MAQUET 1132.XX Maintenance and Alphastar Repair Instruction A Ne $i “TS Fd \ i \ BE rath-Stouscirg - rade Core iSpy a 4 suger pomon 2074. Ton orn. WR1132016B ‘ie ha oe dnMAQUET products are subject to maintenance within an annual inlerval (app. 200 .. 300 hours of equipment operation} Damaged or defective parts are fo be replaced as per this maintenance and repair instructions. Repair work may require special too's and mounting devices. Maintenance or repair work is only te bo carried out by MAQUET AG ‘or other service personnel consed by MAQUET Table of contents Generals 4. Design and function sign and function description Transformer, battery charger Batterios,crive unit Controller toard At JR-supplement Cable hand control Override IRetransmritter Override-pump 2 Measurements (tests), elaktrical and elaktronic system 2A Transformer T1 primary 2.2 Transformer T1 secondary 23. Battery charger A3 24 Batteries Gt/G2 25° Motor Mt 2.8 Motor M2 chive unit 2.7 ,0"- Potentiometers B3/B4/B5/86 2.8 Cable hand control 2.9 [Remote control 2.10 Function LOCK/UNLOCK ALPHASTAR 1132_ Page oot 4.01 4.02 41.04 1.08 1.08 1.40 2 201 202 202 202 202 2.04 204 2.06 2.08 2.08 2.10 WR113268, 12.10.2000 Seite/Page: 0.01Maintenance and Repair Instruction ALPHASTAR 1132 3. Measurements (tests), hydraulic system 301 3.1 System pressure 3.02 32 Checking OM level 3.04 3.3 Hydraulic cylinders. 304 3.4 Check valves 3.08 4, Troublosshooting — what to do Hun 401 ‘5 Ropalrwork, repair instructions for hydraulle components: 5.01 5.1 Twin swivel castors 502 5.2 Hand pump 5.04 5.3 Tilting cylinder 5.08, 5.4 Trendelonburg cylinder 5.08 65 Column casing and bellow 5.08 5.6 Chock valve, solenoid vahe 5.08 87 Locking cylinder 8.10 58 Leg plate cylinder 5.12 5:9 Back plate cylinder 5A2 510 Leg plate side arm 514 5.11 Back plate side arm 514 5.12 Hydraulic unit 5.16 5.13 Elevation cylinder 5.18 6, Repalrwork, repair instructions for electrical components. 01 601 Charging board 6.02 602 PCB for dive unit 602 6.02 Control unit At and IR-Decoder Ad 6.02 6.04 Drive unt 6.08 WR113268. 12.10.2000 Seite/Page: 0.021.01 = cron | DetMaintenance and Repair Instruction ALPHASTAR 1132 1_Design and function description The essential components: = transformer 74 = battery charger A3, batteries G1/G2 + DC-motor Mt + hydraulic pump = valve control block + (Movements of table sections) = valve contol block 2 ( Drive unit, LocktUntock) = drive unit incl, Motor M2 and controller board AS = pressure hoses, cylinders. = Controller board A, IR supplement Ad = override functions A2 (handcontrol.Lock/Unlock) + override pump for manual unlocking of castors = hand control box /IR transmitter / foot switch Please refer to the corresponding spare parts ist for the variants used in the existing operating table. WR1132.01GB. 12.10.2000 SeitePage: 1.02at Hysrauay Hyde ni a 1.03 Page co oar 07.05.98 Det:tenance and Repair Instruction ALPHASTAR 1132 Technical description ‘The 1132 model is an electro-hydraulic O.R. table using electrically controled hyeraulic valves. The oil fow is controled by 5/3 directional solenoid valves (1) -(S hydraulic ‘connections, $ positions of switched channels). Depending on the state ofthe control signal of the valve the piston rod (8) ofthe hydraulic cylinder is moved in our ou, or it remains in ts position. “The 5/3 directional solenoid valves operate along with double check valves (2) which ‘are actuated by the oil fow corting from the solenoid valves, As ong as the double check valve is in its rest position the hydraulic ines A and B remain closed to prevent ‘the piston rod from being moved by any extemal mechanical load, Power supoly ofthe O.R, table — transformer and charging ccc! ‘The mains voltage supply ofthe O.R. table is provided by means of a 2-ine cable with fa standard 3-pin connector. Supply cables are available with mains plugs ether according to American or European standard ‘The transformer assembly T1 includes a voltage selector to enable adaptation to the present mains vottage (100...240V). “The primary col ofthe transformer consists of 4 separate windings, 2 of them for 104V ‘each, 2 further for 12 V each, To connect the O.R. table to a mains voltage of e.g. 230V all the windings are switched in series via the voltage selector (232V). The lowest votage setting avallable is achieved by switching the two 104V-windings in parallel circuit. {A thermal protector fuse is integrated inthe primary col If this