush DU
34
4 144 463
Bush DU
35
1 215 497
Grommet A4,3 1.4301 DIN125
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
I17
Tilt drive, right
Tilt drive, right
10/6x
1/6x
2
11
3
30
29
2
35
12
35
4
28
10
27/4x
35
26
13
5
6
35
25/4x
14
37/2x
24
7/4x
31
32
36
15
17
8
34
16
18
35
23
33
9
21
15
19
20
21
I18
22
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
1 215 355
Hexagon socket head cap screw M8x20
2
4 220 364
Cardan bearing block
3
4 220 361
Cardan
4
4 220 366
Cardan bearing
5
4 220 367
Bearing angle
6
4 083 212
Dowel pin 4x50
7
1 215 358
Hexagon socket head cap screw M6x16 1.4301 DIN912
8
4 220 536
Trapezoidal spindle tilt complete
9
4 144 741
Toothed belt
10
4 075 007
Hexagon socket head cap screw M5x35
11
4 220 421
Belt wheel
12
4 220 423
Bush tilt
13
see Pos. 8
Spindle nut
14
4 220 344
Spindle pipe tilt
15
4 130 027
Roller-bearing
16
4 220 495
Bearing assembly
17
4 220 325
Housing 2 tilt drive right
18
4 220 324
Housing 1 tilt drive right
19
4 144 742
Slotted nut self-locking
20
see Pos. 8
Stop nut
21
4 081 028
Hexagon socket head cap screw M4x8
22
4 144 781
Motor tilt right
X
23
4 220 717
Sensor tilt right
X
24
1 215 379
Hexagon socket head cap screw M10x25 1.4301 DIN912
25
4 220 328
Stay bolt
26
4 220 331
Motor support
27
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
28
4 220 420
Belt pinion
29
4 220 500
Disc additional drive
30
4 081 015
Hexagon socket countersunk head screw M4x8
31
1 215 458
Hexagon nut M4
32
4 079 026
Hexagon screw M4x16
33
1 215 497
Grommet A4,3 1.4301 DIN125
34
4 144 851
Bush DU
35
4 144 463
Bush DU
36
4 220 439
Switching strip
37
1 215 429
Hexagon socket countersunk head screw M4x10
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
I19
Lift Sensors/Cables Motor Control
1
2 / 2 x
1
2 / 2 x
3
Lift Sensors/Cables Motor Control
4
5
2 / 2 x
6
7
8
9
1 0
5
1 1
1 2
1 3 / 2 x
L 1
L 2
L 3
L 4
L 5
L 6
L 7
L 8
L 9
L 1 0
L 1 1
L 1 2
I20
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
4 220 720
Sensor contact Lift down
2
4 079 000
Hexagon socket cap screw MI6K M4x6
3
4 220 406
End position main lift
4
1 215 397
Hexagon socket head cap screw M4x16 DIN912-A2
5
4 220 721
Sensor contact Lift up
6
1 215 497
Grommet A4,3 1.4301 DIN125
7
4 081 028
Hexagon socket head cap screw M4x8
8
4 083 010
Toothed disc A4,3
9
4 101 041
Plastic clamp
10
4 220 714
Terminal block 1
X
11
4 220 713
Cable Accumulator connection
X
12
4 220 712
Cable main lift motor
X
13
1 215 594
Cable holder, middle
L1
4 144 782
Motor tilt left (refers only to cable)
X
L2
4 144 783
Motor Trendelenburg (refers only to cable)
X
L3
4 144 781
Motor tilt right (refers only to cable)
X
L4
4 220 717
Sensor tilt right
X
L5
4 220 728
Sensor Trendelenburg
X
L6
4 220 718
Sensor tilt left
X
L7
4 220 711
Cable motor control Data
X
L8
4 144 782
Motor tilt left (refers only to cable)
X
L9
4 144 783
Motor Trendelenburg (refers only to cable)
X
L10
4 144 781
Motor tilt right (refers only to cable)
X
L11
4 220 710
Cable motor control UB
X
L12
4 220 712
Cable main lift motor
X
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
I21
Column, upper part
1/4x
Column, upper part
1/4x
2
3
3
7/4x
4/4x
17
10
5
6
19/2x
5/2x
20/4x
21
18/12x
11/4x
8/2x
22
23
12
13/4x
9
14/8x
15
I22
16/8x
1/4x
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
Item no.
1
1 215 364
Hexagon socket head M8x16 1.4301 DIN912
2
4 145 367
Rubber belt
3
4 220 379
Frame for rubber belt
4
1 215 443
Hexagon socket head cap screw M5x8
5
4 220 484
Frame part 1
6
4 220 485
Frame part 2
7
1 215 378
Hexagon socket head cap screw M5x12 1.4301 DIN912
8
1 215 429
Hexagon socket countersunk head screw M4x10
9
4 220 377
Plate touch panel
10
4 144 714
Circuit board adapter
11
4 144 852
Bush
12
4 220 368
Cardan shaft
13
4 220 369
Bearing
14
1 215 355
Hexagon socket head cap screw M8x20
15
4 220 358
Cardan plate
16
4 081 116
Hexagon socket head cap screw M8x12
17
4 220 715
Cable touch panel
18
1 215 458
Hexagon nut M4
19
1 215 507
Disc 5,3 DIN9021 A2
20
4 144 738
Spacer
21
4 081 028
Hexagon socket head cap screw M4x8
22
1 215 497
Grommet A4,3 1.4301 DIN125
23
4 083 010
Toothed disc A4,3
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
I23
Column, lower part
Column, lower part
1
2
13/6x
5
3/12x
4
10
6
7
8
11
9
12/20x
14
13/2x
I24
Service Manual JUPITER 4 900 361- 03/03
Appendix I
Pos.
*
Item no.
