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Service Manual
This product corresponds to design class 1 within the meaning of the European Medical Device Directive
(MDD) 93/42/EEC, July 1993, Appendix 9, and the German Medizin Produkte Gesetz (MPG) (Law on
Medical Products), August 1994, Appendix 9.
The manufacturer declares that this product conforms to the essential requirements of the MPG, Appendix 7,
and this is documented by the CE sign.
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
manufacturers instructions.
Contents
1 Introduction
1.1 Notes for Service Personnel ...................................................................................2
1.2 Important Information ...........................................................................................3
1.3 General Safety Instructions ....................................................................................4
1.4 Protection against Infection ....................................................................................5
1.5 Instructions for Protecting the Environment ..............................................................5
1.6 Glossary ..............................................................................................................6
2 Service Manual
2.1 Changing wheels ..................................................................................................7
2.2 Changing the gas spring .......................................................................................8
2.3 Changing Trendelenburg sliding washers................................................................8
2.4 Changing the bushing of Trendelenburg gas spring .................................................9
2.5 Changing control head of Trendelenburg gas springs ............................................10
2.6 Changing bowden cable - Adjustment back section ...............................................11
2.7 Changing gas spring in seat section .....................................................................12
2.8 Changing fork for seat section .............................................................................13
2.9 Replace the operating lever and bar in the head section.........................................14
2.10 Changing the adapter spindle on the MERKUR 3 ...................................................14
2.11 Changing the complete drive for the elevator on the MERKUR 3 .............................15
2.12 Changing the pads the elevator on the MERKUR 3 ................................................16
2.13 Change the pump lever and hydraulic lifting unit ...................................................17
4 Spare Parts
Operating Table MERKUR 2.1 Running gear.........................................................20
Operating Table MERKUR 2.1 Table top ..............................................................22
Operating Table MERKUR 3 Running gear ............................................................24
Operating Table MERKUR 3 Table top .................................................................26
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.
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 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.
WARNING!
Immediate threat of danger!
Consequences are death, serious or slight injuries,
together with property damage.
(The example shown here is the symbol for the danger from
electric shock.)
ATTENTION!
Dangerous situation!
Possible consequences are injuries or damage to property, and
also the risk of infections!
(The example shown here is the symbol for the risk of fingers
being crushed.)
NOTE!
Useful additional information and tips.
TEST!
Performance of functional testing, measurements and tests.
ENVIRONMENT!
Instructions for disposal that will not harm the environment.
· 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.
· Follow the recycling regulations for components which have been removed, particularly
in the case of:
– Metals
– Plastics.
1.6 Glossary
The following terms and abbreviations are used in this service manual:
2 Service Manual
The following service manual is valid for the operatimg tables MERKUR 2.1 and
MERKUR 3!
Differences between the two types are marked!
Wheel, static:
1. Jack up the operating table.
2. Remove screw M8 from the wheel suspension.
3. Change the wheel.
Wheel, lockable:
1. Jack up the operating table.
2. Remove 2 pins from the brake lever.
3. Remove screw M8 from the wheel suspension.
4. Remove parts sideways out of the wheel suspension.
Figure 1: Brake MERKUR 2.1 item no. 4 544 032 and MERKUR 3 item no. 4 544 028
1 screw
2 wheel
NOTE!
Setting the brakes on the MERKUR 2.1 item no. 4 544 032 and
MERKUR 3 item no. 4 544 028: The brakes can be set with a hexagon
socket head cap screw (1) on the under side of the wheel (2).
TEST!
After setting the brakes, check that they are functioning properly.
ATTENTION!
Injury hazard!
Pneumatic pressure springs are under pressure!
Discharge the pneumatic pressure springs before disassembly!
NOTE!
Adjustment:
Both gas springs must release simultaneously!
Adjust at the thread of the shaft. Apply counter nuts, secure screws
using glyptal!
TEST!
Check whether both pneumatic pressure springs release
simultaneously.
ATTENTION!
Injury hazard!
Pneumatic pressure springs are under pressure!
Discharge the pneumatic pressure springs before disassembly!
NOTE!
Both gas springs must release simultaneously!
Adjust at the thread of the shaft. Apply counter nuts, secure screws
using glyptal!
TEST!
Check whether both pneumatic pressure springs release
simultaneously.
ATTENTION!
Injury hazard!
Pneumatic pressure springs are under pressure!
Discharge the pneumatic pressure springs before disassembly!
NOTE!
Both gas springs must release simultaneously!
Adjust at the thread of the shaft. Apply counter nuts, secure screws
using glyptal!
TEST!
Check whether both pneumatic pressure springs release
simultaneously.
Assembling:
1. Hang new bowden cable in release lever of gas spring (big nipple).
2. Hang other end of bowden cable into hand lever.
3. Remove screw driver.
NOTE!
Adjust release point:
Under load, back section in upper position must go back springy into
initial position. In lower position it must release safely!
ATTENTION!
Injury hazard!
Pneumatic pressure springs are under pressure!