fuse has blown the transformer must be replaced. The fuse can not be replaced. WR1132.0168 12.10.2000 SoiterPage: 1.0407.05.98 aa wie MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 “The secondary windings ofthe transfomer provide 2x14V which are the supply voltages {forthe charger board A3. The folowing components are connected tothe charger ‘board 3: 2 batteries G1/G2, the 24V-OC motor, solenoid valves of valve block Y1 and the contioller board AS of the drive unit. All these components are located inthe base of the OLR. table. (On the charger board, the output vltages of the transformer (2x14V AC) are converted into separately regulated charging voltages of 13.75 DC for each battery. Batteries G1/G2 ‘The batteries of the O.R. table are maintenance-free lead-acid types. ‘They supply the motors M11 and M2 (i installed) with 24 V DC. 2 batteries of 12 V each and a capcty of 16 Ah are sufficient for this purpose. ‘The period of use until the batterias must be recharged depends on the current drawn by the motors and the actual running operation time of the ‘motors M1/M2. The motor current is app. 7 A. The useful ifetime of the batteries is specified by the manufacturer as 5..6 years. Hence app. 300 cycles of charge/ discharge can be expected during the battery lifetime if they are charged once a week. Controller of drive unit AS and motor M2 ‘The drive units offered as an option for the O.R. table 1132. Its actuated via the buttons .BACKWA." And ,FORW." ofthe cable-connected hand contol, The forward or backward movement ofthe table dtiven by motor M2 is controled by the controller board AS. WRI192,0168 +2.10.2000 SoitePage: 1.06EEE) i SeaMaintanance and Repair Instruction ALPHASTAR 1132 Conivoler board Aj and infrared receiver boar Ad The controller board At is located under the black blows. If IR remote contol is installed an additional receiver board (Ad) is plugged on. Both IR preamplifiers B1, 82 are connected to this board. The IR preamplifiers are located on the column one directed to the leg side the other to the head side. The receiver board Ad and the preampifiers are continuously supplied by the permanent voltage 5Vp. The current consumetion of these components is very low, hence there is only a very smal oss of battery capacity, If there are more than one O.R. table with IR remote controls in the OR. section (on the same floor) it is necessary o assign each table and the IR transmitter ts ‘own IR code (S20 technical description). 4 potentiometers 83/84/86/B6 for the ,zer0-positioning’ of the table top are connected to the controller board At which monitors and evaluates thelr position. The voltage at the output connector ofthe potentiometers must always be within a range of 0.16..4.84V. Two micro switches, $1/82, wired in series, provide a signal to the controller board A‘ (X3.9 Sock) indicating that the O.R. table is locked on the floor. At the same time the 2 ‘green LEDs of the cable connected hand control / override panel A2 are urinated. To set the 4 twin swivel castors out tothe floor the valve UNLOCK" is actuated until the pressure switch P on hydraulic block Y1 is activated at @ pressure of 40 bar and ‘ho controler board receives the signal thatthe O.R. table is now ready to be moved. ‘The 2 red LEDs are iluminated. If the LOCK/UNLOCK slatus ofthe O.R. table cannot be determined by the controller the red and green LEDs show intermittent flashing light WR1132.016B 12.10.2000 Seite/Page: 1.08at ra 07.05.98 Eat oo Pace 1.09Maintenance and Repair Instruction ALPHASTAR 1132 Gable connected hand contro! ‘The hand control box consists of 2 housing pats, a PCB with pushbutton forthe individual functions, LEDS as indicators of the status, a foil keyboard, and a tine spiral cable (85, SV, OV, DATA). Voltage supply ofthe hand contol is provided by the lines OV and SV. ‘The controller A4 is switchod onloff via the tine BS, The line DATA enables @ bistrectonal data transfer between the hand contol andthe controller board of the OR. table. Serial data signals are sent by the hand contol to actuate the desired function, The controler board sends signals to the hand control to contol the status LEDs. ‘To switch on the systom the button ,ON" must be pressed. The status LEDs BATTERY, MAINS, ON, UNLOCKILOGK, and NORMALIREVERSE show a short flashing ight ‘Afr this poriod only the LEDS indicating the current situation remain iturinate. ‘The desired movement buttons can now be