Description
SP
1
1 219 313
Tilt drive, left
X*
2
4 220 304
Guidance
3
1 215 379
Hexagon socket head cap screw M10x25 1.4301 DIN912
4
1 219 312
Tilt drive, right
X*
5
4 220 445
Cover upper part, complete
X
6
4 220 446
Cover middle part 3, complete
X
7
4 220 447
Cover middle part 2, complete
X
8
4 220 448
Cover middle part 1, complete
X
9
4 220 449
Cover lower part, complete
X
10
1 219 311
Trendelenburg drive
X*
11
4 220 307
Motor main lift
X*
12
1 215 408
Countersunk screw M3x4
13
1 215 406
Countersunk screw M3x6
14
4 144 706
Touch panel column JUPITER
X
4 144 035
Touch panel column JUPITER Universal EU
X
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
I25
Motor control
Motor control
1
2/3x
3/3x
5
4/2x
3/3x
24
2/3x
10
9/2x
6
13/2x
11
17
7/2x
8
14
13/2x
12/2x
7/2x
26/3x
25
15/2x
16/2x
3
2/2x
2/2x
19
22
21
18
23
20
16/3x
22/2x
13/2x
I26
Service Manual JUPITER 4 900 361- 03/03
Appendix I
*
Pos.
Item no.
Description
SP
1
4 220 347
Cover plate
2
4 079 000
Cylinder head screw AM4x6 DIN 84
3
1 215 458
Hexagon nut M4
4
4 220 441
Clamp plate
5
1 215 344
Hexagon socket head cap screw M5x10 1.4301 DIN912
6
4 220 341
Insert
7
4 081 015
Hexagon socket head cap screw M4x8
8
4 144 743
Energy chain
9
1 215 371
Hexagon socket head cap screw M6x12
10
4 220 376
Assembly plate
11
1 215 343
Hexagon socket head cap screw M4x12
12
1 215 406
Countersunk screw M3x6
13
1 215 421
Hexagon socket head cap screw M8x16
14
4 220 509
Energy chain plate
15
1 215 367
Hexagon socket head cap screw M5x16
16
1 215 497
Grommet A4,3 1.4301 DIN125
17
4 220 425
Side plate
18
4 220 362
Tightening strap
19
4 083 010
Toothed disc A4,3
20
4 102 033
Cable clamp
21
4 220 761
Accumulator plate SF
22
4 081 028
Hexagon socket head cap screw M4x8
23
4 220 522
Accumulator plate SM
24
4 144 704
Motor control
X*
25
4 144 764
Accumulator, 12 V, 2 Ah SF
X
26
4 144 324
Accumulator, 12 V, 10 Ah SM
X
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
I27
I28
Service Manual JUPITER 4 900 361- 03/03
Appendix J
Spare parts GM Table top
Service Manual JUPITER 4 900 361 - 03/03
J1
Seat plate
Seat plate
3
1
4
3
2
5
J2
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Item no.
1
4 145 382
Cushion Seat plate
X
2
4 220 120
Seat plate base
X
3
4 220 119
Bolt for cushion support
4
1 215 393
Hexagon socket countersunk head screw M8x20
1.4301 DIN7991
5
4 220 125
Distance plate Seat plate
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
J3
Back plate
Back plate
1
3
4
3
2
5
J4
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Item no.
1
4 145 381
Cushion Back plate 1
X
2
4 220 121
Plate Back plate 1
X
3
4 220 119
Bolt for cushion support
4
1 215 393
Hexagon socket countersunk head screw M8x20
1.4301 DIN7991
5
4 220 126
Distance plate Back plate 1
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
J5
Leg plate joint
Leg plate joint
5
6
2/4x
1
7/2x
4/4x 3
8
6
9/3x
5
17
10/3x
11
9/3x
10/3x
16
J6
15
14
13
12
12
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Description
SP
1
1 219 237
Motor Table Top, Back plate and Leg plate
(incl. Pos. 3 and 4)
2
1 215 378
Hexagon socket head cap screw M5x12 1.4301 DIN912
3
4 220 034
Flange
4
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
5
4 220 026
Slide disc
X
6
4 144 727
Sealing
X
7
4 083 130
Dowel pin 8M6x16 DIN7-A2
8
4 220 025-E Gear
9
4 081 059
Hexagon socket countersunk head screw M4x16
1.4301 DIN7991
10
4 083 208
Dowel pin D10 M6x24 1.4305 DIN7979
11
4 220 099-R Cap right
4 220 099-L
Cap left
12
1 215 424
Hexagon socket countersunk head screw M8x35
1.4301 DIN7991
13
4 220 101
Standard rail hinge
14
4 220 100-R Spacer right
4 220 100-L
Soacer left
15
4 220 736
Sensor addition
16
4 220 095-R Joint leg plate right
17
*
Item no.
4 220 095-L
Joint leg plate left
4 144 726
O-ring
X*
X
X
X
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
J7
Seat plate spar
Seat plate spar
4/3x
2/2x
5/4x
9
6
1
10
7
9
8
11/3x
16
12/3x
17/3x
18/3x
39/2x
3
20/2x
40
21/4x
38
14
11/3x
26/2x
19
22
13
15
23
12/3x
27/2x
24
35
31
34/2x
25
25
28/2x
36
29
30/3x
37/3x
32
33/3x
J8
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
1
Item no.