Discharge the pneumatic pressure springs before disassembly!
NOTE!
Adjustment after changing:
Both gas springs must release simultaneously!
Adjust at the thread of the shaft.
TEST!
Check whether both pneumatic pressure springs release
simultaneously.
ATTENTION!
Injury hazard!
Pneumatic pressure springs are under pressure!
Discharge the pneumatic pressure springs before disassembly!
Changing fork:
1. Remove countersunk socket-head screw M8x40 with bushing
(attaches gas spring to back section).
2. Remove counter nut M10x1 on piston shaft of gas spring.
3. Remove gas spring.
4. Remove bowden cable.
5. Knock 2 spring-type pins out of the shaft (on both sides).
6. Shift the shaft to one side.
7. Remove the retaining ring on the axle of the actuating lever, item no. 4 212 840,
for the pneumatic pressure spring.
8. Remove the axle.
9. Fit a new fork.
NOTE!
Adjustment after changing:
Both gas springs must release simultaneously!
Adjust at the thread of the shaft.
TEST!
Check whether both pneumatic pressure springs release
simultaneously.
2.9 Replace the operating lever and bar in the head section
#
" !
NOTE!
Ensure that the locking pin is correctly orientated when reassembling.
The narrow end of the conical part must point upwards when the head
section is lying on the pad.
TEST!
Check that the head section is held securely in all positions.
2.11 Changing the complete drive for the elevator on the MERKUR 3
#
!
"
Change the pump lever (4) and hydraulic lifting unit (2):
1. Lower the MERKUR to its lowest position.
2. Remove the tabletop.
3. Remove MERKUR-cover.
4. Remove the retaining rings (1) on both sides.
5. Remove (6) bolt.
6. Knock out the cylindrical pin (8).
7. Brake the MERKUR and lay it on its side.
NOTE!
Take care to avoid scratches. Use an underlay.
TEST!
Test the column lift of the MERKUR.
"
!
&
'
" # " " " " ! $ '
!
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$ " # " " " % %
!
#
" # " " " " "
' #
! "
$ % &
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$ %
Pos Item Description of Pos Item Description of
no. no. spare part SP no. no. spare part SP
1 4 145 355 Padding for head section X 16 4 144 135 Gas spring S-28-130-390GZ-A500N, X
customised
2 4 145 371 Padding for seat section X
17 4 101 013 Bowden cable, leg support one-piece, X
3 4 145 372 Padding for upper leg support, right X two pieces per unit
4 4 145 373 Padding for upper leg support, left X 18 4 144 517 Gas spring S-28-100-346GZ-A600N, X
5 4 145 360 Padding for lower leg support, right X customised
6 4 145 361 Padding for lower leg support, left X 19 4 144 191 Switch button X
7 4 145 362 Padding for leg support, right X 20 4 212 735 Lever, for it
8 4 145 363 Padding for leg support, left X 4 144 441 Collar bushing (not shown in the illustration)
9 4 145 364 Padding for leg support, one-piece X 21 4 212 977 Gas spring, customised X
12 4 212 520 Pair of click-stop shafts 24 4 101 015 Bowden cable, back section X
14 4 144 133 Gas spring BOA1 90-61-202/700N X 26 4 213 809 Operating lever, pair X
"
' !
&
'
" # " " " " ! $ '
!
"
#
$ " # " " " % %
!
#
" # " " " " " !
' #
! "
$ % &
' " # " " " % #
$ %
Pos Item Description of Pos Item Description of
no. no. spare part SP no. no. spare part SP
1 4 145 355 Padding for head section X 17 4 101 013 Bowden cable, leg support one-piece, X
two pieces per unit
2 4 145 371 Padding for seat section X
18 4 144 517 Gas spring S-28-100-346GZ-A600N, X
3 4 145 372 Padding for upper leg support, right X
customised
4 4 145 373 Padding for upper leg support, left X
19 4 144 191 Switch button X
5 4 145 360 Padding for lower leg support, right X
20 4 212 735 Lever, for it
6 4 145 361 Padding for lower leg support, left X 4 144 441 Collar bushing (not shown in the illustration)
7 4 145 362 Padding for leg support, right X 21 4 212 977 Gas spring, customised X
8 4 145 363 Padding for leg support, left X 22 4 212 582 Fork
9 4 145 364 Padding for leg support, one-piece X 23 4 212 840 Lever X
10 4 212 542 Button X
24 4 101 015 Bowden cable, back section X
11 4 212 541 Pin X
25 4 121 015 Spring X
12 4 212 520 Pair of click-stop shafts
26 4 213 809 Operating lever, pair X
13 4 145 018 Hand wheel X
27 4 213 803 Bar, entire
14 4 144 133 Gas spring BOA1 90-61-202/700N X 28 4 145 350 Pad elevator 1 X
15 4 101 011 Bowden cable X 29 4 145 351 Pad elevator 2 X
16 4 144 135 Gas spring S-28-130-390GZ-A500N, X 30 4 212 912 Drive, complete
customised