pressed. If no button is pressed within a period of 18 seconds the control units switched off ‘automaticaly. The hand contol can be switched off immediately by pressing the button ,OFF’ For further information pease refer tothe brief operating instructions. Override AZ ‘The functions ofthe overide panel are the same as of the hand control. The ables an emergency operation ifthe hand control oF the controller ‘The difference to the hand contol is that valves are actuated directly. The motor is actuated soparaely by the bution ON" hence 2 buttons must always be pressed ‘simutaneously (,ON" + movement button). WR1192.01G8 42.10.2000 SeiterPage: 1.106m tae waouer (1 Sele lela) Ter owt sow wtsoe RaMaintenance and Repair Instruction ALPHASTAR 1132 Infrared remote control There is no bi-directional data transfer as with the cable connected hand contol ‘The LED .Battery" indicates the charge status ofthe accumulators ofthe hand control ‘The charge status of the batteries ofthe O.R. table is indicated by the LED on the OVERRIDE panel ‘The status LOCK/UNLOCK ‘indicated on the OVERRIDE panel as well. ‘As a safely feature there is no possibility provided to actuate the drive unit Via the infrared remote control Manual override pump Ifa failure of the motor Mt or the hydraulic pump occurs this pump can be used 10 release the locking of the O.R, table from the floor. For detalled information please ‘refer tothe ,Technical description’. WR1132.0168 12.10.2000 SeitePage: 1.12Maintenance and Repair Instruction ALPHASTAR 1132 surements (tests), electric and electronic system 2.1, Transformer primary connectors (1):_The voltage corresponds to the setting atthe voltage selector and tothe local power supply 2.2 Transformer secondary connectors (2): 2 soparate outputs of 14 Volt AC each at plug contacts 2.3 Battery charger (3): ‘Connect the O.R. table to the mains supply. Check the charging voltage at each battery. Voltage 136V - 13.95 V6 ‘Sharaing current ‘The charging current depends on the capacity of the batteries so that no information about the Condition ofthe battery charger can be obtained. 24 Batteries (5): ‘Conctet the test (6) using an automotive light bulb (12 V, approx. 45 W) ‘Soed baile; Bright light for 1 to 2 minutes (good charge) Poor battery: Light visibly darker after approx. 1 minute; voltage falls below 10V. Ifa battery seems to be in poor condition, recharge and test it once again to verify the results. ‘Al two batteries should always be replaced at the same timo. WR1132.0168, 12.40.2000 SeiterPage: 2.022.03 Pope eau 07.05.88 Data ate:Maintenance and Repair Instruction ALPHASTAR 1132 25 26 Motor tost (itt) Cone of the cables, Detach the plugs X3.1 at the charging unit (2); insert the ampereme: press any function button and move the function unt its final postion (and the max. pressure ‘of 100ber) is reached, ‘The unit must draw between 6.5 and 7,5 Ampere. f more than 94s drawn, then either the motor (7) or the pump (8) is defective. Remove the motor and measure the power drawn by the separated motor. ‘Whon operating with ne load, the max. admissible value is 0.6 A. Roplace the motor ifthe current i higher. Ifthe motor proves to be OK, then replace the pump. Check the power value again (< BA) after having installed the new pump. ‘Note: Using the operating table over an extended period of time with the rotor drawing an ‘excessive current (> 8A) can damage the battery charger (9) and, in rare cases, even the hand contro unit. Motortest (M2 - drive unit) ‘Adjustment of the limit switch $3 = Switching threshold app. 1mm before the lower end position is reached. Note: If the limit switch $3 is shorted (contact closed) during troubleshooting and the button ,Drive is ‘not pressed within a period of 3 sec. the controller unit will datect this condition as @ fault ‘The OR. table must be switched off the short must be removed and testing can be resumed. Current consumption ofthe drive unit motor (overload protection at 13Amp,) With no mechanical load: 0.4 A Nominal current: 4.9. app. <4A under normal dive condition WR1132.01GB 12,10,2000 SeiterPage: 2.04Maintenance and Repair instruction ALPHASTAR 1132 27 0”-position potentiometers BETiting, B4=Trendelenburg, BS=Back section. BEE Leg pate Voltage supply 5 V, measured when comected between the red and black wires “The 0-posiion corresponds to approx. 