Description
SP
4 220 122-R Cap assembling window right
X
4 220 122-L
Cop assembling window left
X
2
4 081 059
Hexagon socket countersunk head screw M4x16
1.4301 DIN7991
3
4 144 739
Sealing
4
4 081 065
Countersunk screw M3x4 DIN965-A2
5
4 081 107
Countersunk screw M3x12 DIN965-A2
6
4 220 105-R Cap right
4 220 105-L
7
Cap left
4 220 102-R Cable routing right
4 220 102-L
Cable routing left
8
4 220 112
Spacer
9
4 144 727
Sealing
10
4 220 025-E Gear
11
4 083 208
Dowel pin D10 M6x24 1.4305 DIN7979
12
4 081 059
Hexagon socket countersunk head screw M4x16
1.4301 DIN7991
13
4 220 057-R Cap right
4 220 057-L
Cap left
14
4 220 056
Cable routing
15
4 220 732
Cable Back plate
16
4 102 088
Cable bush
17
4 081 017
Hexagon socket head cap screw M4x8 DIN7984-A2
18
1 215 497
Grommet A4,3 1.4301 DIN125
19
4 220 955
Cassette rail SP
20
4 081 065
Countersunk screw M3x4 DIN965-A2
21
4 081 107
Countersunk screw M3x12 DIN965-A2
21a
4 081 117
Countersunk screw M3x16 DIN965-A2
(for end position longitudinal movement)
21b
4 220 118
End position (for longitudinal movement)
22
4 220 090-R Cable routing joint leg plate right
4 220 090-L
23
X
X
X
X
Cable routing joint leg plate left
4 220 094-R Cap right
4 220 094-L
Cap left
24
4 220 111
Spacer
25
4 220 735
Sensor End/Ref
26
4 083 229
Screwed pin M4x4 DIN 913-A2
Service Manual JUPITER 4 900 361 - 03/03
X
J9
Seat plate spar
4/3x
2/2x
5/4x
9
6
1
10
7
9
8
11/3x
16
12/3x
17/3x
18/3x
39/2x
3
20/2x
40
21/4x
38
14
11/3x
26/2x
19
22
13
15
23
12/3x
27/2x
24
35
31
34/2x
25
25
28/2x
36
29
30/3x
37/3x
32
33/3x
J10
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Item no.
Description
27
1 215 364
Hexagon socket head M8x16 1.4301 DIN912
28
1 215 430
Hexagon socket countersunk head screw M6x12
1.4301 DIN7991
29
4 220 043-R Toothed rack right
4 220 043-L
Toothed rack left
30
1 215 345
Hexagon socket head cap screw M5x16 1.4301 DIN912
31
4 083 104
Dowel pin 6 M6x18 DIN7-A2
32
4 220 039-R Cover plate right
SP
4 220 039-L
Cover plate left
33
4 081 071
Countersunk screw M3x6 DIN965-A2
34
4 210 636
Spacer sleeve
35
4 220 127
Spacer sleeve
36
4 220 123
Standard rail Seat plate
37
1 215 428
Hexagon socket countersunk head screw M8x40
1.4301 DIN7991
38
4 144 726
O-ring
39
1 215 278
Cylinder head screw AM3x12 1.4301 DIN84
40
4 145 562
Cable Leg plate left
X
4 145 563
Cable Leg plate right
X
Service Manual JUPITER 4 900 361 - 03/03
X
J11
Back plate spar
Back plate spar
5
6
2
7
1/2x
9
30
10
3
4/2x
21/2x
16
12
8/3x
20/2x
15
13
19/3x
18
22/2x
11
14
17/3x
23/2x
25/4x
28/2x
24
26
27/4x
29
J12
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
*
Item no.
Description
SP
1
4 081 059
Hexagon socket countersunk head screw M4x16
1.4301 DIN7991
2
4 220 122-R Cap assembling window right
X
4 220 122-L
Cap assembling window left
X
3
4 102 088
Cable bush
4
1 215 278
Cylinder head screw AM3x12 1.4301 DIN84
5
4 220 086
Tension bolt
6
4 220 139
Pressure sleeve
7
4 220 085-R Joint Back plate right
X
4 220 085-L
Joint Back plate left
8
4 121 096
Cup spring
X
9
4 083 082
Shim ring 18x25x0.1 DIN988, ST
X
10
4 083 083
Shim ring 18x25x0.2 DIN988, ST
X
11
4 220 147
Pressure plate
X
12
4 213 606
Pin
13
4 220 010
Lever, small
X
14
4 220 088
Eccentric lever
X
15
4 083 072
Dowel pin 4M6x24 DIN7-A2
16
4 121 033
Pressure spring
17
4 210 636
Distance bush
18
4 220 124
Standard rail Back plate
19
1 215 428
Hexagon socket countersunk head screw M8x40
1.4301 DIN7991
20
1 215 364
Hexagon socket head cap screw M8x16 1.4301 DIN912
21
4 083 229
Screwed pin M4x4 DIN 913-A2
22
4 220 735
Sensor End/Ref
23
1 215 430
Hexagon socket countersunk head screw M6x12
1.4301 DIN7991
24
1 219 237
Motor Back plate/Leg plate (incl. Pos. 25 and 26)
25
1 215 378
Hexagon socket head cap screw M5x12 1.4301 DIN912
26
4 220 034
Collar
27
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
28
4 083 130
Dowel pin 8 M6x16 DIN7-A2
29
4 220 025-E Gear
X
30
4 144 739
X
Sealing
X
X*
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
J13
Connecting plate
Connecting plate
1
3
2/4x
1
1
1
2/4x
7
6/4x
4
9
10
5
8/2x
15/4x
11/4x
19
20
5
17 18
12/2x
18
13
15/4x
13
16
11/6x
14
J14
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
*
Item no.
Description
SP
1
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
2
4 081 015
Hexagon socket countersunk head screw M4x8
DIN7991-A2
3
4 220 106
Cover
4
1 215 306
Cylinder head screw AM4x5 1.4301 DIN84
5
4 102 033
Clip for cable
6
1 215 438
Hexagon socket countersunk head screw M5x10
1.4301 DIN7991
7
4 220 061
Motor support
8
1 215 344
Hexagon socket head cap screw M5x10 1.4301 DIN912
9
4 220 074
Toothed disc
X
10
1 219 238
Motor Longitudinal (incl. Pos. 6, 7 and 9)
X*
11
1 215 378
Hexagon socket head cap screw M5x12 1.4301 DIN912
12
1 215 345
Hexagon socket head cap screw M5x16 1.4301 DIN912
13
4 220 073
Clamping collar
14
4 144 721
Linear guidance
15
1 215 422
Hexagon socket head cap screw M6x12 1.4301 DIN7984
16
1 216 159
Magnet
17
1 215 396
Hexagon socket head cap screw M4x10 1.4301 DIN912
18
1 215 397
Hexagon socket head cap screw M4x16 DIN912-A2
19
4 081 028
Hexagon socket head cap screw M4x8 DIN912-A2
20
1 215 497
Grommet A4,3 1.4301 DIN125
X
See table under "Second-hand parts" on page N-2
Service Manual JUPITER 4 900 361 - 03/03
J15
Wedge holding
Wedge holding
1
2/2x
1
2/2x
2/2x
2/2x
1
1
3
4
9
5/2x
5/2x
10
6
7
11
8
25
16
12
5/4x
15
5/2x
13
17
18 19
26
14
20
21
20
21
23
17/4x
J16
22
24
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Item no.