2.5 V measured betwen the red and green or the black and green wires (voltage divider), i.e, half ofthe salting range of the potentiometer corresponds to 2.6V. ‘Troubleshooting; When pressing the "0" buttons, the function moves into the opposite direction -> ‘exchange the black and red wires. A continuous acoustic signal is generated when pressing the "0" buttons -> a potentiometer is defective or outside its limit range (0.5 ..4V). > Replacement or adjustment of the potentiometer. Note: ‘An adjustment can be carried out manually by means of a screwdriver or alternatively withthe IR-Tester (see .1132"-mode). The standard adjustments of of FLEX: /REFLEX angle positions can be programmed by means ofthe tester os wel, WR1132.0168 12.10.2000 SeiterPage: 2.06esi "07.05.98 oa at MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 28 29 Control unit and receiver board ‘The functions of the control unit can be simulated by pressing the override buttons A2. If the operating table function is actuated, ether the controller board A1 or the hand control is defective. Try another hand controViR-transmiter, Ifthe OR. table dogs stil not respond the controler board is. defective. Functions of the hand control box or ofthe foot switch can be tested by means of the IR-Tester within the mode ,READ DATA BUS 1132" : Test the 5V-supply of the hand contra! box. IR remote contro! “Test the IR transmitter and charging station using the IR tester ~ mode 1132" ‘Check equal settings of the selector ewitches (6/7) of boards (28). Test the IR recelveripreamp. 81/82 by means ofthe IR tester. Test the range of transmission ofthe IR transmitter by means of the IR tester modus IR detect VV" or .IR detect ASIC, Ifthe IR transmitter emits a continuous tone when a function is actuated, the IR code has been set but not acknowledged ~ see technical description. WR1132.016B 12.10.2000 Seite/Page: 2.0834/52 2.09 Emer 07.05.98 Daw. (MigteliseJaintenance and Repair instruction ALPHASTAR 1132 2.10. Function LOCK/UNLOCK ‘The LEDs of the pushbuttons LOCK/UNLOCK indicate the current status of the O.R. table. ‘The iluinated LED ,UNLOCK indicates thatthe castors ate posiioned towards the floor, mmicroswitches $1 and 82 are not activated (open) and the contact ofthe pressure switch UNLOCK is closed. ‘Switching threshold ofthe pressure switch: app. 40 bar. Flashing light of both LEDs LOCK/UNLOCK indicates that the status is pending, Le. the OLR. table is being switched from LOCK to UNLOCK or in reverse order. Flashing light of both LEDs can also indicate that one of the microswitches has not opened though the castors are fully set out onto the floor. WR1132.016B 12.10.2000 Seite/Page: 2.10> 100 bar _|<| INGTON ee 0705.06 |Maintenance and Repair Instruction ALPHASTAR 1192 :surements and tests, hydraulic system Note; Always remove all load from the cylinder affected before opening any hydraulic connection! 3A ‘Move the piston red of the cylinder to the position in which itis relieved of load. ‘Normally this condition is achleved in the lowermost position. The cylinders of the castors are relieved of loadin the ,LOCK"-position Use the spacer plate om the too! kt when working on the elevation function. ‘This measure will prevent the operating table from excessive oil loss. System pressure ‘The system operating pressure Is 100 bar (for older models 120 or 130 bar). ‘This pressure can be measured at any cylinder. To do 80, connect the pressure gauge to the “A" end and actuate the appropriate function; keep the function actuated uni the uppermost poston is reached. Itis also possible to check the pressure at the outlet P of the hydraulle unit If the working pressure ls too low, an adustment can be made at the “DB 100" (1) pressure limiter valve. The nominal pressure is 100 +5 bar. {f this does not recy the prablem, then the DB 100, the pump, or the motor is defective. WR1132.0168 12.10.2000 Seite/Page: 3.023.03 a 07.05.98 aaMaintenance and Repair instruction 32 33 ALPHASTAR 1132 Checking the oil level Raise the operating table to iis uppeimost position and align tha table top horizontally (,0" button), Remove the 2 scraws (1) of the base casing (3), pull the base casing off the base and fix it ‘The oll level must be above the minimum but below the maximum mark on the tank (4). Hydraulic oylindors Before checking any particular hydraulic cylinder, it is necessary to test the ‘corresporiding check valve for its comect function (measure with no eylinder connected). ‘Noto; The pressure (100 bar) must not drop below 70 bar within a period of 30 minutes. {f this proves to be in satisfactory condition, then cary out the cylinder pressure measurements. Use the measuring adapters (5) to connect the pressure gauges (150 bar) to the and ‘BY lines. Press and hold the appropriate button on the control unt the mechanical stop is reached and the pressure rises fo the maximum vals. WR1132.0168 12.10.2000 SeiterPage: 3.04Ly SDEHH DEM FM. 250205 |"Maintenance and Repair instruction ALPHASTAR 1132 Leaks at the check valve (3) ines at the particular actuator cylinder to test for It will be necessary to detach the °A’ and “ internal leakage in the check valve (3). ‘Then connect the test adapter (4) from the too! kit (3111.4913) together withthe pressure gauge. Press the “up” button AsLstep {l) The pressure of 100 bar must not fall below 70 bar within @ peiiod of 30 rin, ‘The presure wil rise to the maximum (100 bar}. Release the function contro! button; the ‘check valve closes. Observe pressure characteristic "Y" (see diagram). Ifthe pressure falls abruptly by 10 - 90 bar (approx) and then remains at @ constant level. the test lead must be bled and the test repeated. 2nd step (ll) Set pressure limiter valve DB 100 to 0 bar. Press the "up" button, the pressure rises to @ maximum value of $0 bar. Release the button, the check valve closes. ‘The pressure of 50 bar must not fall below 35 bar within a period of 15 min. (808 diagram). ‘Observe prossure characteristic WR1132.0168 12.10.2000 SeiterPage: 3.06Maintenance and Repair Instruction ALPHASTAR 1132 44 42 For troubleshooting, the sequence of parts to be checked must always be observed io allow safe and woll-aimodi detection of the faut. ‘Arbitrary checking or roplacoment of components will certainly not be helpful. Also, the most “popular” replacement of microchips on the boards Is not a very professional way to resolve the problem! Howto oroceed: check e.g. transformer; battery charger - charging voltage; battery capacity: motor ‘current consumption; voRage, pump output pressure, - and. override functions, test functions with hand control and IR-tester, receiver board, preamplifiers Motor running without any of the control buttons being prossed Detach the control unit, Ifthe motor stops try another hand control lf the motor still continues running, check the battery charger. {f the problom persists, check the connecting cable from the battery charger to the hand control unit. Motor running but no function is executed when hand control button is pres ‘Test the function button on the control unit > switching stroke of the button is too long. (Check the function by pressing buttons on the override panel If there is sill no movement check the vaive in question and its wiring, To determine whether the faults to be found inthe electrical or hydraulic system ‘exchange the valve supply cables with the cables of another function that is stil working. ‘Check whether the same movement continues to be not working Ifthe faulty movement can still be actuated by pressing the button on the override pane! the valve wiring and the vaive itself is not defective. Continue testing electrical components ‘such as the hand control. Use the ,hand control" and IR- functions ofthe IR tester. {see also testing ofthe hand contro) WR1132.0168, 42.10.2000 SelterPage: 4.02Gan CaaSa@ move CSECBRE, Override IR-TESTER MAQUET bon 0705.98 rarerALPHASTAR 1132 Maintenance and Repair Instruction 4.3 Red light on the battery indicator of the cable connected hand control or the override pane! ed for an extended period of time (8 to 15 hours) though the kattaries have been ch: ‘Test the batters, the battery charger as well as the motor ‘Test the transformer: Ifthe battery charger stops charging the batteries before they are completely charged, the transformer gets 100 warm and the charger is switched off by is monitoring function via the NTC (connection X1.5, X16). For testing, detach the NTC connections. If the battery charging has now improved, exchange the transformer -> too fast overheating, 4.4 Operating table cannot be operated using the IR remote control Check the system code setting ofthe IR transmitter and IR. decoder. See techn. descrigtion. Test with cable control unit, 1 there is stil no reaction, check the transmission power ofthe IR remote control using the IR tester. ‘Test the charging station ofthe IR transmitter using the IR tester. Test the operating table function with another IR