Description
SP
1
1 215 579
Groove pin 6x16 1.4301 DIN1473
2
4 081 012
Hexagon socket head cap screw M8x12 DIN7984-A2
3
4 144 720
Energy chain
X
4
4 145 562
Cable Leg plate left
X
4 145 563
Cable Leg plate right
X
5
4 081 071
Countersunk screw M3x6 DIN965-A2
6
4 081 072
Hexagon socket head cap screw M5x16 DIN7984-A2
7
4 211 517
Lever
8
4 211 521
Collar bushing, twisted
9
4 211 524
Stuffing
10
4 121 040
Pressure spring
11
4 081 017
Hexagon socket head cap screw M4x8 DIN7984-A2
12
4 220 185
Latch
13
4 083 105
Locking washer 7 DIN6799-A2
14
4 220 187
Pin
15
4 220 014-R Wedge holding right
4 220 014-L
Wedge holding left
16
4 220 018
Holding for bushing
17
4 102 111
Lid
X
18
4 102 113
Socket
X
19
4 220 731
Cable Additional components/Section control unit
X
20
1 215 404
Hexagon socket head cap screw M8x60 1.4031 DIN912
21
4 220 128
Dowel pin
22
4 220 020
Cover left
23
4 220 017
Cover
24
4 133 068
Pictogram JUPITER
25
4 144 449
Collar bushing
26
4 220 110
Lid
Service Manual JUPITER 4 900 361 - 03/03
X
J17
Contact plate
Contact plate
3
1/4x
2/4x
7
4
8
5
6
9
10
11/4x
12/5x
13/5x
14/5x
19/2x
6
20
15/3x
16/3x
17/3x
18
23
3
25/3x
21/3x
22/2x
6
26
24/2x
J18
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Item no.
1
4 081 028
Hexagon socket head cap screw M4x8 DIN912-A2
2
1 215 497
Grommet A4,3 1.4301 DIN125
3
4 220 731
Cable Additional component/Section control unit
X
4
4 145 563
Cable Leg plate right
X
5
4 145 562
Cable Leg plate left
X
6
4 220 729
Sensor Ref/OR
X
7
4 220 735
Sensor End/Ref
X
8
4 220 730
Cable Docking part
X
9
4 099 045
Fuse 6.3 A
X
10
4 144 707
Circuit board-distribution Table top
X
11
4 083 213
Spacer bolt
12
4 081 028
Hexagon socket head cap screw M4x8 DIN912-A2
13
1 215 497
Grommet A4,3 1.4301 DIN125
14
4 083 010
Toothed disc A4,3 DIN6797-A2
15
4 081 028
Hexagon socket head cap screw M4x8 DIN912-A2
16
1 215 497
Grommet A4,3 1.4301 DIN125
17
4 083 010
Toothed disc A4,3 DIN6797-A2
18
1 215 399
Hexagon socket head cap screw M5x25 1.4301 DIN912
19
4 081 047
Hexagon socket head cap screw M3x14 DIN912-A2
20
4 144 740
Clamp block
21
4 220 024
Contact pin
22
4 081 103
Hexagon socket head cap screw M3x6
23
4 220 023
Contact plate
24
4 081 015
Hexagon socked countersunk head screw M4x8
DIN7991-A2
25
4 121 105
Pressure spring
26
4 220 027
Lid, contact plate
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
J19
Gear
Gear
2
1
4
3
7
5
10
6
8
9/2x
2
1
4
11
10
8
3
9/2x
J20
Service Manual JUPITER 4 900 361 - 03/03
Appendix J
Pos.
Description
SP
4 220 021-R Gear Longitudinal movement, right
X
4 220 021-L
Gear Longitudinal movement, left
X
2
4 083 118
Dowel pin 4M6x20 DIN7-A2
3
4 220 011
Cone wheel, pair
4
4 083 025
Screwed pin M5x8 DIN915-A2
5
4 144 724
Toothed belt
X
6
4 220 071
Toothed disc
X
7
4 083 044
Screwed pin M5x10 DIN915-A2
8
4 220 072
Bearing support
9
1 215 344
Hexagon socket head cap screw M5x10 1.4301 DIN912
10
4 130 024
Ball bearing 61801 DIN625
11
4 220 008
Shaft
1
Item no.
Service Manual JUPITER 4 900 361 - 03/03
X
J21
J22
Service Manual JUPITER 4 900 361 - 03/03
Appendix K
Spare parts Shuttle 1, Shuttle 2, Shuttle 3
Service Manual JUPITER 4 900 361 - 03/03
K1
Shuttle 1
K2
1 9
1 6
4
7
6
5
1 5
1 4
1 3
1 3
2 1
1 7
2 3
2 2
1 6
3 3
3 9
1 8
4 5
2 0
Service Manual JUPITER 4 900 361 - 03/03
6 1
6 2
5 9 / 4 x
6 0
9 / 3 x
1 0 / 3 x
4 9 / 3 x
6 5
6 3
5 4
5 0 / 2 x
5 3
5 8
3 9
4 6 / 3 x
5 1
9 / 2 x
1 0 / 2 x
4 2 / 2 x
9 / 2 x
1 0 / 2 x
5 2 / 2 x
3 5
4 7
4 3
5 9 / 4 x
6 1
6 4
6 6
2 9
3 5
3 1
3 7
3 8
4 4
1 6
2 3
4 8
4 3
6 1
5 5
3 4
4 0
4 1
2 7
3 4
3 3
3 6
6 2
2 8
1 6
3
2
2 0
2 3
2 4
3 5
5 6
5 7
Shuttle 1
1 /4 x
8
9 /4 x
1 0 / 4 x
1 1 / 4 x
1 2
1 8
3 0
3 2
2 8
2 6
2 5
Appendix K
Pos.