transmitter. Test the function ofthe IR transmitter previously used with another operating table, ‘Test the operating table function by means ofthe IR tester. WR1132.016B, 42.10.2000 Seite/Page: 4.04MAQUET oe [Eat 97.05.98 |45 48 ar ALPHASTAR 1132 ‘Tha olovation function sffeots no rise and moves downwards either very slowly oF not at all, other functions work properly. Test the cylinders, measure the pressure, too high flow resistance, system pressure 0 low. ‘The guides may be set too tight, table with no addlonal load: 40...50bar while moving upward @ Test the check valves, measure the pressure. (I) ‘Trendelenburg or titt functions exhibit play after a short period of time (app. 1..2 days after adjustment) Test the chock vaives.(hi,) Measure the pressure at the A and B fines. Test the cylinders. (1) ‘The operating table does not function at all Connect the table to the mains socket. Ifthe table than functions properly, charge the batteries the table disconnected for about Ynour, and then check the functions again wit {rom mains supply. Check the setting of the cade switchos of the IR decodar board and the transmitter. Measure the current ofthe motor. |F the table sill does not function, test the transformer, the batteries and the motor. WRI 132.0168 12.10.2000 soterPage: 4.06igs: und Repareturanl 1d Ri veitang struction 1432 MAQ' 4s 4 Ba ose J 5.01Maintenance and Repair Instruction 5, Repairwork, replacement of hydraulic and mechanical components 5.4 Replacement of twin swivel castors (1) OR. table must be in LOCK postion. (swivel castors must be released off the floor. ‘Adjust the table top into its level position. Elevate the column to ap. half way of height Remove the 2 screws (2) from each end of the base cover (3). Pll the base cover off nan upward direction and secure it on the table top with straps. Warning: Be aware of the heavy weight of the O.R. table! ‘Tit the whole O.R. table and lay it down on the floor (this work requires 2 persons) see picture Remove the fixing screws (4) of the 3 spring bolts (5). Extend the spring (8) by means of appropriate tools (pir, wire ote) ‘80 thatthe spring bot (6) can be removed. Remove the screws (6) ofthe guide bolts (7) Replace the swivel castor. Do net stretch the springs (8) more than necessaryl (max. 67 mm) ALPHASTAR 1192 WR1132.0168 12.10.2000 SeiterPage: 5.02= 6.03 cant 07.05.28 ate52 intenance and Repair Instruction ALPHASTAR 1132 Removallreplacement of hand pump (12) Ensure that the table is in LOCK position. Remove the 2 screws (2) from each end of the base cover (3). Pull the base cover off upward and secure straps to the cover local to ‘screw positions and secure on the table top. Remove the charger board (13) - (2 fxing screws in the base see also 5.15) Remove controller board of drive unit that is disconnect all cables, unciip securing device and slide out of mounting, Remove hydraulic hose from hand pump. Remove the 4 fixing screws and withdraw the pump assembly (12) Replace in reverse order. Piston of the pump must bo in correct postion (tum counterclockwise up to the stop!) ‘Actuate UNLOCK function to refll the pump Check oll level WR1132.01GB, 12.10.2000 seiterPage: 5.04AB iM 7 oP at 5.05 MAQUET oe 07.05.96Maintenance and Repair Instruction ALPHASTAR 1132 83 64 Replacemont of the titing cylinder (1) Carry out pressure measurements of the check valve and the cylinder (see 3.) ‘Completely remove the column casing and the bellows, Remove the set sorew (2) and the bott (3). Caution! The table top may drop aside! Fully move the piston rod to its lowest positon Remove the hydrauiic hoses (6). Remove the set screw (5) and the pivot bolt (4) of the tting cylinder Replace the cyiinder. Use the rod head piece (7) of the old cylinder. Secure the set screws (2) and (5) with blue Loctite 243. Replacement of the trendelenturg cylinder (10) Carry out pressure measurements of the check valve and the cylinder (se9 3.) Completely remove the column casing and the belows, ‘Adjust the trendelenburg movement of the table top to lowest ,nead-down’ position (00 picture) and adjust the backplate to its highest position. Remove the seat pate (11) 4 screws (12). Remove the 4 screws (1) of the rendolenburg pivot bots (14) and fully move the tabletop to lowest .head-down" positon. Note: To prevent the coated surfaces of the column from being damaged place cloth or sheet of similar material in between. Remove the 2 trendolonburg pivot bots (14) and