Item no.
1
1 215 429
Hexagon socket countersunk M4x10
2
4 231 334
Sliding plate
3
4 231 333
Initiator plate
4
4 231 039
Distance plate
5
4 121 013
Pressure spring
6
4 231 015
Initiator core
7
4 231 017
Sliding piece
8
4 231 446
Initiator housing
9
1 215 500
Grommet A6,4 1.4301 DIN125
10
1 215 489
Spring washer B6
11
1 215 351
Hexagon socket head cap screw M6x20
12
1 215 501
Grommet A8,4
13
4 121 031
Pressure spring
14
4 231 016
Counter bearing
15
1 215 456
Hexagon nut M8
16
4 144 124
Clevis for gas spring
17
4 144 155
Bolt BEK 8x20x16,5 MBO
18
4 231 445
Slide bar
19
4 144 156
Locking ring
X
20
1 215 783
Adjusting feet
X
21
4 231 014
Bolt
22
4 231 031
Clevis
23
4 144 167
Spring bolt
24
4 231 009
Threaded rod
25
4 121 030
Pressure spring
26
4 084 005
Rived 2.5x16
27
4 231 012
Lever arm
28
1 215 344
Hexagon socket head cap screw M5x10 1.4301 DIN912
29
4 231 010
Cross shaft
30
4 231 008
Lever arm, simple
31
4 231 011
Switch button
32
1 215 691
Threaded pin with finger M6x10
33
4 231 049
Bush
34
4 145 014
Cap
X
35
4 145 011
Cap
X
36
4 133 026
Pictogram Plate support
X
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
X
K3
Shuttle 1
K4
1 9
1 6
8
1 /4 x
4
2 1
1 5
1 4
1 3
1 3
1 7
2 3
2 2
9 /4 x
1 0 / 4 x
1 1 / 4 x
7
6
5
1 2
1 8
1 6
3 5
3 3
3 9
1 8
4 5
2 0
Service Manual JUPITER 4 900 361 - 03/03
6 1
6 2
5 9 / 4 x
6 0
9 / 3 x
1 0 / 3 x
4 9 / 3 x
6 5
6 3
5 4
5 0 / 2 x
5 3
5 8
3 9
4 6 / 3 x
5 1
9 / 2 x
1 0 / 2 x
4 2 / 2 x
9 / 2 x
1 0 / 2 x
5 2 / 2 x
3 5
4 7
4 3
5 9 / 4 x
6 1
6 4
6 6
2 9
3 5
3 1
3 7
3 8
4 4
1 6
2 3
4 8
4 3
6 1
5 5
3 4
4 0
4 1
2 7
3 4
3 3
3 6
6 2
2 8
1 6
3
2
2 0
2 3
2 4
5 6
5 7
3 0
3 2
2 8
2 6
2 5
Appendix K
Pos.
Item no.
37
4 133 025
Pictogram Start
X
38
4 133 027
Pictogram Wheel function
X
39
4 145 012
Cap
X
40
4 133 072
Pictogram TRUMPF
X
41
4 231 028
Wheel support, front
42
1 215 354
Hexagon socket head cap screw M6x30 DIN912-A2
43
4 081 058
Hexagon socket head cap screw M8x10
44
4 231 007
Fender, pair
45
4 082 012
Pop rivet nut
46
1 215 579
Groove pin 6x16 1.4301 DIN1473
47
4 083 008
Disc 15
48
4 231 041
Initiator bush
49
1 215 352
Hexagon socket head cap screw M6x25
50
1 215 434
Hexagon socket countersunk head screw M6x20
51
4 231 003
Initiator plate
52
1 215 460
Hexagon nut M6 1.4301 DIN934
53
4 231 025
Wheel support, back
54
4 083 128
Dowel pin 4x16
55
4 231 269
Threaded rod
56
4 231 045
Switch bush
57
4 144 165
Rubber ball Ø 50
58
4 231 048
Hexagon shaft
59
1 215 371
Hexagon socket head cap screw M6x12
60
4 231 004
Hexagon shaft
61
4 145 022
Bearing bush
62
4 129 006
Rubber disc
63
4 231 034
Gear shift control, pair
64
4 231 109
Adjusting disc
65
4 145 432
Wheel, front
X
66
4 145 431
Wheel, back
X
Service Manual JUPITER 4 900 361 - 03/03
Description
PR
X
K5
Shuttle 2 / Shuttle 3
S h u ttle 2
Shuttle 2 / Shuttle 3
S h u ttle 3
1
2
3
4
5
6
7
8
9
3 8
1 0
3 9
1 1
1 2
S h u ttle 3
1 9
2 0
1 3
2 1
1 5
1 6
1 7
1 8
2 2
1 4
2 3
2 4
2 5
2 6
2 7
2 8
2 9
3 0
3 1
3 2 1 6
1 7
1 8
1 7
1 6
3 4
3 5
3 6 3 7
3 3
K6
Service Manual JUPITER 4 900 361 - 03/03
Appendix K
Part.
Item no.
1
1 215 430
Hexagon socket countersunk head screw M6x12
1.4301 DIN7991
2
4 083 022
Locking washer
3
1 215 504
Grommet 13,0 1.4301DIN125
4
4 231 387
Lever
5
4 144 191
Switch button
6
4 231 413
Lever
7
4 231 375
Driving unit complete Shuttle 2
X
8
4 231 381
Driving unit complete Shuttle 3
X
9
4 231 403
Locking device
10
1 215 359
Hexagon socket head cap screw M5x12
11
4 083 022
Locking washer
12
4 231 373
Pivot
13
4 081 103
Hexagon socket head cap screw M3x6
14
4 081 026
Countersunk screw M4x6
15
4 231 426
Lid
16
4 082 004
Hexagon nut M6 DIN439-A2
17
4 230 575
Adjusting screw
18
4 101 020
Bowden cable Shuttle 2
X
4 101 021
Bowden cable Shuttle 3
X
19
4 081 065
Countersunk screw M3x4
20
4 231 436
Cover complete
21
1 215 357
Hexagon socket head cap screw M10x40
22
4 144 178
Hydraulic aggregat lift
23
1 215 423
Hexagon socket countersunk head screw M8x16
24
4 212 270
Clamp right
25
4 212 269
Clamp left
26
1 215 545
Parallel pin 8 M6x24
27
4 231 204
Pump lever
28
4 144 112
Rubber pedal
29
4 231 103
Sliding piece
30
4 121 002
Pressure spring
31
4 231 410
Pipe
32
4 231 102
Locking screw
33
1 215 572
Parallel pin 3 M6x8
34
4 231 427
Snap into position housing
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
X
X
X
K7
Shuttle 2 / Shuttle 3
S h u ttle 2
S h u ttle 3
1
2
3
4
5
6
7
8
9
3 8
1 0
3 9
1 1
1 2
S h u ttle 3
1 9
2 0
1 3
2 1
1 5
1 6
1 7
1 8
2 2
1 4
2 3
2 4
2 5
2 6
2 7
2 8
2 9
3 0
3 1
3 2 1 6
1 7
1 8
1 7
1 6
3 4
3 5
3 6 3 7
3 3
K8
Service Manual JUPITER 4 900 361 - 03/03
Appendix K
Part.
Item no.
35
1 216 001
Pressure spring
36
4 231 379
Parallel pin
37
4 231 396
Snap into position bolt
38
4 231 435
Crank
X
39
4 250 176
Crank holder
X
Service Manual JUPITER 4 900 361 - 03/03
Description
SP
K9
K10
Service Manual JUPITER 4 900 361 - 03/03
Appendix L
Status and Error Messages: Operating Table Software
Messages advising of specific states are output over the RS232 interface. These can be
either normal operating messages or error messages. Specific errors are, in part, stored in
the EEPROM with additional information.
1.
Status or error message
Description
No. in the EEPROM
Error No.
Those states which are requested over the RS232 interface are not included in this
document.
Additional
information
(2 bytes)
Output
decimal
Start Messages
Output of the version of motor computer and operating computer.
Output of messages of the function motor_on(), see 01-03
01 Shuttle found -> ZERO set
A shuttle has been recognised,
zeroing is set validly
-
02 Power on: transfer
Error: shuttle jam recognised
at switch on
10
03 System ready
End of start phase
-
04 ZERO reached
Zero position reached
-
05 SYN_ERR>120: pos1 pos2
Error: synchronisation during
run, stop
06 SYN_ERR>250: pos1 pos2
Error: the motor which is
running on is stopped
07 SYN_ERR>500: pos1 pos2
Error: positions to zero, further 11 2 back section, 0
travel only to REF
3 leg section, 0
12 additional, 0
08 Limit flex
End position of flex reached
-
09 Zero: transfer on
Error: sensors transfer with
zeroing still active
13
10 Table top direction set
manually
Manual selection of section
direction is made (after error)
-
11 SYN: delta pos1 pos2
End of synchronisation
movement (difference + pos.)
-
12 S
Start of a movement
-
13 E
End of movement
-
2.
Main loop messages
Service Manual JUPITER 4 900 361 - 03/03
12 2 back section, 0
3 leg section, 0
12 additional, 0
-
L1
Appendix L
3.
Test Messages every Second
14 Accu overload
Error: Battery voltage too high, 14
charging is switched off
15 Accu empty soon
Battery will soon be flat
-
16 Accu empty
Error: Battery id flat, further
movements are blocked
4 -- in operation
1- in transfer
2- in cleaning function
4.
Movement Control Messages (motor_sv(), saeulen_sv())
17 ERR Mx:
Motor x only travels to REF
(error routine)
-
18 Direction?
Determing the permitted
direction of movement
-
19 ZERO
Reference (both) reached,
error routine finishes
-
20 DIR_ERR1, 2
Objection to direction,
new determination requested
-
21 W4M2
Wait for 2nd motor,
stop this motor
-
22 ERR_pos, ERR_neg
Attempt to move in a forbidden
direction
-
23 REF seen -> stop
1st motor to REF, stop it
-
24 W4M22
Prevents movement if 1 motor
has error (synchronisation)
-
25 Limit 2
2nd motor in end position,
no movement
-
26 Motor: state single drive
Status error of motor x
16 TP motor number
17 Column motor number
27 Fx
Motor driver error x with SV
command
-
28 Limit Mx
End position of motor x
reached
-
29 Stop error Mx -> Table top off Error: movement control,
15 Motor number
motor x stopped, Table top off
L2
30 Stop REF
Normal movement stop at
reference
-
31 Limit column stat
End position of additional lift
with current status
-
32 Limit M11 ellipse stat
End position ellipse as per
motor control SPAT with status
-
Service Manual JUPITER 4 900 361 - 03/03
Appendix L
5.