the head piece (15) ofthe piston ro. ‘Move the wiper ring (16) on the piston rod so thatthe fixation screws (17) can be removed. Remove the wiper ring (16) long with its holder (20) Remove the set screws (18) and the trendelonburg pivot bolts (19). Disconnect the hydraulic hoses, remove and replace the cylinder. ‘Secure the head piece (15) ofthe piston rod with blue LOCTITE 243. WR1132.01GB 12.10.2000 Seite/Page: 5.06or Date 07.05.98 Saar Poge 5.07 MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 55 Column casing (1) and bellows (2) ‘Adjust the elovation cylinder, the legplate, and the back section to the highest positon. Remove all expander rivets (3) from the bellows (2). Note: Before removing the upper parts of the casing disconnect the plugs. from the override board (4) and the connectors of the hand control sockets (5)! Remeve the sraws (6) of the 2 upper parts ofthe column casing. Rernove the upper (9) and mide parts ofthe casing Remove the fixation screws ofthe lower column casing (7} and remove the casing, Replacement of the check valve (10) andlor the solenoid valve(12) Remove the column casing (1), 880 section 5 Measure the pressure loss of the check valve (10) as desorbed in section 3 Secure the eyinder in question -or clear of mechanical loa. Remove the 3 fixation screws (11) ofthe check vahe and remove the vaive Before replacing the new valve apply some vaseline grease onto the oxings. Tighten the screws ata torque of 3 Nm. WR1132.01GB 12.40.2000 SeiterPage: 5.084132 MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 5.7 Removal and replacement of locking cylinder (1) Unscrew, it off and secure base cover as described. Ensure that table top is in level position and locked on the floor. Remove the hand control and disconnect the batteries (2) from the charger board (3). Lay the table on its side as described in section 5.1 Remove the swivel castor (4) as described in section 6.1. Remove the microswitch actuator shaft (5) (lake care of micro switch (6) Mar location of cylinder (1). Remove and blank off the hydraulic hose (7). Remove the cylinder fixing screws (8) ‘and remove the cylinder. Replace in reverse order. If location of work is on T-side of the base check correct position and function of micro switches. WR1132.0168, 12.10.2000 Seite/Page: 5.10Maintenance and Repair Instruction ALPHASTAR 1132 5.8 Replacement of leg plate cylinder (1) Remove the leg and seat plates along with the O-ings. Remove side rails and inner guide rals. Move the leg plate arms (3} fo uppermost position, remove the cover plato assembly (4). Remove the pivot C-ctio (5) and withdraw the piston pivot 6) Put the leg plate arm to its lowest positon ~ the side arm is now free. Remove te soat plata side cover (7). ‘Move the trendolanburg function to head-down position and remove the set screws (8) ofthe cylinder pivot Withdraw the pivot (9), remove the cylinder from the arm, Disconnect and blank of the hydrauil lines. Remove the head piece (10) from the piston Refit in reverse order. Adjust the potentiometer, check ,LEVEL" positon, 5.9 Replacement of backrest cylindor (11) Remove the side rails 12) on the outside of the backrest arm, Remove the backrest plate (13) and the 2 seals, as well as the springs and washers mounted below the plat. Remove the rail (14) on the inside ofthe side arm. Raise the backrest io its uppermost position. Remove the grub sorews (15) from the piston pivot (16) and withdraw the pivot ‘Actuate the cylinder to its lowest position and remove the cylinder pivot (17). Disconnect and blank off the hydraulic hoses. Remove the head piece (18) ofthe piston rod. Refit in reverse order. Adjust the potentiometer, check ,LEVEL* positon, WR1132.016B, 12.10.2000 Seite/Page: 5.12wee.Maintenance and Repair Instruction ALPHASTAR 1132 5.10 Replacement of lag plate side arm (3) Remove seat and lag plates. Remove the side ral. Elevate the leg plate arms (3) and remove the side covor assombly (4). Remove the C-clip (6) ofthe piston pivot and withdraw the pivot (3) ‘Actuate the function ,downt to alow the piston to withdraw. Remove the potentiometer cover plate (20), the potentiometer (21) and the O-rings. Now remove the securing grub sorew (22) and the feg plata pivot (23). Refit reverse order. Aajust the potentiometer, check .LEVEL" position, 5.41 Replacement of backrest side arm (26) Remove back pte, side rails and cylinder as previously described. ‘Also remove the seat plate, Remove