Transfer Functions Messages
33 Missing ZERO position on
transfer: x y (hex. output 232)
Error: missing zeroing on
transfer, x actual, y expected
18 0 status, actual and
target
NULL_STATUS:
#define RUECKEN_NULL 0x01 Bit1
// zeroing back section
#define BEIN_R_NULL
0x02 Bit2
// zeroing right leg
#define BEIN_L_NULL
0x04 Bit3
// zeroing left leg
#define BEINE_NULL
0x06
// both legs combined
#define VERSCHIEB_NULL 0x08 Bit4
// zeroing horizontal displacement
#define PLATTE_NULL
0x0f
// total section combined
#define ZUSATZ_NULL
0x10 Bit5
// zeroing additional lift
#define HAUPTHUB_NULL 0x20 Bit6
// zeroing main lift
#define SAEULE_NULL
0x30
// total column combined
#define NULL_BEEP
0x40 Bit7
// flag bit, whether already beeped
What is set in the target to 1 must have a 0 in the actual, if a 1 stands in the actual then this
indicates the error, zeroed axes have a 0.
34 Transfer requested d!
Start transfer in direction d
(0=upwards 1=downwards)
-
35 Motor current i without moving Motor error: power despite
-> error (decimal over 232)
standstill
26 255 = 7.9 A
36 Accu empty
Error: total discharge with
immediate switch off
4
37 Limit transfer
End position reached
-
38 Only 1 sensor seen
Error: there is a shuttle jam, it 19
is not located correctly at both
sensors
39 Transfer finished
End transfer
6.
-
Collision Control and Ellipse Control Messages
40 Error x LAPOS collision test
Error: during collection of the 33 Motor number
motor positions
41 L x; B y; F z
Displacement (x),
back angle (y),
legs (z) positions
-
42 Error x SWE_SET collision test
Error when setting the software
end switch
-
43 Error x MSTAT collision test
Error during read out of new
motor static (end positions!!)
-
44 Inclination S:x y; N:x y
Measured inclination angle of
column and inclination sensor
-
45 Error: inclination main control Error: angle measurement
SPAT
20
46 Error: inclination sensor
Error: angle sensor TETRA
21
47 Error: inclination difference
Error: difference between
inclination sensors
22
48 Limit inclination s, t
End position inclination with
status bits internally
Service Manual JUPITER 4 900 361 - 03/03
-
L3
Appendix L
7.
Power ON/OFF Messages
49 Power off
Operating table switched off
-
50 Table top off
Table top switched off
-
51 Motors off
All motors switched off
-
52 Motor ON failed on hardware Error: after several attempts to
switch on
5
53 TEST: motor on without control Switch on without control
sensors/table top
-
54 Accu empty - motors not
powered
Battery too flat,
motors remain off
-
55 Motor on...
Begin the switch on test
-
56 Table top direction not defined Error: direction of the table
top not clear
1
57 Table top not wedged
Error: table top not wedged
2
58 Table top in normal direction
Table top recognised in
normal position
-
59 Table top in inverse direction
Table top recognised in reverse
position
-
60 Table top chosen manually
Manual selection of direction
recognised
-
61 Only column on
On the column is switched on
-
62 Motor: no answer M11
Error: no communication with 23
the motor control
63 Motor: no answer M10
Error: no communication with 24
the main lift
64 Column state x
Error: error bit,
25 Bit 0
position storage of column set
65 Main lift state x
Error: error bit,
position storage
25 Bit 1
66 Error x table top state
Error: while determining the
table top status
25 Bit 2
Explanation of the significance of the bits in the additional bytes with error 25:
1st byte - error source, summarised
Bit 0 - Error in column
Bit 1 - Error in main lift
Bit 2 - Error in table top, more information on this in the 2nd byte
Bit 3 - Error, back left
Bit 4 - Error, back right
2nd byte, return value table top status.
Motor number with error plus 10, that is 16 for motor 6.
If there is no answer from the motor, then 10 is not added.
Other errors, such as table top type, create their own error numbers and so return zero
(output over 232 hex).
67 Position save error x - INIT
L4
Error: position storage of any
motor, all positions are set to
zero and the motors are
switched off
25 Evaluate bits
Service Manual JUPITER 4 900 361 - 03/03
Appendix L
8.
Table top Status Messages
68 Table top removed
Table top has been removed
3
69 Motor current i without moving Error: motor current without
-> error
target movement
26 255 = 7.9 A
70 Error: Table top type sensors
27
Error: logic error,
Reed contacts
71 No motor found - mech. table Mechanical table top
top
recognised
-
72 Table top type t Mx found
Table top type t has been
recognised on motor x
-
73 Table top type error
Error: table top type does not
match motor
28
74 EU
Additional module OR adapter
recognised
-
75 2 legs
Movement of single leg
sections possible
-
76 Extra: only synchro available
Attempt to run single motor
with additional drives
-
77 Extra: not initialised
Error: INIT additional drives
missing
-
78 Motor on failed
Error: switch on of all motors
failed
-
79 Extra motors only with table top Additional drives only
allowed
permitted with servo table top
-
9.
Additional Drive Messages
80 Error extra 1 / 2 (dec)
Error: reading the status of
motor 12 or 13
29 Motor number
81 Error PosMem extra 1 / 2
Error: reading the status of
motor 12 or 13
29 Motor number
82 Extra synchron
Additional module recognised,
synchronisation traverse
-
83 ExtraPos saved
Position of additional drives
was stored
-
84 Extra INIT
INIT additional drives
succeeded
-
Service Manual JUPITER 4 900 361 - 03/03
L5
Appendix L
10. Motor Driver Messages
85 Error stat SV
Error SV command,
status output
-
86 Mx E err Bb (dec, dec, hex)
Error: (from motor)
motor x, command b (dec.)
30 Motor number,
error Spat
87 Mx Bb (dec, dec)
Error: general error motor x,
command b (dec.)
31 Motor number,
command
88 M: SIO_OVL
Buffer error motor interface
K-line
-
89 M: Address
Invalid motor address
-> 0x81
-
90 M: Command
Invalid command (>127)
-> 0x82
-
91 M: Bytes
Invalid data count
-> 0x83
-
92 M: Send n
Sending check error
(n bytes ok) -> 0x8B
-
93 M: Timeout n
Timeout answer
(n bytes received) -> 0x84
-
94 M: Sender x
Sender does not match
addressee -> 0x85
-
95 M: Parity
Parity error
-> 0x86
-
96 M: Timeout_2
Timeout error data bytes
-> 0x87
-
97 M: CRC
Checksum error
-> 0x88
-
98 M: Receipt
Handshake bit missing
-> 0x89
-
99 M: ACK
ACK bit missing
-> 0x8A
-
11. Cleaning Functions Messages
L6
100 Cleaning function d start
Start cleaning function with
direction d
-
101 Error table top/wedges
Error: table top or wedges
32
102 Accu empty
Battery flat, switch off
-
103 BREAK
User presses abort key
-
104 End of cleaning function
End the cleaning function
-
Service Manual JUPITER 4 900 361 - 03/03
Appendix L
12. Messages about Computer Communication Routines (I2C)
105 Timeout I2C
Timeout data request I2C
106 START I2C
No start condition recognised
107 STX-Error I2C
Incorrect start ID/address
108 ACK-Error I2C
No acknowledgement from
operating computer
109 STOP-Error I2C
No stop condition recognised
110 Error TC x; TCN y
Error code negation
111 T: t; S: s
Keyboard test output: key t,
sensor status s
6
13. Key Evaluation Messages in the Motor Computer
112 IR error e
IR error in the operating
computer with status
-
113 Remote control accu empty
The remote control battery is
flat
-
114 Start TEST -> No?
Enter test mode, select single
test
-
115 TEST d started
Single test d started
-
116 End single TEST
End single test, option to select
new single test
-
117 End TEST mode
Test mode ended
-
118 Accu empty - keystrokes
deleted
Keys discarded because battery
flat
-
119 Changing transfer direction
Transfer direction change
requested
-
120 Only column active
No table top, only column up,
down, zeroing
-
121 Table top without motors
Mech. table top, table top keys
discarded
-
122 Add. Leg element
Single legs not permitted
-
123 Longitudinal locked
OR adapter recognised, no
horizontal displacement
-
124 Only longitudinal with motor
GL table top, only horizontal
displacement permitted
-
125 Only legs with motor
GY/GR table top, only legs
permitted
-
Buffer error PC interface
RS232
-
14. Miscellaneous
126 SIO1_OVL
Service Manual JUPITER 4 900 361 - 03/03
L7
Appendix L
Conversion of Decimal Outputs
Option A:
WINDOWS calculator (reset to scientific display), the decimal or hexadecimal number can
be directly converted into a binary number.
Option B:
conversion using the table
Bit 8 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1
27
Examples:
28
16+8+4
14
8+4+2
7
4+2+1
26
25
24
23
22
21
20
128 64
32
16
8
4
2
1
x
x
x
x
x
x
x
x
x
After the conversion into a binary number with this table, the error output can be assigned
to the individual error bits.
L8
Service Manual JUPITER 4 900 361 - 03/03
Appendix M
Operation and power supply
Service Manual JUPITER 4 900 361 - 03/03
M1
Exchange Units
Exchange Units
M2
Service Manual JUPITER 4 900 361 - 03/03
Appendix M
Pos.
Item no.
1
4 544 148
Section control unit
X*
2
4 544 149
Charging unit for section control unit
X*
3
4 144 892
SM column power pack
X*
4 144 897
SF column power pack (USA)
X
4 220 709
Charging cable (for 4 544 121/1 219 657), old
X
4 220 900
Charging cable (for 3)
X
4 544 119
Cable remote control
X*
4 500 119
Cable remote control (USA)
X
4 544 120
IR-remote control
X*
4 500 120
IR-remote control (USA)
X
7
4 544 118
Foot control
X
8
4 544 122
Charging unit for IR-remote control (mobile)
X
4
5
6
*
Description
SP
See table under "Second-hand parts" on page N-2
Spare parts for IR- and cable remote control
Pos.
Item no.
Description
SP
4 145 177
IR- and cable remote control, upper part
X
4 145 178
IR- and cable remote control, lower part
X
4 144 996
Circuit board hand control cable 2.0
X
4 144 995
Circuit board remote control IR 2.0
X
4 144 502
9 V/160 mAh NiMH battery
X
4 220 434
Bracket
X
4 100 157
Connecting cable with plug
X
4 144 739
Sponge rubber band
X
4 144 705
Touch panel IR remote and hand control JUPITER
X
4 144 029
Touch panel IR remote and hand control JUPITER (USA)
X
4 081 066
Countersunk screw M3x10 DIN965-A2 (5x)
X
1 215 277
Cylinder head screw M3x8 1.4301 DIN84 (2x)
X
Service Manual JUPITER 4 900 361 - 03/03
M3
Exchange Units
M4
Service Manual JUPITER 4 900 361 - 03/03
Appendix N
Second-hand parts
Service Manual JUPITER 4 900 361 - 03/03
N1
Second-hand parts
N2
Pos.
Item no.
Description
1
1 219 656
IR-remote control
2
1 219 655
Cable remote control
3
1 219 657
SM column power pack (from 4 544 121)
4
1 222 711
SM column power pack
5
1 219 658
Charging unit for IR-remote control (mobile)
6
1 219 328
Section control unit
7
1 219 327
Charging unit for section control unit
8
1 222 712
Main circuit board (sensor inclination contained)
9
1 240 583
Tilt drive, left
10
1 240 585
Tilt drive, right
11
1 240 586
Trendelenburg drive
12
1 225 102
Motor main lift
13
1 222 713
Motor control
14
1 225 090
Motor table top, back plate and leg plate
15
1 225 101
Motor longitudinal
Service Manual JUPITER 4 900 361 - 03/03
e-mail: info@de.trumpf-med.com
www.trumpf-med.com
Service Manual JUPITER 4 900 361 - 03/03
TRUMPF Medizin Systeme GmbH
Postfach 1263
D-07303 Saalfeld, Germany
Phone:
+49 3671 586-0
Telefax:
+49 3671 58 61 65