the side cover assembly (24). Pull the hydraulic hoses from the backrest side arm. Remove potantiomater cover (26) and carefully withdraw the potentiometer (21) along ‘with the 3 O-rings. Raise the backrest arm and remove the grub screws (28}of the pivot ‘Withdraw the pivot (28). Now the side arms free. RRoft in reverse order. ‘Adjust the potentiometer check ,Level* ~ position. WR1132.01G8, 12.10.2000 Seite/Page: 5.14Maintenance and Repair Instruction ALPHASTAR 1132 5.12 Removal and replacement of hydraulic unit (1) Remove base cover as previously described. Elevate the column to its highest postion and secure with a bar for safety (see next page) Disconnect the hand control, disconnect the battery connector (3) from the charger board (4). Remove the hydraulic P* and, tines from the pump and close the ports with biank caps. Disconnect the motor grounding cable and other cables from the ‘charger board for ease of motor removal. | Remove motor mounting nuts (5). Romave the hydraullc unit (1) from tho base. i Roft in roverse order. WR1132.0168 12,10.2000 SeiterPage: 5.16saree 5.17Maintenance and Repair Instruction 5.13 ALPHASTAR 1132 piston sealing (1) Roplacoment of height elevati Remove covers of base and column as described. Lower the back section and the seat plate by app 15°. Place 2 stands under the table top and lower the table so that the base is clear of the floor. Place 3 suitable wooden blocks under the base and actuate the function up" to lower the base onto the blocks. Elevate the table top to highest postion and put safety bar (4) in the guide (3). Remove the piston rod securing scrow (8) from below the base and engege the piston rod (8) into the cylinder up to a remaining length of Sem. ‘Unscrew the bushing (7) with a special spanner Press the function .up* and fully withdraw the sealing assembly. Use cloth and crip tray to catch the escape of ol at this stage, ‘Open the fine HA atthe valve unt 2 ‘With new sealing assembly over the piston rod (6) push the piston firmly upwards. Ensure that dip tray is placed below the JHA" line to catch oll discharge, ‘Screw the seal assembly into place with the .V"-spanner. Extend the piston rod (6) and refix the securing screw (5) through the base to the piston using blue locfite. Refi oil and check to see that oll level is correct. WR1132.0168 12.10.2000 SeiterPage: 5.18MAQUET 42.10.2000 seitoiPage: 6.01Maintenance and Repair Instruction ALPHASTAR 1132 64 Repainwork, replacement of electrical components Replacement of drive unit (14) ‘+ Ensure that the table is in LOCK position. ‘+ Remove the 2 screws (2) from each end of the base cover (3) ‘+ Pull the base cover off upward and secure straps to the cover local to ‘screw postions and secure on the table top. ‘+ Tut the entire O.R. table aside and secure it on a distance block. (Observe the elocttical cables! Disconnect hydraulic hoses and blank off + Remove the entre drive unit as follows: Remove the 4 screws (15). Unsrew the .Z* fixation of the spring (16) from the base housing. Replace the crive unt, adjust the micro switch $3 to @ position of electrical switching 1mm before reaching the mechsnicat end position. Ensure thal there is suffcient space between tho ive unit (14) and the valve block 1 (17) when lowering the columa WR1132.016B 12.10.2000 Seite/Page: 6.02Seite/Page: 6.03 12.10.2000 MAQUETMaintenance and Repair Instruction ALPHASTAR 4132 6.2 Removal and replacement of the charger board (1) Unscrew, If off and secure base cover (2) as previously desorbed. Disconnect all plugs from the charger board (1) Disconnect the motor grounding cable. Remove the 2 fixing screws (9) of the board (aluminium rai) inthe base. Remove the charger board (1) Rafitin reverse order, ensure that battery cables are connected last Measure the charging voltagos, check board for correct function. 6.3 Replacement of controller board of drive unit (5) Unscrew, lft off ahd secure base cover as previously described. Disconnect all plugs from the PCB (5). Unlock the securing pins and pull the board out ofthe guide rats Insert and connect the new PCB Test function 6.4 Replacement of control unit A and IR-decoder unit Ad Remove the column casing as previously described. Tako off the IR-decoder A4 insort the new board. Setting the IR-code see Tech description Disconnect all plugs from the PCB At, remove the fixing screws of the PCB. Ingert and connect the new PCB, test function. WR1132.0168 12.40.2000